Abstract:
An improved, multifunctional furniture system having a novel fastening means which permits the easy assembly of structural components. The system includes vertical panels connected to a host structure to form the furniture. The host structures, fasteners, and vertical panels form the furniture system without the need for horizontal cross supports. The fasteners are cams that are rotated which engage locking members on the host structure, and thus allows for quick assembly of the components.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    The present invention relates generally to a locking mechanism assembly. In particular, the present invention relates to a cam locking system for assembling various structures such as home furniture.  
           [0002]    Home furniture systems exhibiting superior structural characteristics and which exhibit flexibility and interchangeably among parts to create adjustable shelving systems are in demand for many applications. In particular, the advent of home theater systems has created a need for adjustable and quick-to-assemble furniture to store and display home theater equipment. There are a wide variety of entertainment centers available on the market which require the user to assemble the furniture. Typical assembly includes the use of screws and bolts and other such permanent, unadjustable fasteners. The main structure comes with predrilled holes or pre-made slots for the placement of fasteners. The drawback of these systems is the lack of adjustability for the shelves to accommodate different sizes of home theater equipment.  
           [0003]    Prior art systems have tried to overcome the problem of adjustability in various ways. One way is to use a structure utilizing a host structure that contains a slot running the entire length of the structure. A common example of this is an extruded geometrically configured tube. Furniture can be made using a plurality of these tubes with appropriate cross supports, such as shelves or side panels. Thus, furniture may be constructed by fastening items to the geometric tubes.  
           [0004]    Different methods for connecting shelves or walls to a host structure formed of an extruded geometric tube have been disclosed. For example, U.S. Pat. No. 6,161,262, discloses a clamp assembly which is installed in a slot in the host structure at any position along the slot. This allows for adjustability of the clamp assembly. However, this assembly must be used by rotating a screw perpendicular to the slot, thus preventing the clamping device from being part of a linear shelf.  
           [0005]    Similarly, U.S. Pat. 6,286,192 discloses a clamp assembly for use in a host structure that has a slot. In this clamping structure, four pieces must be utilized to adjust it, including two clamp bodies composed of two opposing jaws each having teeth for entering into a slot in the host structure, a rod between the two, and a screw for adjusting the clamp.  
           [0006]    Thus, there is a need in the art for a shelving system that overcomes the drawbacks of these prior art systems by providing a system which is simple, yet has great versatility and adjustability.  
         BRIEF SUMMARY OF THE INVENTION  
         [0007]    The present invention is not only practical but provides an attractive, structurally sound, free standing final product which is ideally suited for modern entertainment systems. The system is easy to assemble and disassemble by relatively unskilled laborers.  
           [0008]    The invention is an improved fastening system for a host structure containing slots and a support member, such as a shelf or panel, to be attached to the host structure by using the slots. The support member to be attached to the host structure contains a locking member and a cam for tightening the locking member. This allows for the support member to be easily adjusted along the slot contained in the host structure. In addition, the support member can be attached to the host structure perpendicularly, parallel to, or at an angle as well.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]    [0009]FIG. 1 is a perspective view of an entertainment center.  
         [0010]    [0010]FIG. 2 is a top perspective view of two host structures connected to a cross support member.  
         [0011]    [0011]FIG. 3 is an assembly view showing the host structure, a locking body, a cam and the cross support member.  
         [0012]    [0012]FIG. 4 illustrates a cross sectional view of the host structure, locking body, cam and cross support member.  
         [0013]    [0013]FIG. 5 illustrates a side view of the cam and locking body in a locked position and an unlocked position.  
         [0014]    [0014]FIG. 6 illustrates a shelving assembly in an unlocked position.  
         [0015]    [0015]FIG. 7 illustrates the shelving assembly in a locked position.  
     
    
     DETAILED DESCRIPTION  
       [0016]    [0016]FIG. 1 shows a perspective view of an entertainment center containing host structures  10   a - 10   f  and cross supports  12   a - 12   c . Preferably, all numbered host structures  10   a - 10   f  are of the same dimension, thus creating a uniform part. The cross supports  12   a - 12   c  are panels of the same dimensions. The cross supports  12   a - 12   c  are fastened to the host structures  10   a - 10   f . With the configuration present, the cross supports  12   a - 12   c  provide the base of the structure, and thus no horizontal or other angled supports are required. The host structures  10   a - 10   f  contain slots on all four sides so cross supports  12   a - 12   c  can be attached to any of the faces of host structures  10   a - 10   f.    
