Abstract:
A furniture member joining system includes a U-shaped fastener having first and second posts extending transversely from a post body. First and second post receiving bight inserts are each engageable with one of a first and second furniture member. The first post is slidably received in the first bight insert and the second post is slidably received in the second bight insert to releasably couple the first furniture member to the second furniture member.

Description:
FIELD 
       [0001]    The present disclosure relates to devices used to releasably couple furniture members. 
       BACKGROUND 
       [0002]    The statements in this section merely provide background information related to the present disclosure and may not constitute prior art. 
         [0003]    Furniture members such as chairs, sofas, sectionals, loveseats, and the like often include multiple members that can be joined to create larger seating or reclining surfaces. Common devices to attach multiple furniture members include fasteners such as brackets which couple together, and plates joined individually to each furniture member which are fastened together to semi-permanently join the furniture members. Known joining methods create alignment problems between the furniture members, are often cumbersome and difficult for an end user to disassemble or reassemble the furniture members, and require additional tools to connect and/or disconnect the joining couplings. Known joining methods are also prone to inadvertently disconnect or disengage. 
       SUMMARY 
       [0004]    According to several embodiments of the present disclosure, a furniture member joining system includes a U-shaped fastener having first and second posts extending transversely from a post body, wherein each of the first and second posts are adapted to engage with one of a first and second furniture member to releasably couple the first and second furniture members. 
         [0005]    According to additional embodiments of the present disclosure, a furniture member joining system includes a U-shaped fastener having first and second posts extending transversely from a post body. First and second post receiving bight inserts are each engageable with one of a first and second furniture member. The first post is slidably received in the first bight insert and the second post is slidably received in the second bight insert to releasably couple the first furniture member to the second furniture member. 
         [0006]    According to still further embodiments of the present disclosure, a furniture member joining system includes a U-shaped fastener having first and second posts extending transversely from a post body. First and second fastener brackets are each fastenably connected to one of a first and second furniture member. The first post is slidably received in the first fastener bracket and the second post is slidably received in the second fastener bracket to releasably couple the first furniture member to the second furniture member. 
         [0007]    Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
     
    
     
       DRAWINGS 
         [0008]    The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. 
           [0009]      FIG. 1  is a front perspective view of two furniture members joined using a joining system of the present disclosure; 
           [0010]      FIG. 2  is a front perspective view of the two furniture members of  FIG. 1  joined showing inserted bight inserts of the present disclosure; 
           [0011]      FIG. 3  is an end elevational view of a furniture member having bight insert fastener brackets of the present disclosure; 
           [0012]      FIG. 4  is the end elevational view of  FIG. 3 , after installation of upholstery and insertion of the bight inserts into the bight member fastener brackets; 
           [0013]      FIG. 5  is a front elevational view of a fastener bracket of the present disclosure; 
           [0014]      FIG. 6  is a top plan view of the fastener bracket of  FIG. 5 ; 
           [0015]      FIG. 7  is a front elevational view of a bight insert of the present disclosure; 
           [0016]      FIG. 8  is a top plan view of the bight insert of  FIG. 7 ; 
           [0017]      FIG. 9  is a front elevational view of a U-shaped fastener of the present disclosure; 
           [0018]      FIG. 10  is front elevational view of an installation of a fastener bracket to a furniture member frame, and a bight insert below an upholstery layer of the present disclosure; 
           [0019]      FIG. 11  is a front elevational view similar to  FIG. 10 , showing partial installation of a U-shaped fastener; 
           [0020]      FIG. 12  is a front elevational view modified from  FIG. 11  to additionally show a second furniture member frame member and fastener assembly of the present disclosure; 
           [0021]      FIG. 13  is a front elevational view modified from  FIG. 12  to show installation of a U-shaped fastener directly into abutting furniture member frames; 
           [0022]      FIG. 14  is a front elevational view modified from  FIG. 13  to show installation of a U-shaped fastener into bight inserts inserted into abutting furniture member frames; 
           [0023]      FIG. 15  is a front elevational view of a molded polymeric fastener bracket of the present disclosure; and 
           [0024]      FIG. 16  is a top plan view of the molded polymeric fastener bracket of  FIG. 15 . 
