Abstract:
An assembly system permitting separate construction and transport of subcomponents for seating furniture items. The disassembled subcomponents allow for more efficient transportation by eliminating the dead space created by transporting irregularly shaped assembled furniture items. The assembly system includes a seat box having a rectangular frame defining an accessible internal cavity covered by an upper support surface. The assembly system also comprises a back rest having a seat box interface surface and at least arm rest interface surface. The back rest also defines an internal cavity accessible through closable opening for internal access to the arm rest interface surfaces. The assembly system also includes mounting an interface surface to the arm rest for securing the arm rest to the arm rest interface surface of the back rest and the rectangular frame of the seat box.

Description:
PRIORITY CLAIM 
       [0001]    This application is a continuation of U.S. patent application Ser. No. 13/304,172, filed Nov. 23, 2011, now U.S. Pat. No. 8,777,319 issued on Jul. 15, 2014, and entitled “FURNITURE ASSEMBLY SYSTEM”, which application claims the benefit of U.S. Provisional Application No. 61/469,332 filed Mar. 30, 2011, and entitled “FURNITURE ASSEMBLY SYSTEM”, and U.S. Provisional Application No. 61/515,677 filed Aug. 5, 2011, and entitled “FURNITURE ASSEMBLY SYSTEM”, which applications are hereby incorporated by reference in their entirety. 
     
    
     FIELD OF THE DISCLOSURE 
       [0002]    The present invention is directed to a ready to assembly furniture item and related method of assembling. Specifically, the present invention is directed to a ready to assemble furniture item that can transported as a plurality subcomponents and assembled without tools. 
       BACKGROUND OF THE INVENTION 
       [0003]    Furniture items used for seating commonly comprise a support structure covered by upholstery and/or cushioning. In particular, sofas typically comprise a seat base, a back rest and at least one arm rest. A common aesthetic and practical design consideration is assembling the sofa to minimize the visible gaps between the subcomponents. Typically, the furniture item is fully assembled at the factory to insure the individual subcomponents are properly assembled and upholstered to minimize the appearance of visible gaps in the assembled furniture item. 
         [0004]    The inherent drawback of assembling the furniture item at the factory is that the shape of the assembled furniture item typically prevents efficient packing of the furniture items for transport. Depending on the shape and size of the furniture item, the packing of the furniture item can result in a significant amount of dead space within the shipping container or truck. In addition to increasing the cost of transportation, the dead space can allow the furniture items to shift during transport resulting in safety risks or damage to the furniture item. Similarly, assembled furniture items can be awkwardly shaped and difficult to navigate into the home or other structure without significant positioning and reorienting of the furniture item. The awkward maneuvering and positioning of the furniture item required to move the furniture item into the structure can result in injury to the movers and/or damage to the furniture or the structure. 
         [0005]    An approach to addressing the drawbacks of factory assembled furniture items comprises providing individually upholstered subcomponents as a ready to assemble (“RTA”) furniture kit. The individual components can be more efficiently packed and allows the furniture item to be assembled in situ eliminating the need for navigating the furniture item through the building. However, the inherent challenge of providing RTA furniture kits is that the consumers who assemble the furniture kits are typically untrained and may not have ready access to the tools necessary to assemble the subcomponents. In addition, aligning the heavy subcomponents to install the fasteners for connecting the subcomponents can be difficult, particularly if a single individual is assembling the furniture item. If the fasteners are not properly installed the structural integrity of the furniture item could be compromised resulting in collapse and/or injury of users. 
         [0006]    As such, there is a need for a means of providing furniture items that does not suffer from the drawbacks of factory assembled furniture and currently available RTA furniture kits. 
       SUMMARY OF THE INVENTION 
       [0007]    The present invention is directed to a furniture item that can be entirely or partially assembled from a plurality of disassembled sub-components using a plurality of manual handled threaded fastener. The fasteners each comprise a threaded shaft that can be hand rotated by an integrated handle to pull together and retain two subcomponents. Each fastener also comprises an alignment portion for fine adjustment of the alignment of the two subcomponents. The alignment portion comprises a tapered surface adapted engage the edges of the bore hole through which the shaft is inserted if the subcomponents are misaligned to shift relative position of the subcomponents as the threaded shaft is rotated into the subcomponents. 
         [0008]    A furniture item, according to an embodiment of the present invention, generally comprises at least one manual handled threaded fastener, a seat box and a back rest. Each manual handled threaded fastener comprises a handle, a tapered alignment portion and at least one shaft, wherein at least a portion of the shaft is threaded. The seat box further comprises at least one interface plate and also defines an interior cavity for accessing the interior face of each interface plate. The interior cavity is accessible through an opening defined in the bottom of the seat box that can be selectively closed by a flap positionable over the opening to restrict access to the interior cavity. Similarly, the back rest also further comprises an interface plate, which corresponds to the interface plate of the seat box. 