         [0017]    In assembling the entertainment center illustrated in FIG. 1, or similar furniture, one cross support  12   a  is first attached to host structure  10   e . Next, another cross support  12   b  is attached to host structure  10  at 90°, creating a L-shape structure which is able to stand by itself. Host structure  10   d  attaches to the face of cross support  12   a  that parallel to the face attached to host structure  10   e . Similarly, host structure  10   f  attaches to the face of cross support  12   b  that is parallel to the face attached to host structure  10   e . Two more cross supports (not shown) can be added at 90° of cross supports  12   a  and  12   b , respectively, to create a rectangle when viewed from the top. A final host structure (not shown) is placed in the corner previously without a host structure  10 , thus completing the free standing assembly. A top panel and a bottom panel are mounted to the structure to form an enclosure and complete construction of the item of furniture.  
         [0018]    [0018]FIG. 2 shows a cross support  12  positioned between two host structures  10 . Each host structure  10  is an extruded geometrically configured tube having slotted surfaces. The host structure  10  can have a number of slots  14 , and in the example illustrated, four are provided. Although a rectangular tube is shown the host structure  10  could be of numerous shapes and forms. The host structure  10  is constructed from various materials such as metal, composites, or polymers. Slots  14  contained in the host structure  10  are for the accommodation and engagement of fasteners. In the preferred embodiment, the tube of the host structure  10  has slots  14  on all sides, which allows for utilizing one or multiple sides for the reception fasteners.  
         [0019]    In FIG. 2, the cross support  12  is a side panel. The cross support  12  can be of varying length, width, and thickness so long as there is room for a locking mechanism  16  to be installed within the body of the cross support  12 . The sides of the cross support  12  may be beveled to obtain a desired mating with a surface of the host structure  10  if the host structure  10  is of a non-rectangular shape. In one embodiment, the cross support  12  is of a thickness that is nominally the same as the outer dimension of a parallel side of a rectangular host structure  10  that attaches to the cross support  12 . In such an embodiment, the parallel faces of the host structure  10  are flush with the corresponding parallel faces of the cross support  12 .  
         [0020]    As illustrated in FIG. 2, there are four locking mechanisms  16  installed in the cross support  12 . The number of locking mechanisms  16  in a cross support  12  will vary depending upon the dimensions required for a particular finished item. The cross support  12  can be made of composites, particle wood product, or a wood board. The cross support  12  used in the furniture structures are constructed with pre-drilled holes or other such means as to accommodate the placement of shelves within an enclosure created by the cross supports  12  and host structures  10 . The locking mechanism  16  is used to connect the host structure  10  with the cross support  12 .  
         [0021]    [0021]FIG. 3 is an exploded view of one embodiment of the locking mechanism  16  showing the host structure  10 , support structure  12 , locking body  18 , and cam  20 . The locking mechanism  16  is a fastener made from the combination of the locking body  18  and cam  20 . FIG. 3 illustrates the host structure  10  as a rectangular geometrically configured tube with slots  14   a - 14   c , including the slot  14   c  on the right side and  14   b  on the top side. The slots  14   a - 14   c  are created by a portion of the surface of the extruded geometrical tube. Struts  15   a  and  15   b  extend downward from the outer surface of the host structure  10 , and opposing segments  13   a  and  13   b  protrude perpendicular from the ends of the strut to define the top of slot  14   b . Bottom segment  17  defines the lower boundary of the slot  14   b.    
         [0022]    A second embodiment contains slots  14  comprising the structure described, but offset to one side rather than centered on each face of the rectangular host structure  10 . In this embodiment, the offset allows a cross support  12  that has a thickness thinner than the dimension of the side of the host structure  10  to be positioned in a manner where a face of cross support  12  is flush with the outer face of the host structures  10  parallel to the cross support  12 .  
