FASTENER SYSTEM FOR SLATTED CONSTRUCTION

A fastener system for quick and easy assembly of a slatted article is used to join multiple slats and connects a support thereto. A flange inserted into one of the slats receives a stud connected to the support. A rod connects a plurality the slats, and mates with the flange. The flange and rod are rotatable within the slats to properly position and tighten the fastener system.

TECHNICAL FIELD

The present invention pertains generally to construction of slatted articles, such as furniture, architectural components, or the like, and more particularly to fastener systems therefor.

BRIEF SUMMARY OF THE EMBODIMENTS

The embodiments of a fastener system described herein provide a way to quickly and easily assemble an article having several parallel slats, such as an article of furniture, an architectural component, or the like. The fastener system joins multiple slats and connects a support (such as a leg, an extruded member, another slatted article, or the like) thereto. The fastener system may also join a support to a solid, non-slatted article, such as a furniture member, panel, or similar. The system is suitable for various types of furniture, such as a bench, table, stool, bed frame, shelf, or the like. The system is also suitable for various architectural components, such as wall and/or ceiling systems, fences, decking, walkways, docks, atriums, pergolas, and so on. Elements of the fastener system are hidden from view in the finished assembly, providing an appealing overall aesthetic.

According to one or more embodiments, a fastener system is configured to cooperate with a slatted article, the slatted article including a support and multiple slats each having a through hole. At least one of the slats may have a retainer hole. The fastener system includes:a stud configured for connection to the support;a flange configured for insertion into at least one slat, the flange having: a longitudinal channel having a proximal end dimensioned to receive the stud therethrough and an opposing distal end; a transverse channel oriented substantially orthogonally to the longitudinal channel and opening thereto; and an external aperture opening to the transverse channel;a rod configured to connect a plurality of the multiple slats, the rod having a rod end which is configured to mate with the distal end of the flange;wherein, when the stud is inserted through the flange, a portion of the stud (e.g., a notch) is positioned to align with the external aperture of the flange; andwherein, the flange is rotatable within the at least one slat to position the external aperture of the flange for access through the retainer hole.

According to one or more embodiments, the rod is configured to be freely rotatable within the through holes of the connected plurality of slats.

According to one or more embodiments, the transverse channel passes through a diameter of the flange and two opposing external apertures open to the transverse channel.

According to one or more embodiments, a retainer is configured for insertion through the external aperture of the flange into the transverse channel and engagement with the notch in the stud.

According to one or more embodiments, a notch is circumscribed around the stud.

According to one or more embodiments, a notch has sidewalls which taper inwardly from an exterior surface of the stud to a floor of the notch.

According to one or more embodiments, the flange has a flange head configured to mate with a driver for rotating the flange within the at least one slat.

According to one or more embodiments, the stud may have two stud heads at opposing ends of the stud. According to one or more embodiments, the stud includes a spacer intermediate the two stud heads.

These and other aspects of the embodiments will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. The following description, while indicating various embodiments and details thereof, is given by way of illustration and not of limitation. Many substitutions, modifications, additions, or rearrangements may be made within the scope of the embodiments, and the embodiments may include all such substitutions, modifications, additions, or rearrangements.

DETAILED DESCRIPTION OF THE INVENTION

Referring initially toFIGS.1-6, there are illustrated upper and lower perspective, end, top, side, and bottom views, respectively, of an article of slatted furniture generally designated500. Slatted furniture500includes an embodiment of a fastener system designated20. In general, fastener system20connects multiple slats to form a slatted surface, also referred to herein as a deck. Fastener system20connects a furniture support510to the deck. Support510may be, for example, a leg, a stand, a mounting bracket, or similar.

View orientations used herein are with respect to an article of furniture, where a side refers to a major dimension, an end refers to a minor dimension, the top is oriented away from a floor, and the bottom is oriented toward the floor.

As used herein, the term “shaped” means that an item has the overall appearance of a given shape even if there are minor variations from the pure form of said given shape.

As used herein, the terms “generally” or “substantially” when referring to a shape mean that an ordinary observer will perceive that an object has said shape even if there are minor variations from said shape.

As used herein, the conjunction “or” is to be construed inclusively (e.g., “A or B” would be interpreted as “A, or B, or both A and B”; e.g., “A, B, or C” would be interpreted as “A; or B; or C; or any two of A, B, and C; or all three of A, B, and C”).

As used herein, the term “about” or “approximately” or “substantially when referring to a number refers to a range of values within plus or minus 10% of the specified number.

