Abstract:
A ready to assemble article of furniture includes a connecting assembly to enable shipment of the article in a partially assembled condition. By the use of the connecting assembly, the user can quickly assemble the article of furniture. The connecting assembly includes brackets which are attached to the disassembled components of the article of furniture. The brackets are mateable with each other during the assembly process to secure the components together.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates in general to the field of furniture and furniture assemblies. More specifically, the present invention relates to knock-down furniture which may be partially disassembled for compact and efficient packaging. 
     Historically, furniture was manufactured and packaged wholly assembled, where it was then shipped to various retailers or end users in a fully assembled condition. Particularly for end users, this method of delivery was preferred as no assembly was required. However, this method of manufacture has drawbacks in the current marketplace, as shipping of wholly assembled furniture leaves voids in the packaging, which add to the overall shipping cost per unit shipped. Although this method of delivery does remain a viable method, typically it is only utilized for high-end or specialty furniture. 
     A subset of this method is furniture that may be packaged in a predominantly assembled condition, but which may require connection of limited numbers of components. Furniture produced by these methods of manufacture are often referred to as knock-down or “K.D.” furniture. 
     K.D. furniture suffer from a number of disadvantages over fully assembled furniture. In the case of furniture such as chairs having a base assembly such as a rocker mechanism, it has been the practice to manufacture and sell such furniture with a permanently attached base assembly. The permanently attached base assembly limits the ability to compactly package the furniture, and is undesirable because of the costs associated with shipping such furniture with the resultant large packaging voids. In addition, the joints formed between the consumer assembled components are often not as strong as joints which are factory assembled. As a result, the furniture may not last as long or be as stable in use. Even if the consumer assembled components are as stable as those which may be factory assembled, many end-users have the perception that such joints are less secure. 
     The present invention has arisen to solve the need for articles of furniture which are capable of being shipped in a relatively compact manner, but which do not require complete assembly by the end user. The present invention solves this need while also alleviating the concerns, justified or not, that end user assembled components suffer from strength or longevity deficiencies. 
     SUMMARY OF THE INVENTION 
     The present invention overcomes the shortcomings of the prior art by providing, in various embodiments, a partially assembled article of furniture, such as a rocking chair or rocking couch, that may be compactly and efficiently packaged for transportation while enabling the connection of joints that are secure and stable over the life of the article. 
     A ready to assemble article of furniture is described in accordance with one embodiment of the present invention. The article includes a base component for supporting the assembled article on a surface. A first support frame is coupled to the base component by a pair of spaced apart springs securing the first support frame in spaced apart relationship to the base component; First and second brackets are attached to the first support frame in spaced relationship. An occupant supporting component supports an occupant when secured to the base component. A second support frame is arranged underlying the occupant supporting component and coupled thereto. Third and fourth brackets are attached to the second support frame in spaced apart relationship, the first bracket connectable with the third bracket and the second bracket connectable with the fourth bracket when the supporting component is assembled to the base component. 
     The first bracket includes a projection and the third bracket includes an opening for receiving the projection when the supporting component is assembled to the base component. The second bracket includes an opening and the fourth bracket includes an opening aligned with the second bracket opening when the supporting component is assembled to the base component. 
     An article of furniture is described in accordance with another embodiment of the present invention. The article includes a base component for supporting the article of furniture on a surface. A first support is attached to the base component. A pair of spaced apart coiled springs attaches the first support frame and the base component in spaced apart relationship. First, second, third and fourth brackets are attached to the first support frame in opposing pairs; the first and second brackets each including a projection and the third and fourth brackets each including an opening. An occupant supporting component is provided for supporting an occupant. A second support frame is attached to the occupant supporting component. Fifth, sixth, seventh and eighth brackets are attached to the second support frame in opposing pairs, the fifth, sixth, seventh and eighth brackets each including an opening. The occupant supporting component secured to the base component by (i) the projections of the first and second brackets received with the opening of the fifth and sixth brackets, (ii) the openings of the third and seventh brackets being aligned and the openings of the fourth and eighth brackets being aligned, and (iii) a fastener received with the aligned openings of the fifth and sixth brackets and the seventh and eighth brackets. 