       
    
    
     DETAILED DESCRIPTION 
       [0025]    The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. 
         [0026]    Referring generally to  FIG. 1 , a furniture assembly  10  can include two or more furniture members which are temporarily and releasably connected together. In several embodiments, a first furniture member  12  and second furniture member  14  are joined and retained as an assembly using at least one U-shaped fastener  16 . In the embodiment shown in  FIG. 1 , first and second U-shaped fasteners  16 ′,  16 ″ are used. U-shaped fasteners  16  are releasably insertable through the face(s) of adjoining furniture portions such as furniture upholstery face  18 ′ and furniture upholstery face  18 ″ of first and second furniture members  12 ,  14  respectively. 
         [0027]    To help retain the U-shaped fasteners  16 , according to several embodiments a plurality of bight inserts  20  are first inserted into adjoining and aligned furniture upholstery faces  18 . Bight inserts  20  which are aligned between the first and second furniture members  12 ,  14  slidably receive and engage the U-shaped fasteners  16 . In the embodiment shown, bight inserts  20 ′,  20 ″ are connected through furniture upholstery face  18 ′ and bight inserts  20 ′″,  20 ″″ are connected through furniture upholstery face  18 ″. According to several embodiments, U-shaped fasteners  16  can be made of a metal such as steel or stainless steel, but can also be made from a rigid polymeric material. Bight inserts  20  can be made such as by injection molding from a polymeric material including polyamide materials. 
         [0028]    Referring now to  FIG. 2 , each of the first and second furniture members can further include an occupant back support member  22  (shown as back support members  22 ′,  22 ″), an occupant lower support area  24  (shown as lower support areas  24 ′,  24 ″), an outward arm rest  26  (shown as arm rests  26 ′,  26 ″), and an armrest support structure  28  (shown as armrest support structures  28 ′,  28 ″). Occupant lower support area  24  is commonly supported using a plurality of springs (not shown) such as sinuous wire springs which are overlayed with a cloth or matting material (not shown). An additional cushion (not shown) is commonly stacked above each of the occupant lower support areas  24 ′,  24 ″ after insertion of the U-shaped fasteners  16 . 
         [0029]    After frame structures of first and second furniture members  12 ,  14  have an upholstery covering provided, first and second furniture members  12 ,  14  are butted against each other for example having a first and second member side surface  30 ,  32  in abutment with each other. At this time, a first and second member upholstery surface  34 ,  36  of first and second furniture members  12 ,  14  should be approximately co-planer with each other. With the first and second furniture members  12 ,  14  aligned as shown in  FIG. 2 , bight insert  20 ′ is aligned with bight insert  20 ′″ and bight insert  20 ″ is aligned with bight insert  20 ″″. The arrangement is then ready to receive U-shaped fasteners  16 ′,  16 ″ shown in  FIG. 1 . 
         [0030]    Referring now to  FIG. 3 , a furniture member frame  38  which is commonly manufactured from a plurality of wooden and/or composite frame elements can include a frame side  40 , a frame back structure  42 , a frame arm structure  44 , and an arm support member  46 . A front leg  48  and a rear leg  50  are also shown, however, it should be obvious that two or more each of front legs  48  and rear legs  50  are commonly used for each furniture member frame  38 . Each of the front and rear legs  48 ,  50  position furniture member  38  above a floor surface  52 . 
