A furniture unit includes at least one shelf. The shelf includes a substrate having an upper surface, a lower surface opposite the upper surface, a proximal peripheral surface, a distal peripheral surface, a first seam, and a second seam. The proximal peripheral surface extends from the upper surfac
A furniture unit includes at least one shelf. The shelf includes a substrate having an upper surface, a lower surface opposite the upper surface, a proximal peripheral surface, a distal peripheral surface, a first seam, and a second seam. The proximal peripheral surface extends from the upper surface to the lower surface. The distal peripheral surface is opposite the proximal peripheral surface and extends from the upper surface to the lower surface. The second seam is spaced apart from the first seam. The first and second seams extend in a direction parallel to the proximal peripheral surface. The proximal peripheral surface engages one of the distal peripheral surface, the upper surface, and the lower surface.
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1. A furniture unit comprising at least one shelf including a substrate having a base layer and a laminate layer, wherein the base layer has an upper surface, a lower surface opposite the upper surface, a proximal peripheral surface extending from the upper surface to the lower surface, a distal per
1. A furniture unit comprising at least one shelf including a substrate having a base layer and a laminate layer, wherein the base layer has an upper surface, a lower surface opposite the upper surface, a proximal peripheral surface extending from the upper surface to the lower surface, a distal peripheral surface opposite the proximal peripheral surface and extending from the upper surface to the lower surface, a first seam, and a second seam spaced apart from the first seam, the first and second seams extending in a direction parallel to the proximal peripheral surface, wherein the laminate layer is disposed on one of the upper surface or the lower surface and includes a channel exposing a portion of the base layer, and wherein the proximal peripheral surface is disposed within the channel and engages the portion of the base layer. 2. The furniture unit of claim 1, wherein at least one of the first seam and the second seam is defined by a first channel wall and a second channel wall. 3. The furniture unit of claim 2, wherein the first channel wall and the second channel wall define a common edge. 4. The furniture unit of claim 2, wherein the first channel wall engages the second channel wall. 5. The furniture unit of claim 1, wherein the first and second seams extend from the upper surface, and wherein the proximal peripheral surface engages the upper surface. 6. The furniture unit of claim 1, wherein the substrate includes a third seam and a fourth seam spaced apart from the third seam, the third and fourth seams extending in a direction parallel to the distal peripheral surface, wherein the distal peripheral surface engages one of the upper surface and the lower surface. 7. The furniture unit of claim 6, wherein the first and second seams extend from the upper surface, and the third and fourth seams extend from the lower surface, and wherein the proximal peripheral surface engages the upper surface and the distal peripheral surface engages the lower surface. 8. The furniture unit of claim 6, wherein the first, second, third, and fourth seams are defined by first, second, third, and fourth channels, respectively, formed in the upper surface, and wherein the proximal and distal peripheral surfaces engage the upper surface. 9. The furniture unit of claim 6, wherein a forward portion of the upper surface engages a rearward portion of the upper surface. 10. The furniture unit of claim 1, wherein the substrate includes a proximal portion and a distal portion opposite the proximal portion, the proximal portion forming a hollow support portion. 11. The furniture unit of claim 10, wherein the hollow support portion defines a polygonal cross section. 12. The furniture unit of claim 11, wherein the polygonal cross section defines a square. 13. The furniture unit of claim 10, wherein the distal portion forms a hollow support portion. 14. The furniture unit of claim 1, wherein the upper surface includes a first portion and a second portion, the first portion extending between the proximal peripheral surface and the first seam, the second portion extending between the first seam and the second seam, and wherein the first portion and the second portion define an angle therebetween. 15. The furniture unit of claim 14, wherein the angle is between about fifteen degrees and about sixty degrees. 16. The furniture unit of claim 14, wherein the angle is equal to ninety degrees. 17. The furniture unit of claim 1, wherein the proximal peripheral surface defines an angle between about fifteen degrees and about sixty degrees relative to the one of the upper surface and the lower surface. 18. The furniture unit of claim 17, wherein the proximal peripheral surface defines an angle substantially equal to ninety degrees relative to the one of the upper surface and the lower surface. 19. The furniture unit of claim 1, wherein the substrate includes a lateral peripheral surface and a medial peripheral surface opposite the lateral peripheral surface, the lateral and medial peripheral surfaces each extending from the upper surface to the lower surface, the first and second seam each extending from the lateral peripheral surface to the medial peripheral surface. 