     A ready to assemble article of furniture includes a base component for supporting the assembled article on a surface. An occupant supporting component is provided for supporting an occupant when secured to the base component. A plurality of first brackets is coupled to the base component or the occupant supporting component and a plurality of second brackets is coupled to the occupant supporting component or the base component. One of the first brackets includes a projection for engagement with an opening in one of the second brackets, and another one of the first brackets includes an opening for alignment with another one of the second brackets for securing the base component to the occupant supporting component. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The subject matter regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and methods of operation, together with features objects, and advantages thereof, may be best understood by reference to the following detailed description when read with the accompanying drawings in which: 
         FIG. 1 . is a perspective view of a an article of furniture of the knock-down type having a connection assembly constructed pursuant to one embodiment of the present invention; 
         FIG. 2  is a perspective view of a base component of the article of furniture showing a portion of the connection assembly; 
         FIG. 3  is another perspective view of the base component showing a portion of the connection assembly; 
         FIG. 4  is a perspective view of an enlarged section of the base assembly showing a portion of the connection assembly; 
         FIG. 5  is a perspective view showing the article of furniture having an occupant supporting component attached to the base component by the connection assembly; 
         FIG. 6  is a perspective view of a portion of the connection assembly; 
         FIG. 7  is a perspective view showing another portion of the connection assembly; 
         FIG. 8  is a perspective view of an article of furniture having a connection assembly in accordance with another embodiment of the present invention; 
         FIG. 9  is a perspective view of an article of furniture having a connection assembly in accordance with another embodiment of the present invention; 
         FIG. 10  is a perspective view of an article of furniture having a connection assembly in accordance with another embodiment of the present invention; 
         FIG. 11  is a perspective view of an article of furniture having a connection assembly in accordance with another embodiment of the present invention; and 
         FIG. 12  is a perspective view of an article of furniture having a connection assembly in accordance with another embodiment of the present invention; 
     
    
    
     DETAILED DESCRIPTION 
     In the following paragraphs are described the preferred embodiments of the furniture assembly in accordance with the present invention. In describing the embodiments illustrated in the drawings, specific terminology will be used for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents that operate in a similar manner to accomplish a similar purpose. Where like elements have been depicted in multiple embodiments, identical reference numerals have been used in the multiple embodiments for ease of understanding. 
     Referring now to the drawings, wherein like reference numerals represent like elements, there is shown in  FIG. 1  an article of furniture of the knock-down type which is packaged in a predominantly assembled condition in accordance with one embodiment of the present invention. The article of furniture has been designated generally by reference numeral  100 , being illustrated as a chair  102 . By way of example only, the chair  102  is of the rocker type, however, the present invention is applicable to any article of furniture having a base component which desirably is removable prior to shipping for reducing costs associated therewith. Moreover, although the article of furniture will be described in the context of the chair  102 , it is to be understood that other articles of furniture, for example, loveseats, sofas, tables, or other articles of furniture which have a base component may incorporate the connection assembly in accordance with the present invention. 
     In the illustrated example, the chair  102  generally includes an occupant supporting component  104 , a base component  106  and a connecting assembly  108 . The occupant supporting component  104  is in the nature of a bucket type seat having a back rest portion  110 , and an intregally formed seat portion  112 . A connecting assembly support frame  114  is attached underlying the seat portion of the occupant supporting component  104 . Optionally, the chair  102  may include side arms  116 . 
     The base component  106 , as further illustrated in  FIGS. 2-4 , is constructed from a pair of parallel spaced apart U-shaped leg frames  118  forming supporting legs  120  connected by cross braces  121 . A vertically arranged coiled spring  122  is attached at an extension end  123  to each of the leg frames  118  by any suitable means such as welding, clamps, brazing, brackets and the like. Another extension end  123  of each coiled spring  122  is attached to an overlying connecting assembly supporting frame  124 . The connecting assembly support frame  124  is illustrated, in the preferred embodiment, as a continuous rigid member of rectangular shape having spaced apart side members  126 ,  128 . The base component  106 , generally other than the coiled springs  122 , can be constructed from hollow or solid metal members of any desirable cross sectional shape, such as round, oval, square and the like. 
     The resulting construction of the base component  106  provides the leg frames  118  spaced apart by cross braces  121  and connected to the connecting assembly support frame  124  by means of the pair of coiled springs  122 . This provides the article of furniture  100  having the capability of rocking by virtue of the coiled springs  122 . However, this is only one example of an article of furniture to which the present invention pertains. In this regard, it is not required that a rocking mechanism be employed in an article of furniture embodying the connecting assembly  108  as to be described hereinafter. 
     Turning to  FIGS. 1 and 5 , there will now be described the construction of the connecting assembly support frame  114  which is attached to the occupant supporting portion  104 . The connecting assembly support frame  114  is constructed from a continuous frame having a pair of spaced apart side members  130 ,  132 . The connecting assembly support frame  114  may be of a similar construction to the connecting assembly support frame  124 , such as a rigid tubular or hollow member attached to the occupant supporting component  104  underlying seat portion  112  by any suitable means. Although not required, in accordance with one embodiment of the present invention, the connecting assembly support frame  114  has a generally similar shape and size to that of the connecting assembly support frame  124 . 
     The connecting assembly  108  will now be described with respect to  FIGS. 2 ,  3 ,  5  and  6 . The connecting assembly  108  is constructed from a plurality of brackets which are secured to the connecting assembly support frames  114 ,  124 . As shown in  FIGS. 2 and 3 , the connecting assembly  108  includes a pair of angle brackets  134  attached to the side member  128  of the connecting assembly support frame  124  in spaced apart relationship. Each of the angle brackets  134  include a downwardly depending flange  136  provided with an opening  138 . A pair of tab brackets  140  each having a horizontal projection  142  are attached to the side member  126  in spaced apart relationship. It is not a requirement of the present invention that the angle brackets  134  be aligned with the tab brackets  140 . 