         [0009]    During assembly, the corresponding interface plates are roughly aligned such that the corresponding bore holes bored through the plates are generally aligned. One of the hand fasteners can then be inserted through the opening in the seat box. The shaft is then inserted through the bore hole of the seat box interface plate into the corresponding bore hole of the back rest interface plate. According to an embodiment, the bore hole of the back rest interface plate is treaded to engage the threaded portion of the engaged shaft such that the rotation of the threaded portion pulls the interface plates together. As the interface plates are pulled together, the tapered alignment portion of the fastener is adapted to engage the edge of the bore hole of the seat box if the seat box and back rest are misaligned. The tapered surface of the alignment portion shifts the position of the seat box relative to the back rest as the shaft is rotated to pull the interface plates together. 
         [0010]    According to an embodiment, the furniture item can further comprise at least one arm rest having an interface plate engagable to the seat box and the arm rest. A portion of the interface plate is engagable to one of the interface plates of the seat box. In this configuration, the back rest can further comprise at least one interface plate engagable to a portion of the arm rest interface plate. The back rest can also define an interior cavity and a closeable opening for accessing the interior face of the interface plates corresponding to the arm rests. The closeable opening can be covered by a flap that can be positioned to selectively close the opening in the back rest. As with the back rest-seat box assembly, a hand fastener can be inserted through the opening to align and affix the corresponding interface plates of the arm and back rests. According to an embodiment, the opening is proximate to the back rest interface plate corresponding to the seat box such that the seat box will cover the opening when the seat box is affixed to the back rest. 
         [0011]    According to an embodiment, the furniture item can further comprise at least one bushing assembly corresponding to each of the hand fasteners. Each bushing assembly comprises a bushing portion defining a threaded interior for engaging the threaded portion of the shaft and sized to fit within the corresponding bore hole. The bushing portion protects the bore interface plate by preventing splitting or cracking of the interface plate caused by the threaded portion of the shaft. According to an embodiment, the bushing assembly can further comprise at least one engagement feature for gripping the interface plate to maintain the bushing portion within the bore hole. 
         [0012]    A method of assembling a ready to assemble furniture item, according to an embodiment of the present invention, generally comprises providing a back rest and a seat box, each comprising a corresponding interface plate, wherein the seat box defines an interior cavity for accessing an inner face of the interface surface of the seat box. The method further comprises boring a first hole through seat box interface plate and a corresponding second hole through the back rest interface plate. The method also comprises providing a fastener having an shaft, an alignment portion and a handle for rotating the shaft. The method further comprises inserting the fastener through the opening into the seat box and inserting the shaft into the first and second holes of the corresponding interface plates, wherein the shaft and the second hole are threaded to engage each other. Finally, the method comprises rotating the shaft by twisting the handle to pull the corresponding interface plates together, wherein the alignment portion is adapted to engage an edge of the first hole if the seat box and back rest are misaligned and shift the seat box relative to the back rest until aligned as the interface plates are pulled together. 
         [0013]    The above summary of the various representative embodiments of the invention is not intended to describe each illustrated embodiment or every implementation of the invention. Rather, the embodiments are chosen and described so that others skilled in the art can appreciate and understand the principles and practices of the invention. The figures in the detailed description that follow more particularly exemplify these embodiments. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    The invention can be completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which: 
           [0015]      FIG. 1  is a perspective view of a packaged ready to assemble furniture kit according to an embodiment of the present invention. 
           [0016]      FIG. 2  is a perspective view of an assembled furniture item according to an embodiment of the present invention. 
           [0017]      FIG. 3  is an exploded perspective view of a ready to assemble furniture item according to an embodiment of the present invention. 
           [0018]      FIG. 4  is a perspective view of the furniture item depicted in  FIG. 3  after assembly. 
           [0019]      FIG. 5  is a perspective view of the ready to assemble furniture kit depicted in  FIG. 1  after unpacking 
           [0020]      FIG. 6  is a bottom view of a furniture item according to an embodiment of the present invention after two arm rests are affixed to a back rests. 
           [0021]      FIG. 7  is a representative perspective view illustrating an opening in a back rest for inserting a fastener into the back rest for affixing the back rest to an arm rest according to an embodiment of the present invention. 