20. The furniture unit of claim 1, wherein at least one of the first seam and the second seam is defined by a primary channel formed in the base layer. 21. The furniture unit of claim 20, wherein the laminate layer includes a first fold and a second fold, the first fold aligned with the first seam, the second fold aligned with the second seam. 22. The furniture unit of claim 20, wherein the laminate layer is a paper material or a polymer material. 23. The furniture unit of claim 22, wherein the base layer is one of a medium-density fiberboard and a particle board. 24. The furniture unit of claim 20, further comprising an adhesive between where the proximal peripheral surface engages the portion of the base layer. 25. The furniture unit of claim 20, wherein the proximal peripheral surface is adhered to the portion of the base layer. 26. The furniture unit of claim 1, further comprising a first lateral leg, a first medial leg, a second lateral leg, and a second medial leg, wherein the at least one shelf includes a first shelf and a second shelf, the first lateral leg and the first medial leg supporting the first shelf, the second lateral leg and the second medial leg supporting the second shelf. 27. The furniture unit of claim 26, wherein the first lateral leg is removably coupled to the second lateral leg, and the first medial leg is removably coupled to the second medial leg. 28. The furniture unit of claim 26, further comprising a connector removably coupled to the first lateral leg and to the second lateral leg. 29. The furniture unit of claim 1, further comprising an adhesive between where the proximal peripheral surface engages the portion of the base layer. 30. The furniture unit of claim 29, wherein the adhesive includes a glue. 31. The furniture unit of claim 1, wherein the proximal peripheral surface is coupled to the portion of the base layer. 32. The furniture unit of claim 31, wherein the proximal peripheral surface is adhered to the portion of the base layer. 33. A method of manufacturing a furniture unit from a substrate having a base layer and at least one laminate layer, wherein the base layer has an upper surface, a lower surface, and a peripheral surface extending from the upper surface to the lower surface, the method comprising: forming a first primary channel and a second primary channel in the base layer adjacent a proximal end of the substrate;removing a portion of the at least one laminate layer to form a secondary channel and to expose a portion of the base layer;folding the substrate in a first direction at the first and second primary channels to form a hollow proximal support;placing the peripheral surface within the secondary channel; andengaging the peripheral surface with the portion of the base layer. 34. The method of claim 33, further comprising: forming a third primary channel and a fourth primary channel adjacent a distal end of the substrate; andfolding the substrate in the first direction at the third and fourth primary channels to form a hollow distal support. 35. The method of claim 34, wherein the first and second primary channels are formed in the upper surface of the substrate, the third and fourth primary channels are formed in the lower surface of the substrate, the lower surface of the substrate being opposite the upper surface of the substrate. 36. The method of claim 34, wherein the first, second, third, and fourth primary channels are formed in the upper surface of the substrate. 37. The method of claim 34, wherein the folding step results in a first fold and a second fold formed in the at least one laminate layer. 38. The method of claim 37, wherein the first fold is aligned with the first primary channel, and the second fold is aligned with the second primary channel. 39. The method of claim 34, wherein the at least one laminate layer includes an upper laminate layer disposed on an upper surface of the base layer, and a lower laminate layer disposed on a lower surface of the base layer, the lower surface of the base layer being opposite the upper surface of the base layer, and wherein the first and second primary channels extend through the upper laminate layer and the third and fourth primary channels extend through the lower laminate layer. 40. The method of claim 33, wherein forming the first and second primary channels includes miter cutting through a portion of the substrate. 41. The method of claim 33, further comprising: forming a third primary channel and a fourth primary channel in the substrate; andfolding the substrate in a second direction at the third and fourth primary channels to form a hollow distal support, the second direction being opposite to the first direction. 42. The method of claim 41, wherein the first direction is counterclockwise and the second direction is clockwise. 43. The method of claim 33, further comprising applying an adhesive between where the peripheral surface engages the portion of the base layer. 44. The method of claim 43, wherein the adhesive includes a glue. 45. The method of claim 33, wherein engaging the peripheral surface with the portion of the base layer includes coupling the peripheral surface to the portion of the base layer. 46. The method of claim 45, wherein the coupling includes adhering the peripheral surface to the portion of the base layer.
Hunter Bruce W. (Pennsburg PA) Hieter Harold C. (Quakertown PA), Miter-foldable saturated paper-based overlay system and method for fabricating the same.
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