         [0031]    With the furniture frame  38  oriented as shown, at least one fastener bracket  54  is connected to the furniture frame  38 . According to additional embodiments including the example shown, two fastener brackets  54  identified as fastener bracket  54 ′ and fastener bracket  54 ″ are connected to frame side  40 . More than two fastener brackets  54  can also be used if the connecting side lengths of the furniture members warrant additional fasteners. Fastener brackets  54  each include a U-shaped bight member receiving portion  56  shown in this embodiment as bight member receiving portions  56 ′,  56 ″. Bight member receiving portions  56  are adapted to receive and engage the bight inserts  20  described in reference to  FIG. 1 . Each of the fastener brackets  54 ′,  54 ″ are oriented as shown to align with an upper edge  58  of frame side  40 . Fastener brackets  54  are then connected to frame side  40  using a plurality of fasteners  60  such as screws or rivets. Upper edge  58  of frame side  40  is positioned at a height “A” with respect to the floor surface  52 . Each of the fastener brackets  54  is separated from the other fastener brackets  54  by a bracket spacing “B”. Bracket spacing “B” is maximized so that when U-shaped fasteners  16  are subsequently inserted the potential for separation between first and second furniture members  12 ,  14  is minimized. 
         [0032]    Referring to  FIG. 4 , an upholstery layer  62  is applied to furniture member frame  38  in contact with upper edge  58  as shown. Apertures (not clearly visible in this view) are created through upholstery layer  62  co-axial with bight member receiving portions  56 ′,  56 ″ for example by cutting, punching, or similar operation. Bight inserts  20  which in the example shown are indicated as bight inserts  20 ′,  20 ″ are then inserted through these apertures. The bight inserts  20 ′,  20 ″ are each inserted in an insertion direction “D” and an insertion direction “E” respectively. After application of upholstery layer  62 , an upholstered elevation “C” results. A portion of bight inserts  20  abuts with and extends above the upholstery layer  62 . Additional layers of upholstery which are commonly applied to frame back structure  42 , frame arm structure  44 , and arm support member  46  are not shown for clarity. 
         [0033]    Referring to  FIG. 5 , each of the fastener brackets  54  includes first and second planar wings  64 ,  66  which are each located outwardly of the bight member receiving portion  56 . At least one and preferably a plurality of apertures identified as fastener receiving apertures  68 ′,  68 ″,  68 ′″, and  68 ″″ are created in the first and second planar wings  64 ,  66  to permit fastener bracket  54  to be fastened to the individual furniture member. Each fastener bracket  54  has a bracket width “F” and a bracket height “G”. Bracket width “F” and bracket height “G” can be dimensionally equal, however, the present disclosure is not limited to the rectangular geometry or dimensions of fastener brackets  54 . 
         [0034]    Referring to  FIG. 6 , further details of fastener brackets  54  include a bracket plate thickness “H”, a receiving portion radius “J” defined by bight member receiving portion  56 , and a receiving portion stand-off dimension “K” of bight member receiving portion  56 . According to several embodiments of the present disclosure, bracket width “F” can be 2.18 inches (5.54 cm), bracket height “G” can be 2.00 inches (5.08 cm), bracket plate thickness “H” can be 0.03 inches (0.76 mm), receiving portion radius “J” can be 0.36 inches (0.91 cm), and receiving portion stand-off dimension “K” can be 0.72 inches (1.83 cm). These dimensions are provided for example only and do not limit the scope of the present disclosure. 
         [0035]    Referring now to  FIG. 7 , each of the bight inserts  20  include a tubular body  70  having a plurality of bight elements  72  sequentially positioned in an axial direction of tubular body  70 . Each of the bight elements  72  include a bight face  74  which all face toward a flange  76 . Bight elements  72  are deflectable to allow insertion of bight inserts  20 . Bight inserts  20  include a bight member length “L” and each of the bight elements  72  has a bight length “M”. Each of the bight elements  72  also has a minimum diameter “N”. A lead-in end of the bight inserts  20  have a diameter “P” at a free end of each of the bight inserts  20  which define a minimum diameter of the bight elements  72  and also provide for easier initial insertion of bight inserts  20 . Referring back to  FIG. 6 , a dimension for receiving portion radius “J” is predetermined to receive the minimum diameter “N” of body portion of bight inserts  20  while frictionally engaging the bight elements  20 . According to several embodiments of the present disclosure, bight member length “L” can be 2.125 inches (5.39 cm), bight length “M” can be 0.15 inches (0.38 cm), diameter “N” can be 0.72 inches (1.83 cm), and lead-in diameter “P” can be 0.64 inches (1.63 cm). As previously noted, these dimensions are not limiting to the present disclosure. 
