Mostly pre-assembled kit for casegood furniture

Abstract

The application discloses a ready-to-assemble kit containing pre-assembled components for a casegood. The kit comprises a plurality of component parts, wherein a majority, but less than all, of the component parts are pre-assembled to at least one other component part to form subassemblies. Preferably, at least seventy percent and no more than ninety percent of the component parts are pre-assembled to at least one other component part to form the subassemblies. The subassemblies and balance of component parts are configured for packaging together in a rectilinear shipping container such that the packed container includes less than about twenty-five percent void regions by volume when the kit is so packaged in the container.

What is claimed is:  
     
         1 . A ready-to-assemble kit containing pre-assembled components for a casegood, the kit comprising a plurality of component parts, wherein a majority of the component parts are pre-assembled to at least one other component part to form at least two subassemblies.  
     
     
         2 . A kit according to  claim 1  at least seventy percent and no more than ninety percent of the component parts are pre-assembled to at least one other component part to form subassemblies.  
     
     
         3 . A kit according to  claim 1  wherein the subassemblies and balance of component parts are configured for packaging together in a rectilinear shipping container such that the packed container includes less than about twenty-five percent void regions by volume when the kit is so packaged in the container.  
     
     
         4 . A kit according to  claim 1 , wherein the kit includes side walls having drawer slide tracks pre-assembled thereto, and at least one drawer sub-kit including drawer slide rails for sliding engagement in the drawer slide tracks.  
     
     
         5 . A kit according to  claim 4  wherein the at least one drawer sub-kit comprises: 
 (a) a pair of side drawer panels, wherein the drawer slide rails are pre-mounted thereon;  
 (b) a front drawer panel;  
 (c) a back drawer panel;  
 (c) a bottom drawer panel; and  
 (c) at least one drawer handle pre-mounted on an outer face of the front drawer panel.  
 
     
     
         6 . A kit according to  claim 1 , wherein the kit includes a top panel having pre-assembled front and side edge trim pieces.  
     
     
         7 . A kit according to  claim 1 , wherein the kit includes a bottom front rail pre-assembled to a front base panel.  
     
     
         8 . A ready-to-assemble kit according to  claim 1  wherein the casegood is a chest of drawers carcass, and the kit includes side walls with pre-assembled drawer slide tracks, and a plurality of drawer sub-kits, each drawer sub-kit including side drawer panels having pre-assembled drawer slide rails.  
     
     
         9 . A ready-to-assemble kit according to  claim 1  wherein the casegood is a dresser carcass, and the kit includes side walls with pre-assembled drawer slide tracks, and a plurality of drawer sub-kits, each drawer sub-kit including side drawer panels having pre-assembled drawer slide rails.  
     
     
         10 . A ready-to-assemble kit according to  claim 1  wherein the casegood is a night stand carcass, and the kit includes side walls with pre-assembled drawer slide tracks, and at least one drawer sub-kit including side drawer panels having pre-assembled drawer slide rails.  
     
     
         11 . A ready-to-assemble kit according to  claim 1  wherein the casegood is a desk carcass, and the kit includes side walls with pre-assembled drawer slide tracks, and a at least one drawer sub-kit including side drawer panels having pre-assembled drawer slide rails.  
     
     
         12 . A ready-to-assemble kit according to  claim 1  wherein the casegood is an armoire carcass, and the kit includes side walls with pre-assembled drawer slide tracks, and at least one drawer sub-kit including side drawer panels having pre-assembled drawer slide rails.  
     
     
         13 . A ready-to-assemble kit according to  claim 1  wherein the kit includes a plurality of removable fasteners of a single type and size, and the component parts and sub-assembled components for a casegood carcass are configured for rigid connection together by the one type and size of removable fasteners.  
     
     
         14 . A method of merchandising casegoods comprising: 
 (a) providing structural component parts for constructing a casegood carcass;    (b) assembling at least a majority of each of the component parts to at least one other component part to form at least two subassemblies; and    (c) packing the subassemblies and separate parts in compact stacked arrangement inside a rectilinear shipping container, wherein the packed shipping container includes less than about twenty-five percent voids by volume.    
     
     
         15 . The method of  claim 14  further comprising providing at least one drawer kit for constructing at least one drawer assembly for installation in the finished casegood carcass, the components of the at least one drawer kit being stackable together with the subassemblies and separate parts of the carcass in the shipping container such that the packed shipping container includes less than about twenty-five percent void regions by volume.  
     
     
         16 . The method of  claim 14  further comprising providing at least one door for assembly onto the finished casegood carcass, the door being stackable with the subassemblies and separate parts of the carcass in the shipping container such that the packed shipping container includes less than about twenty-five percent void regions by volume.  
     
     
         17 . The method of  claim 14  further comprising providing at least one shelf for assembly into the finished casegood carcass, the shelf being stackable with the subassemblies and separate parts of the carcass in the shipping container such that the packed shipping container includes less than about twenty-five percent void regions by volume.  
     
