Flat pack friction fit furniture system

Abstract

An article of furniture and associated methods and kits comprising at least one first leg support structure, at least one second leg support structure, the at least one first leg support structure being inter-fitted with the at least one second first leg support structure via an interference fit to define a support assembly, a top that is supported by and attached to the support assembly without the need for a mechanical fastener or adhesive; and means for creating a force state that attaches the top to the support assembly without the need for a mechanical fastener or adhesive, and thereby stabilizes the article of furniture, wherein the force state includes one or more forces applied to the at least one first leg support structure and the at least one second leg support structure, in addition to any frictional force from the interference fit.

1 .- 20 . (canceled) 
     
     
         21 . A method of making an article of furniture, the method comprising:
 (a) providing a sheet of stock material;   (b) cutting at least one first leg support structure, at least one second leg support structure, and at least one top from the sheet of stock material;   (c) inter-fitting the first leg support structure with the second leg support structure via an interference fit; and   (d) creating a force state that attaches the top to the inter-fitted first and second leg structures, thereby stabilizing the article of furniture, wherein the force state includes one or more forces applied to the first and second leg support structures, in addition to any frictional force from the interference fit.   
     
     
         22 . The method of  claim 21 , wherein the first and second leg support structures and the top are cut from the same sheet of stock material. 
     
     
         23 . The method of  claim 21 , wherein the first and second leg support structures and the top are cut from the sheet of stock material with a powered cutting tool. 
     
     
         24 . The method of  claim 21 , wherein the first and second leg support structures and the top are laser-cut from the sheet of stock material. 
     
     
         25 . The method of  claim 21 , wherein the sheet of stock material has a thickness less than about 30 mm. 
     
     
         26 . The method of  claim 21 , wherein the sheet of stock material is a substantially homogenous material. 
     
     
         27 . The method of  claim 21 , wherein the sheet of stock material is a composite material. 
     
     
         28 . The method of  claim 27 , wherein the sheet of stock material is an aluminum faced composite board material. 
     
     
         29 . The method of  claim 21 , further comprising applying a graphic design to a surface of the article of furniture. 
     
     
         30 . The method of  claim 29 , wherein applying the graphic design includes printing the graphic design onto the surface. 
     
     
         31 . The method of  claim 29 , wherein applying the graphic design includes etching the graphic design into the surface. 
     
     
         32 . The method of  claim 29 , wherein the graphic design is a decal. 
     
     
         33 . A method of making an article of furniture, the method comprising:
 (a) providing a sheet of stock material;   (b) cutting a pair of first leg support structures and a pair of second leg support structures from the sheet of stock material, each of the first and second leg support structures including a pair of opposing and spaced apart slotted leg supports;   (c) cutting a top from the sheet of stock material;   (d) inter-fitting the pair of first leg support structures with the pair of second leg support structures via an interference fit between the slotted leg supports, thereby defining a support assembly; and   (e) creating a force state that attaches the top to the support assembly, thereby stabilizing the article of furniture, wherein the force state includes one or more forces applied to the first and second leg support structures, in addition to any frictional force from the interference fit.   
     
     
         34 . The method of  claim 33 , further comprising:
 (a) cutting a cross support from the sheet of stock material; and   (b) inter-fitting the cross support with one of either the first or second pair of leg support structures, thereby creating a tensile state or a compressive state of sufficient magnitude that the selected pair of leg support structures are elastically deflected.   
     
     
         35 . The method of  claim 34 , wherein the cross support has an upper edge that bears against a bottom surface of the top to bow an upper surface of the top convexly outward. 
     
     
         36 . The method of  claim 34 , wherein the pair of first leg support structures, the pair of second leg support structures, the top, and the cross support are cut from the same sheet of stock material. 
     
     
         37 . The method of  claim 33 , wherein the sheet of stock material is a substantially homogenous material. 
     
     
         38 . The method of  claim 33 , wherein the sheet of stock material is a composite material. 
     
     
         39 . The method of  claim 33 , further comprising applying a graphic design to a surface of the article of furniture. 
     
     
         40 . The method of  claim 33 , wherein the sheet of stock material has a thickness less than about 30 mm.