         [0023]    Pictured in FIG. 3 is the corner of cross support  12  in which a section has been removed, thus showing a cross sectional view of the location of the locking mechanism  16  within the cross support  12 . There is a hole  22  drilled vertically through the cross support  12  to a predetermined depth, and a hole  26  drilled through the cross support  12  horizontally to a predetermined depth that terminates upon intersecting the vertical hole  22 . The cam  20  mounts in the vertical hole  22  leaving a slotted surface  24  flush with cross support  12  or below the surface of cross support  12 . This allows the panel to be installed without requiring a finishing of fastening devices. The cam  20  contains slotted surface  24  for rotational activation using an ordinary tool, such as a screwdriver or allen wrench.  
         [0024]    Also pictured in FIG. 3 is the locking body  18 . The locking body  18  can be made using various products by various methods such as machining, thermal molding, or casting. The locking body  18  is composed of five parts-an engagement disk  32 , a distal neck  34 , a central shaft  36 , a proximal neck  38 , and a ball  40 . The locking body has on its proximal end ball  40  made to fit into cam  20 . The distal end contains round engagement disk  32 . In the preferred embodiment, the engagement disk  32  is sized so that it maybe movable within the slot  14   c  when the cam  20  is in an unlocked or open position, as explained later. The engagement disk  32  will not be able to be removed from the slot  14   c  when the locking body  18  is centrally located within slot  14   c  and pulled towards the outer edge of the slot  14   c  in the host structure  10 .  
         [0025]    Preferably, the engagement disk  32  is sized to allow insertion of locking body  18  into slot  14   b  by angling the locking body  18  and inserting one edge of the engagement disk  32  into the slot  14   b  first, and then leveling the locking body  18  to rest perpendicular against the face of the host structure  10 . Upon being brought to perpendicular, the edge opposite of the edge of the engagement disk  32  initially inserted in slot  14   b  will not interfere with either opposing segment  13   a  or  13   b  on the end of respective perpendicular struts  15   a  and  15   b  of slot  14   b  on the host structure  10 . This allows for the locking body  18  to be inserted from at any point along the slot  14   b  in the host structure  10 , providing adjustability along the entire length of the slot. The engagement disk  32  could also be of other shapes, such as cylindrical, rectangular, or polygonal, so long as it engages both sides of the slot  14 .  
         [0026]    The locking body  18  also has a central shaft  36  that is made to fit into horizontal hole  26  of the cross support  12 . The central shaft  36  diameter is the same or slightly smaller of that of the horizontal hole  26 , and the shaft is concentrically aligned with the hole in the cross support  12  allowing for linear, reciprocal movement of the shaft within the aperture of the horizontal hole  26 . Although the preferred embodiment is for a cylindrical shaft, any shape of the slot  14  and corresponding central shaft  36  would work that allows for reciprocating motion.  
         [0027]    Between the engagement disk  32  and the central shaft  36  is the distal neck  34 . Preferably, the distal neck  34  is cylindrical. The diameter is smaller than that of the central shaft  36 , and is of a diameter which allows the engagement disk  32  to be inserted into slot  14  without impediment as previously described. Similarly, between the central shaft  36  and the ball  40  is the proximal neck  38 . The diameter of this cylindrical neck fits between tabs  52  and  54  of the cam  20 .  
         [0028]    [0028]FIG. 4 is a cross sectional view of the locking mechanism  16  with the cross support  12  abutting the host structure  10 . The locking mechanism  16  is in a closed position. As illustrated ball  40  is cradled within of the cam  20 , and that the engagement disk  32  is pulled tight against the outer edge of the slot  14 . The cam  20  and locking body  18  are positioned within the cross support  12  such that in the engaged position, the edge of the engagement disk  32  is abutting opposing segments  13   a  and  13   b  in the slot  14  the host structure  10 . As a result, the cross support  12  is held firmly in place against the host structure  10 .  