     The connecting assembly  108  further includes a pair of spaced apart angle brackets  144 , see  FIGS. 5 and 7 , attached to the side member  130  of the connecting assembly support frame  114 . Each of the angle brackets  144 , of similar construction angle brackets  134 , includes a downwardly depending flange  146  having an opening  148 . A pair of angle brackets  150  is secured in spaced apart relationship to the side member  132 . Each of the angle brackets  150 , see  FIG. 6 , includes a shortened downwardly depending flange  152  having an enlarged opening  154 . In a similar manner as previously described, is not a requirement that the angle brackets  144  be aligned with the angle brackets  150  within the connecting assembly support frame  114 . However, it is required that the angle brackets  134  and tab brackets  140  attached to the connecting assembly support frame  124  align with the angle brackets  144 ,  150  attached to the connecting assembly support frame  114 . This will become more apparent from a further description of the connecting assembly  108  in accordance with the present invention. 
     Although the angle brackets  144 ,  150  have been described as being attached to the connecting assembly support frame  114 , the brackets may be attached to other portions of the occupant supporting component  104  thereby eliminating the support frame. For example, the angle brackets  144 ,  150  can be secured to bracing members underlying the seat portion  112 . Likewise, the angle brackets  134  and tab brackets  140  can be secured to other portions of the base component  106  other than the connecting assembly support frame  124 , depending upon its construction. It is therefore only required that the brackets  134 ,  140 ,  144 ,  150  be attached to the occupant supporting component  104  and base component  106  in a manner which allows for their alignment and connection during the assembly process. 
     Turning to  FIGS. 5-7 , there will now be described the securing of the occupant supporting component  104  to the base component  106  using the connecting assembly  108 . The occupant supporting component  104  is generally positioned overlying the base component  106  with the brackets  134 ,  140 ,  144  and  150  in general alignment with each other. The occupant supporting component  104  is tipped forwardly such that the projections  142  of the tab brackets  140  align with and are receivable within the enlarged openings  154  of the opposing spaced apart angle brackets  150 , see  FIG. 6 . Once the projection  142  is engaged with the enlarged opening  154 , the occupant supporting component  104  is rocked rearwardly for mating the angle brackets  144  with a corresponding underline angle bracket  134  such that the corresponding openings  138 , 148  are aligned with each other, see  FIG. 7 . The angle brackets  134 ,  144  are secured together by inserting a bolt  156  or other fastening means through their aligned openings. In this regard, it is contemplated that a nut may be used to secure the bolt  156 , or that one of the openings  138 ,  148  may be threaded to secure the bolt and the corresponding brackets. 
     The use of the connecting assembly  108  in an article of furniture  100  enables the shipping of articles in a partially disassembled state, while permitting its assembly by the consumer in a simple manner which ensures the integrity and long use of the article without unintended disconnection. In this regard, the connecting assembly  108  attaches the base component  106  to the occupant supporting component  104  in a manner as effective and secure as if these components were fully assembled at the factory. The limited assembly only requires minimum effort by the consumer which can be accomplished in a matter of minutes. If necessary, the consumer can disassemble the base component  106  from the occupant supporting component  104  for any desired reason, such as storage or shipment to another location if desired. 
     The connecting assembly  108  has been described as comprising four brackets secured to the connecting assembly support frame  114  and four aligned brackets connected to the connecting assembly support frame  124 . However, it is to be understood that any lesser or greater number of brackets may be employed in accordance with the present invention. For example, six brackets arrange in a triangular arrangement may be used, such as a pair of tab brackets  140  and a single angle bracket  134 . 
     Referring now to  FIG. 8 , there is illustrated another embodiment of the present invention wherein the connecting assembly support frame  114  includes a pair of connecting brackets for mating with a pair of connecting brackets secured to the connecting assembly support frame  124 . The connecting assembly support frame  124  includes a single angle bracket  134  attached to the side member  128  and a single tab bracket  140  connected to the side member  126 . The connecting assembly support frame  114  includes a single angle bracket  144  secured to the side member  130  and a single angle bracket  150  secured to the side member  132 . The assembly of the base component  106  to the occupant supporting component  104  using the connecting assembly  104  of four brackets is as previously described. 
     Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. For example, as shown in  FIG. 9 , it is contemplated that the tab brackets  140  can be attached to the connecting assembly support frame  114 , with the mating angle brackets  150  attached to the connecting assembly support frame  124 . In this regard, it is further contemplated that the angle brackets  150  would extend upwardly to engage the projection  142  on the angle brackets  140 . The tab brackets  140  can also be attached to the side member  128  and angle brackets  134  to the side member  126 , see  FIG. 10 . Moreover, as shown in  FIGS. 11 and 12 , it is contemplated that the brackets  134 ,  140 ,  150  can be attached to the side members connecting the side members  126 ,  128  together, or the side members connecting the side members  130 ,  132  together. 
     It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.