         [0036]    Referring to  FIG. 8 , each of the bight inserts  20  further include a post receiving aperture  78  created throughout the total bight member length “L” including through flange  76 . Flange  76  has a flange diameter “Q” and post receiving aperture  78  has a post aperture diameter “R”. According to several embodiments flange diameter “Q” can be 1.0 inches (2.54 cm), and post receiving aperture diameter “R” can be 0.52 inches (1.32 cm). 
         [0037]    Referring to  FIG. 9 , each of the U-shaped fasteners  16  include a base portion  80  having a base portion width S, and each of a first post  82  and a second post  84 . First post  82  has a first post length “T” and second post  84  has a second post length “U”. First post length “T” is greater than second post length “U” to allow U-shaped fasteners  16  to accommodate minor discrepancies in the elevation as well as alignment between the various furniture members to be joined. The difference in post length also allows first post  82  to be partially inserted in one of the bight inserts  20  while aligning second post  84  with the corresponding aligned one of the other bight inserts  20 . Each of the first and second posts  82 ,  84  define a post to base angle alpha with base portion  80 . According to several embodiments, post to base angle alpha is approximately 90°. 
         [0038]    First post  82  has a free end defined by a first post apex  86 . Similarly, second post  84  has a free end defined by a second post apex  88 . The rounded post apexes  86 ,  88  of the first and second posts  82 ,  84  are adapted to permit insertion alignment and ease of insertion of the posts. U-shaped fasteners  16  have a post diameter “V” which is maintained for both the first and second posts  82 ,  84 . A post spacing “W” is maintained between first and second post apexes  86 ,  88 . According to several embodiments of the present disclosure, first post length “T” can be 2.5 inches (6.35 cm), second post length “U” can be 1.5 inches (3.81 cm), post diameter “V” can be 0.5 inches (1.27 cm), and post spacing “W” can be 3.3125 inches (8.41 cm). Referring to both  FIGS. 8 and 9 , post receiving aperture diameter “R”, which in the present example is 0.52 inches (1.32 cm), is larger than post diameter “V” 0.5 inches (1.27 cm) to allow a sliding clearance fit for the first and second posts  82 ,  84 . These dimensions are exemplary only and do not limit the size or shapes of the components of the present disclosure, which can be scaled up or down or sized differently for different furniture member applications within the scope of the present disclosure. 
         [0039]    Referring now to  FIGS. 10 through 12 , the difference in post length between first and second posts  82 ,  84  can also accommodate insertion of the U-shaped fasteners  16  below an existing layer of upholstery if desired rather than above the upholstery layer. As shown in  FIG. 10 , fastener bracket  54 ′ is fastened to a furniture member frame  90 . A bight insert  20 ′ is inserted through upholstery layer  62 ′ and into the bight member receiving portion  56 ′ of fastener bracket  54 ′. An upper surface of the flange  76 ′ of bight insert  20 ′ is positioned substantially flush or co-planar with an upper edge  92  of furniture member frame  90 . An upholstery layer  94  is then applied to the furniture member frame  90  above the bight insert  20 ′, but is not fastened to the frame  90  proximate to bight insert  20 ′. As shown in  FIG. 11 , this allows the upholstery layer  94  to be lifted proximate to bight insert  20 ′. After lifting upholstery layer  94 , the longer first post  82 ′ of U-shaped fastener  16 ′ is partially inserted into bight insert  20 ′ and the shorter second post  84 ′ is positioned as shown. 