           [0022]      FIG. 8  is a representative perspective view illustrating an opening in a back rest for inserting a fastener into the back rest for affixing the back rest to an arm rest according to an embodiment of the present invention. 
           [0023]      FIG. 9  is a representative bottom view of a seat box illustrating an opening in a bottom of a seat box according to an embodiment of the present invention. 
           [0024]      FIG. 10  is a representative bottom view of the seat box depicted in  FIG. 9  and cushions that can be stored within the seat box. 
           [0025]      FIG. 11  is a representative bottom view of the seat box depicted in  FIG. 9  being fitted to the arm rest-back rest assembly depicted in  FIG. 6 . 
           [0026]      FIG. 12  is a representative bottom view of a manual handled threaded fastener according to an embodiment of the present invention and the assembled furniture item formed by fitting seat box depicted in  FIG. 9  with the arm rest-back rest assembly depicted in  FIG. 6 . 
           [0027]      FIG. 13  is partial bottom view of a seat box according to an embodiment of the present invention. 
           [0028]      FIG. 14  is partial bottom perspective view of a seat box according to an embodiment of the present invention. 
           [0029]      FIG. 15  is a representative perspective view illustrating the placement of the cushions on the assembled furniture item. 
           [0030]      FIG. 16  is a perspective view of a bushing assembly according to an embodiment of the present invention. 
           [0031]      FIG. 17  is an exploded side view of a manual handled threaded fastener according to an embodiment of the present invention. 
           [0032]      FIG. 18  is an assembled perspective view of the manual handled threaded fastener depicted in  FIG. 17 . 
           [0033]      FIG. 19  is a representative cross-sectional view illustrating join two subcomponents of a furniture item together with bushing assembly depicted in  FIG. 16  and the manual handled threaded fastener depicted in  FIG. 18 . 
           [0034]      FIG. 20  is a representative cross-sectional view illustrating the insertion of the bushing assembly depicted into the bore hole of a subcomponent. 
           [0035]      FIG. 21  is a representative cross-sectional view illustrating engagement of the bushing assembly with the threaded shaft of the fastener. 
           [0036]      FIG. 22  is representatives cross-sectional view illustrating pulling the subcomponents by rotating the fastener within the bushing assembly. 
           [0037]      FIG. 23  is a representative view of a set of diagram instructions included with a ready to assemble furniture kit according to an embodiment of the present invention. 
       
    
    
       [0038]    While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. 
       DETAILED DESCRIPTION 
       [0039]    As shown in  FIGS. 1-2  and  5 , a furniture item  2 , according to an embodiment of the present invention, can comprise a seat box  4 , a back rest  6  and at least one manual handled threaded fastener  8 . The furniture item  2  can also comprise at least one arm rest  10  depending on the type of furniture. As depicted, the furniture item  2  is a sofa, but can comprise any number of conventional furniture types including, for example, chaises, sectionals, love seats, chairs, benches, or recliners. Similarly, the furniture item  2  is depicted as entirely upholstered, but can comprise un-upholstered or partially upholstered furniture. 
         [0040]    As shown in  FIGS. 3-4  and  9 , the seat box  4  further comprises a rectangular frame  12  and an upper support assembly  14 . The rectangular frame  12  comprises at least one interface plate  16  defining a side of the rectangular frame  12 . Each interface plate  16  can comprise at least one bore hole  18  through the interface plate  16 . The upper support assembly  14  is positioned over the rectangular frame  12  to create an internal cavity with the seat box  4  beneath the support assembly  14 . The bottom of the seat box  4  defines an opening for accessing the internal cavity within the seat box  4 . 
         [0041]    As shown in  FIGS. 3-4 , the back rest  6  further comprises a support structure  20  and a seat box interface plate  22 . The seat box interface plate  22  can further comprise at least one bore hole  24  corresponding to the bore hole  18 . According to an embodiment, the support structure  20  can define an engagement shelf  25 . 
         [0042]    As shown in  FIGS. 17-18 , each fastener  8  can further comprise a shaft  26 , an alignment portion  28  and a handle  30 . The shaft  26  comprises a threaded portion  32  positioned proximate to the end of the shaft  26 . The alignment portion  28  comprises a tapered portion  34  transitioning between the shaft  26  and an engagement portion  36 . The shaft  26  comprises a smaller diameter than the engagement portion  36 . According to an embodiment, a locking pin  38  is insertable through the handle  30  and the shaft  26  to lock the handle  30  to the shaft  26 . According to an embodiment, the locking pin  38  can comprise a hex shape. Similarly, the shaft  26  can define a head portion  41  having a hex shape. In this configuration, the handle  30  can further define a hex shaped recess  43  for receiving the hex shaped head portion  41  of the shaft  26 . According to an embodiment, the shaft  26  can have a length in the range of ½ inch to 3 inches. According to an embodiment, the shaft  26  diameter of the handle  30  can range from 1 inch to 6 inches. As depicted, the handle  30  comprises three prongs that can be gripped by the user, but can comprise any conventional handles that can be manually grasped by the user and rotated. 