Components of an embodiment of fastener system20are shown in the end view ofFIG.7, where hidden elements are shown in dashed lines, and in the exploded views ofFIGS.8A and8B. In the shown embodiment, furniture500is a slatted bench having four supports510, which are legs. Multiple slats (e.g.,520,530,540) are connected in spaced apart relation along rods60. In the shown embodiment, four rods are present, offset from one another along the major dimension of the deck. Spacers70(see alsoFIG.18-19) may be interposed between the slats. The deck is assembled by inserting each rod60alternately through a through hole (522,532,542) in a slat and through a central aperture72of a spacer, forming a deck sub-assembly.

FIGS.9-12are enlarged perspective, end, side, and bottom views, respectively, of a flange40of the fastener system. Flange40is shaped and dimensioned to be inserted into a through hole522of an exterior slat520, and may extend through one or more additional slats (e.g. into a through hole532of a second slat530). A distal end48of flange40is configured to mate with a rod end62of rod60(see alsoFIG.17).

During assembly (refer toFIGS.7,8A, &8B), rod60is inserted into through holes542of multiple slats540. Twelve of slat540are present in the shown embodiment (see alsoFIGS.25-26), although more or fewer slats may be used depending on the desired size of furniture. Flange40is inserted into exterior slat520, through second slat530, and distal end48of flange40mates with rod end62(shown internal to slat540inFIG.7). In the shown example, distal end48has an internal thread sized to mate with an external thread of rod end62, although other mating configurations may be used.

Flange40has a flange head49. The flange head49may include a slot45suitable for insertion of a screwdriver or a custom driver, such as flange tool90discussed below. The shown flange head49has a flat exterior face configured to fit within a counter-bore of through hole522, visible inFIGS.20-21. The counter-bore provides a smooth exterior surface when flange40is assembled in exterior slat520, and allows the surfaces of leg510and exterior slat520to closely contact one another (seeFIG.7).

Flange40has a longitudinal channel42dimensioned to receive the stud through a proximal end50. Flange40also has a transverse channel44which opens to longitudinal channel42. Transverse channel44has an external aperture46configured to align with a hole in bottom of one of the slats, such as retainer hole534of second slat530(shown inFIGS.22-24). Flange40may be rotated within the slats to align external aperture46with retainer hole534. In the shown embodiment the transverse channel goes through the entire diameter of the flange, and may therefore be aligned with retainer hole534in either of two positions (rotated about 180 degrees apart from one another).

FIGS.13-16are enlarged perspective, end, side, and bottom views, respectively, of an embodiment of a stud30. Stud30is connectable to leg510, for example in threaded region512, shown inFIGS.27-28. An end32of the shown stud has an external thread configured to mate with a threaded region512of leg510. Alternative ways of mating the stud with the leg could be used, such as providing a shaft at end32to be mated with a hole in leg510, with or without adhesive. A stud head34has a recess35suitable for inserting a driver. In the shown embodiment, recess35is suitable for a flathead screwdriver, although a recess for a hex wrench, Phillips head, or other type of driver may alternatively be provided.

In the shown embodiment, two studs30are assembled to each of four legs510by screwing threaded ends32into corresponding threaded regions512. A screwdriver may be inserted into recess35and used to drive the stud into the leg. The assembly of a leg with mated studs is referred to herein as a support sub-assembly.

Stud30further includes a notch36, shown revolved around the body of stud30(i.e., notch30may be rotationally symmetric about a longitudinal axis of the stud). Notch36is configured to align with external aperture46of the flange when the stud is inserted into the flange (seeFIG.7). The notch has angled sidewalls38a,38bwhich taper inwardly from an exterior surface33of the stud toward the central longitudinal axis of the stud, forming a wider opening at the outer region of the notch and a more narrow floor39of the notch. As shown, sidewalls38a,38btaper inwardly at a 45° angle, although different angles may be used to achieve the same result.

The support sub-assemblies are joined to the deck sub-assembly by inserting each stud30into the longitudinal channel42of one flange40to a depth where notch36of the stud aligns with external aperture46of the flange. A retainer80, such as a set screw, is inserted through retainer hole534and external aperture46to contact floor39or sidewalls38a,38bof the notch. In the shown embodiment, transverse channel44is threaded for mating with a threaded retainer80. Angled sidewalls38a,38bguide retainer80toward the narrow floor39of notch36, while drawing the support sub-assembly inward to contact the deck sub-assembly.