     
         18 . The method of  claim 14  wherein the component parts and subassemblies are configured for connection together by fasteners of substantially one type and size.  
     
     
         19 . A method of producing and merchandising casegoods comprising: 
 (a) providing structural component parts for constructing an unfinished casegood carcass;    (b) assembling the component parts together to form the unfinished carcass;    (c) finishing selected surfaces of the unfinished carcass;    (d) providing and installing selected hardware on the finished carcass;    (e) partially disassembling the finished carcass into subassemblies and separate parts such that a majority of the component parts comprising the carcass remain assembled to at least one other individual part to form at least two subassemblies, the subassemblies and separate parts being suited for stacking together in a substantially compact stack;    (f) packing the subassemblies and separate parts in compact stacked arrangement inside a rectilinear shipping container; and    (g) shipping the container to a remote location.    
     
     
         20 . The method of  claim 19  further comprising providing at least one drawer kit for constructing at least one drawer for assembly into the finished casegood carcass, the components of the at least one drawer kit being stackable together with the subassemblies and separate parts of the carcass in the shipping container such that the packed shipping container includes less than about twenty-five percent void regions by volume.  
     
     
         21 . The method of  claim 19  further comprising providing at least one door for assembly onto the finished casegood carcass, the door being stackable with the subassemblies and separate parts of the carcass in the shipping container such that the packed shipping container includes less than about twenty-five percent void regions by volume.  
     
     
         22 . The method of  claim 19  further comprising providing at least one shelf for assembly into the finished casegood carcass, the shelf being stackable with the subassemblies and separate parts of the carcass in the shipping container such that the packed shipping container includes less than about twenty-five percent void regions by volume.  
     
     
         23 . The method of  claim 19  wherein reassembly includes connecting the subassemblies and separate parts together with fasteners of substantially one type and size.  
     
     
         24 . A ready-to-assemble kit for constructing a casegood having at least one drawer, the kit comprising: 
 (a) a carcass portion including at least two side panel subassemblies, each side panel subassembly including a sidewall panel having an inner surface and at least one drawer slide track pre-mounted to the inner surface of each sidewall panel;    (b) at least one drawer sub-kit for constructing the at least one drawer, the at least one drawer kit including a pair of side drawer panels, a pair of drawer slides, a front drawer panel, a rear drawer panel, a bottom drawer panel, and least one drawer handle, the drawer slides being designed for sliding engagement with the drawer slide tracks and being pre-mounted on the first and second side drawer panels, and the at least one drawer handle being pre-mounted on an outer face of the front drawer panel.    (c) wherein kit is suited for packaging in a suitably sized rectilinear shipping container such that the packaged kit includes not more than twenty-five percent voids by volume inside the container.    
     
     
         25 . A kit according to  claim 24  wherein the carcass portion further includes: 
 (a) at least two back rails, a top front rail, and a bottom front rail for connecting the first and second sidewall panels together in opposed parallel relationship with each other; and  
 (b) a top panel, the top panel being designed to be supported by and between top edges of the opposed sidewall panels of the side panel subassemblies.  
 
     
     
         26 . A kit according to  claim 25  wherein the bottom front rail includes a front base molding member mounted on a front face of the bottom front rail.  
     
     
         27 . A kit according to  claim 25  wherein the top panel includes: 
 (a) a top plate having an upper surface, a lower surface, a forward edge, and first and second opposed side edges;  
 (b) a front edge trim member affixed to the lower surface of the top plate, the front edge trim member being proximate to and substantially parallel to the forward edge of the top plate; and  
 (c) first and second side edge trim members affixed to the lower surface of the top plate, the first and second side edge trim members being proximate to and substantially parallel to the first and second side edges of the top plate, respectively.  
 
     
     
         28 . A kit according to  claim 24  wherein each sidewall panel includes; 
 (a) an outer surface, a lower end, and a forward edge;  
 (b) a side base molding member affixed to the outer surface proximate the lower end; and  
 (c) a front face member affixed to the sidewall panel along its forward edge.  
 
     
     
         29 . A kit according to  claim 24  further including a plurality of fasteners suited for fastening the kit together to finally assemble the casegood, the plurality of fasteners including a first set of fasteners of substantially one type and size for fastening the carcass portion together, and a second set of fasteners of substantially one type and size for fastening the at least one drawer kit together.  
     
     
         30 . A ready-to-assemble kit according to  claim 24  wherein the casegood is a chest of drawers.  
     
     
         31 . A ready-to-assemble kit according to  claim 24  wherein the casegood is a dresser.  
     
     
         32 . A ready-to-assemble kit according to  claim 24  wherein the casegood is a night stand.  
     
     
         33 . A ready-to-assemble kit according to  claim 24  wherein the casegood is a desk.  
     
     
         34 . A ready-to-assemble kit according to  claim 24  wherein the casegood is an armoire.