         [0040]    As shown in  FIG. 12 , a bight insert  20 ″ is installed similar to bight insert  20 ′ through upholstery layer  62 ″ and under an upholstery layer  96  of a furniture member  98  (which is shown lifted away from bight insert  20 ″). The shorter second post  84 ′ is then readied for insertion by aligning with the post receiving aperture  78 ″ of bight insert  20 ″ and both first and second posts  82 ′,  84 ′ can then be fully inserted. Both upholstery layers  94  and  96  can be replaced above the furniture member frames  90 ,  98 . This configuration allows the installation of U-shaped fasteners  16  which can be kept substantially out of sight for furniture members such as chairs which do not have a cushion member installed after installation of the U-shaped fasteners  16 . 
         [0041]    Referring again to  FIGS. 1 ,  3 , and  9  in additional embodiments of the present disclosure, the bight inserts  20 ′,  20 ″,  20 ′″, and  20 ″″ can be eliminated if the furniture members  12 ,  14  each include a frame structure having a width sufficient to allow apertures to be created in the frame structure which can accommodate the diameter of the posts  82 ,  84 . These embodiments also permit the elimination of the fastener brackets  54 . According to additional embodiments, the fastener brackets  54  can be eliminated if the furniture members  12 ,  14  each include a frame structure having a width sufficient to allow apertures to be created in the frame structure which can accommodate the diameter of the bight inserts  20 . According to still further embodiments, the bight inserts  20  can be eliminated by creating fastener brackets with a post receiving diameter adapted to slidably receive the diameter of posts  82 ,  84 . Fastener brackets of these embodiments can be created from a metal or a polymeric material. 
         [0042]    Referring to  FIG. 13 , a U-shaped fastener  16 ′ is shown inserted through upholstery layers  62 ′,  62 ″ and into the furniture member frames  90 ,  98 . This embodiment eliminates both the bight inserts  20  and the fastener brackets  54 . Apertures (not shown), can be pre-formed such as by drilling into each of furniture member frames  90 ,  98  to receive the posts  82 ′,  84 ′ of U-shaped fastener  16 ′. 
         [0043]    Referring to  FIG. 14 , the embodiment of  FIG. 13  can be modified by inserting bight inserts  20 ′,  20 ′″ through upholstery layers  62 ′,  62 ″ and into furniture member frames  90 ,  98  prior to insertion of U-shaped fastener  16 ′. This embodiment provides bight inserts  20 ′,  20 ′″ which frictionally engage within apertures (not shown) created in furniture member frames  90 ,  98 , but eliminates the fastener brackets  54 . 
         [0044]    Referring to  FIGS. 15 and 16 , according to further embodiments, a homogenous, one-piece body, molded polymeric fastener bracket  100  can be used in place of fastener bracket  54 . Similar to fastener brackets  54 , fastener bracket  100  includes a bight member receiving portion  102 , and first and second planar wings  104 ,  106  which are each located outwardly of the bight member receiving portion  104 . At least one and preferably a plurality of apertures identified as fastener receiving apertures  68 ′,  68 ″,  68 ′″, and  68 ″″ are created in the first and second planar wings  104 ,  106  to permit fastener bracket  100  to be fastened to the individual furniture member. Similar to fastener brackets  54 , each fastener bracket  100  has a bracket width “F” and a bracket height “G”. Bracket width “F” and bracket height “G” can be dimensionally equal, however, the present disclosure is not limited to the rectangular geometry or dimensions of fastener brackets  100 . Further details of fastener brackets  100  include a bracket plate thickness “H”, a receiving portion radius “J” defined by bight member receiving portion  102 , and a receiving portion stand-off dimension “K” of bight member receiving portion  102 . 
         [0045]    The furniture member attachment system of the present disclosure offers several advantages. The U-shaped fasteners of the present disclosure allow two or more furniture members to be releasably joined without the use of additional tools. The different length posts of the U-shaped fasteners allow insertion of a longer first post in a first furniture member to help align the second furniture member before insertion of the second shorter post. Post receiving bight inserts made of a polymeric material can be installed through upholstery layers of the furniture member and provide a sliding fit to receive the posts of the U-shaped fastener. Misalignment of the furniture members can also be accommodated by the different post lengths and angular engagement of the U-shaped fasteners.