FIGS.29-33are views of a flange tool90which may be provided with fastener system20. Flange tool90may be used to rotate flange40within the deck sub-assembly, for the purpose of aligning external aperture46with retainer hole534. In the shown embodiment, flange tool90has a blade92sized to engage slot45of the flange head. The tool also includes a tongue96which is sized to engage the flange through the longitudinal channel44(seeFIGS.9-12). A shank94is provided on the opposite side from blade92, and may be used to grip or drive the flange tool, such as with pliers, a drill, or a bit driver.FIG.34illustrates how flange tool90may engage flange40.

FIG.35shows components of another embodiment of fastener system20, for joining a support (e.g. leg510) to a solid member580of the article of furniture. Solid member580may be, for example, a bench top, a chair seat, or a shelf. Stud30is connected to support510in the manner described above. Flange40is inserted into a complementary shaped hole in solid member580, and may have features and a shape as described above. External aperture46of the flange is aligned with a hole in solid member580. To join the solid member to the support, stud30is inserted into flange40and a retainer is inserted into external aperture46to contact notch36of the stud. In this manner the support is drawn inwardly to contact solid member580. While theFIG.35embodiment shows support510being a leg, the support may take alternate forms, such as a shelf bracket which may be mounted to a wall before or after connection to solid member580.

The following dimensions for elements of fastener system20provide an exemplary embodiment suitable for a slatted bench. Flange40may have a length of about 3 inches and a diameter of about 0.75 inches. Stud30may have a length of about 2.75 inches and a diameter of about 0.375 inches. Each slat (520,530,540) may have a length of about 36 inches, a width of about 0.875 inches, and a height of about 1.25 inches. Spacers70may have an outer diameter of about 1 inch and an inner diameter (of central aperture72) of about 0.75 inches (FIG.18) or of about 0.5 inches (FIG.19).

The flange, stud, and rod may be made of stainless steel or other materials suitable for fastening hardware. The slats may be made of wood, composite plastic, or other material suitable for construction of furniture or architectural members. The spacers may be formed of anodized aluminum, plastic, rubber, or other materials. The legs may be cast aluminum, wood, composite plastic, or other material suitable for furniture supports.

The supports of the shown embodiment (legs510) are exemplary, and the system may function in a similar manner with other types of support. Support legs may be of different shape or dimensional ratio from the illustrated leg510. More or fewer than four legs may be used to support different styles of furniture. In another embodiment, the support may be a mounting bracket for a shelf. One side of the mounting bracket may connect with studs30of the fastener system, while the opposite side is configured to contact a wall or other surface. In such an embodiment, supports may be present on only one side of the slatted furniture.

FIGS.36-37are front and enlarged exploded front views, respectively, of an exemplary slatted article600including an embodiment of the fastener system. In the shown embodiment, slatted article600includes several slatted panels (e.g., a first slatted panel650and a second slatted panel652) which are connectable to one another as well as to one or more supports610. Each slatted panel is shown constructed with four rods660and corresponding flanges and spacers as described elsewhere herein. It will be understood that more, or fewer, rods, flanges, and other fastener system components may be used as desired for the size of the slatted article and the application. Supports610may be, for example, deck or fence posts, but it is to be understood that the fastener system may be installed in a similar manner by connection to other types of support such as an extruded member, a post that is anchored in the ground, a joist, a stud, and so on. One or more studs630aof the fastener system may be configured for connection to support610, such as described elsewhere herein (e.g., with respect to studs30ofFIGS.8A-8B).

Slatted article600may also include one or more studs630bconfigured for connecting two slatted articles to one another (e.g., first slatted panel650and second slatted panel652).FIG.38is an enlarged front view of an embodiment of stud630b. Studs630bmay include two stud heads634, located at opposite ends of stud630b. A notch636may be located adjacent to each stud head634(on other words, two notches636may be present on each stud630b). Each notch636may include features described elsewhere herein, such as with respect to stud30). In this manner, stud630bmay be configured for coupling to a flange of a fastener system on each end (in other words, each two stud heads634may couple to a flange), thereby connecting two slatted articles without a support, or intermediate to a support. Stud630bmay also include a spacer670located intermediate the two stud heads634. When two slatted articles are joined with a stud having spacer670, spacer670may provide the same visual appearance as other spacers of the fastener system (such as spacers70ofFIG.8B), so that multiple slatted articles joined with such a stud have a continuous or seamless overall appearance. This style of joining slatted articles may be used for constructing large structures such as deck surfaces, walkways, walls or partitions, docks, ceilings, and the like.