         [0029]    [0029]FIG. 5 is an isometric view of the locking body  18  and cam  20 . The cam  20  has two tabs  52  and  54 , extending upward from the centerline of the cam  20 . These two tabs  52  and  54  form an opening which receives the proximal neck  38  of the locking body  18 . The distance between the tabs  52  and  54  is less than the nominal diameter of ball  40 . Thus, ball  40  prevents the locking body  18  from disconnecting with the cam  20  by impeding linear motion of the locking body  18  past the tabs  52  and  54  of the cam. Also, the cam  20  has been hollowed out spherically to allow for reception of the ball  40  of the locking body  18 . As is shown by arrow  56 , upon rotating the cam  20  90° counterclockwise from the initial position, the locking body  18  is linearly pulled to the left as represented by arrow  58 . This results from the original ball  40  placement in the cam  20  at the starting position not centered concentrically with the cam itself. As the cam  20  is turned, the angle of the hollowed out sphere section engages the ball  40  and pulls it toward the center of the cam  20 . The small amount of rotation required to engage the locking mechanism allows for quick assembly of cross supports  12  and host structures  10 . Rotating the cam 90° clockwise from the initial position will align the cam  20  so that the tabs  52  and  54  are no longer around the proximal neck  38 . Thus, the locking body  18  can be removed entirely from the cam  20 , with the ball  40  not being impeded by the tabs  52  and  54  of the cam  20 .  
         [0030]    The practical result of this can be seen in FIGS. 6 and 7. FIG. 6 shows a side view of host structure  10 , cross support  12 , and locking body  18  engagement disk  32  and distal neck  34 . There is a space between host structure  10  and cross support  12  denoting that the locking mechanism  16  is in the open position. FIG. 7 shows the engagement disk  32  flush against the host structure  10  thus pulling cross support  12  flush against the outer edge of host structure  10 . Although a rectangular structure is pictured, using host structures  10  of differing geometries can be used to create differing structures such as a trapezoid or other polygon. This is accomplished by altering the dimensions of the host structures  10  and cross supports  12 .  
         [0031]    In an alternate embodiment, a bumper (not shown) is connected to the locking body on the distal end. In this embodiment, the bumper is rubber or a similarly elastic material that allows for cushioning between the tube face in the slot and the locking body. Preferably, the bumper is adhesively attached to the locking member, and is concentric with the distal face of the engagement disk  32 . Such bumpers are readily obtained at hardware stores, such as a 3M Bump-on™. The cushioning of the bumper allows the locking body  18  to be inserted into the slot  14  in the host structure  10  and remain in place due to the outward pressure exerted on the proximal face of the engagement disk  32  from the spring action of the elastic material pushing against the tube face in the slot  14 . Once placed, a cross support  12  can be aligned so that the horizontal hole  26  receives a preplaced locking body  18 . Once the cross support  12  is positioned so that the cam  20  is engaging the ball  40  of the locking body  18 , the cam  20  can be rotated to fasten the host structure  10  and cross support  12 .  
         [0032]    In a second alternate embodiment, the cross support  12  contains a tongue (not shown) on the edge that abuts the host structure  10 . The tongue can extend partially or the entire length of cross support  12 , and helps in the alignment of the host structure  10  and cross support  12  to be assembled. The tongue is notched to allow the locking body  18  to enter the slot in the host structure  10 . Preferably, the tongue itself is a width allowing fit between the opposing segments  13   a  and  13   b  perpendicular to the struts  15   a  and  15   b  of the slot  14  in the host structure  10 . The tongue&#39;s thickness is no more that the depth of the slot  14  in the host structure  10 . The tongue adds structural support between the host structures  10 , but still allow the face of the host structure  10  and surface at the end of the tongue on the cross support  12  to be flush to one another when the locking body  18  and cam  20  are engaged.  
         [0033]    In another alternate embodiment, the rectangular tube of the host structure  10  contains an extension from a corner of the host structure  10  to create a channel. The extension comprises a flat surface extending perpendicular to the surface of the tube, and another surface that is angled or arced that begins at the comer of the tube of the host structure  10  and terminates at a point near the intersection with the flat surface. The opposite end of the channel comprises a segment perpendicular to the surface of the host structure  10 , which may also comprise the strut  15 . The extension covers the edge of a cross support  12  mounted to the host structure  10  to conceal any imperfections along the edge, such as chipping or splintering of the material, of the cross support  12 . In this alternate embodiment, the tongue of the cross support  12  mates into a channel in the host structure  10 . The channel comprises an extension on the host structure  10  and the surface of the host structure  10  near the slot  14 . In such an embodiment, the tongue is not notched, and extends the entire length of the cross support.  
         [0034]    Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.