FIGS.39-40are perspective and end views, respectively, of an embodiment of a stud730a support710. Support710may be an extruded member and may have any shape or length as desired for the application (e.g., supports610ofFIGS.36-37may include similar features of support710). Stud730may have features similar to other studs described herein, such as a stud head734, a notch736, a spacer770, and a threaded end732. Threaded end732may couple to a threaded region712of support710; threaded region712may for example be a threaded square washer inserted into a channel711of support710. In this manner, stud730may be positionable within support710(e.g., along the channel of the extrusion).

FIGS.41-42are front and reduced top views, respectively, of a slatted article800(e.g., a planter) including an embodiment of the fastener system. Slatted article800may include one or more extruded supports810which may have a similar structure described elsewhere herein (e.g., with respect to support710ofFIG.39). Examples of other slatted articles that may be constructed in a similar manner include shelving units, standing lights, bins, and so on.

FIG.43is a front perspective view of a slatted article900including an embodiment of the fastener system (hidden from view in this figure).FIG.44is an enlarged perspective view of an embodiment of a stud930and a support910, which, for example, may be used with slatted article900ofFIG.43. Slatted article900includes several slatted panels (e.g., a first slatted panel950and a second slatted panel952). One or more of slatted panels950and952may be slidingly positionable within slatted article900. Stud930of a slidingly positionable slatted panel may be connected to a support910which is a component of a track system (e.g., a wheeled component as shown inFIG.44. Stud930may include other features described elsewhere herein, such as a stud head934and a notch936.

FIGS.45-46are schematic representations of embodiments of the fastener system including one or more slats940and a rod960. The shown embodiments illustrate non-rectangular profiles of slats940. Numerous profiles of slat940may be envisioned; such profiles may have aesthetic appeal and/or functional features (for example, features to permit water runoff such as for exterior cladding).

Furthermore, while embodiments discussed herein may refer to connecting multiple slats in a substantially flat arrangement, slatted articles having curved shapes may also be formed using one or more fastener systems of this disclosure. For example, using assembly methods disclosed slats or slat assemblies may be connected on a bent threaded rod or hoop. Such assemblies may be interconnected in numerous arrangements to provide slatted articles that are circular, rounded, serpentine, or irregularly shaped.

Further provided is a slatted article, wherein fastener system20is packaged with the slats, supports, and other components for construction of the slatted article. In other embodiments, the components of the fastener system may be packaged independently of the other pieces useful for construction of the slatted article (e.g., the slats). Embodiments may optionally include a flange tool.

In terms of use, a method of assembling a slatted article includes: (refer toFIGS.1-35)a. providing a plurality of slats (520,530,540), each having a through hole (522,532,542), one of the plurality of slats having a retainer hole534;b. providing a support510;c. providing a fastener system20including:i. a stud30configured for connection to the support;ii. a flange40configured for insertion into at least one of the plurality of slats, the flange having: a longitudinal channel42having a proximal end50dimensioned to receive the stud therethrough and an opposing distal end48; a transverse channel44oriented substantially orthogonally to the longitudinal channel and opening thereto; and an external aperture46opening to the transverse channel;iii. a rod60configured to connect two or more of the plurality of slats, the rod having a rod end62which is configured to mate with the distal end of the flange; andiv. a notch36in the stud positioned to align with the external aperture of the flange when the stud is inserted therethrough;d. building a support sub-assembly by mating the stud to the support;e. building a deck sub-assembly by inserting the rod through two or more of the plurality of slats;f. inserting the flange into at least one of the plurality of slats and mating the rod end with the distal end of the flange;g. rotating the flange with the rod mated therewith within the deck sub-assembly to position the external aperture of the flange for access through the retainer hole;h. inserting the stud of the support sub-assembly through the proximal end of the flange into the longitudinal channel, so that the notch of the stud aligns with the external aperture of the flange; andi. fastening the support sub-assembly and deck sub-assembly to one another by inserting a retainer80through the retainer hole of the slat and through the external aperture in the flange to contact the notch of the stud, thereby retaining the stud within the flange and drawing the support sub-assembly toward the deck sub-assembly.

The method further including: providing a plurality of spacers70; and, in (e), positioning one of the plurality of spacers between each slat of the deck sub-assembly and inserting the rod therethrough.

The method further including: providing a driver90; in (c)(ii), the flange having a flange head49configured to mate with the driver; and, in (g), mating the driver with the flange head and rotating the flange with the rod mated therewith with the driver.

The embodiments of the fastener system and methods of use described herein are exemplary and numerous modifications, combinations, variations, and rearrangements can be readily envisioned to achieve an equivalent result. Further, nothing in the above-provided discussions of the system and method should be construed as limiting the invention to a particular embodiment or combination of embodiments. The scope of the invention is defined by the appended claims.