         [0043]    As shown in  FIGS. 4 ,  19 - 22  the seat box  4  is affixable to the back rest  6  by aligning the seat box interface plate  22  with one of the interface plates  16  of the rectangular frame  12  such that the bore holes  18 ,  24  are generally aligned. The engagement shelf  25  can be engaged to the rectangular frame  12  to assist in the vertical alignment of the seat box  4  to the back rest  6 . A fastener  8  can then fed be into the inter cavity of seat box  4  through the opening in the bottom of the seat box  4 . The shaft  26  is inserted through the bore holes  18 ,  24  until the threaded portion  32  engages the bore hole  24  of the back rest  6 . According to an embodiment, the bore hole  24  can be threaded to engage the threaded portion  32  of the fastener  8  such that the rotation of the fastener  8  pulls and retains the interface places  16 ,  22  together. The diameter of the bore hole  18  of the seat box  4  is greater than the diameter of the bore hole  24  of the back rest  6 . If the seat box  4  and back rest  6  is misaligned, the tapered portion  34  of the alignment portion  28  will engage the edges of the bore hole  18  and shift the seat box  4  to correct alignment as the fastener  8  is rotated into the bore holes  18 ,  24 . The engagement portion  36  is sized to fit the larger diameter bore hole  18  when the interface plates  16 ,  22  are pulled together to assist in maintaining the seat box  4  and the back rest  6  in alignment. According to an embodiment, the bore hole  18  diameter can be greater than the outer diameter of the engagement portion  36 . 
         [0044]    As shown in  FIG. 19 , the furniture item  2  can further comprise a bushing assembly  40  having a bushing portion  42  and at least one engagement portion  44 . The bushing portion  42  is sized to fit within the smaller diameter of the bore hole  24  and defines a threaded interior for engaging the threaded portion  32  of the fastener  8 . As depicted, the engagement portion  44  comprises a spike  46  for engaging the interface plate  22  to maintain the bushing portion  42  within the bore hole  24 . The bushing portion  42  protects the bore hole  24  and prevents cracking or splintering of the interface plate  22  due to stress from the engagement of the threaded portion  32  of the fastener  8 . 
         [0045]    As shown in  FIGS. 3-4 , each arm rest  10  further comprises a support structure  48  and at least one interface plate  50  having at least one bore hole  52 . In this configuration, the back rest  6  further comprise at least one arm rest interface plate  54  having at least one bore hole  56  and defines an internal cavity within the back rest  6 . The back rest  6  further defines an opening for accessing the internal cavity within the back rest  6  and comprises a flap  58  for selectively closing the opening. The flap  58  can be biased closed by an elastic strap or held closed by a zipper, Velcro or other conventional means of releasably closing the flap  54 . 
         [0046]    As shown in  FIGS. 19-22 , the arm rest  10  can be mounted to back rest  6  in same fashion as the back rest  6  is affixed to the seat box  4 . A fastener  8  can be inserted through the opening in the back rest  6  and inserted through the bore holes  52 ,  56  until the treaded portion  32  of the shaft  26  engages the bore hole  52  to pull the interface plates  50 ,  54  together and secure the arm rest  10  to the back rest  6 . The bore hole  56  of the back rest  6  has a greater diameter than the bore hole  52  of the arm rest  10  such that tapered portion  34  of the fastener  8  can adjust the alignment of the arm rest  10  to the back rest  6 . According to an embodiment, the bushing assembly  40  can be used with the interface plate  54  to protect the interface plate  50  of the arm rest  10 . According to an embodiment, the interface plate  54  can be sized to also correspond to one of the interface plates  16  of the rectangular frame  12  and engaged to the seat box  4  with a fastener  8 . 
         [0047]    As shown in  FIG. 9 , according to an embodiment of the present invention, the seat box  4  can further comprise a closeable flap  60  for selectively closing the opening in the bottom of the seat box  4 . The closable flap  60  can be maintained in the closed by an engagement feature  62  such as a zipper, Velcro or other releasable closure means. The closeable flap  60  allows the interior cavity of the seat box  4  to be used as storage space for cushions, seating elements or other removable items of the furniture item  2 . 
         [0048]    As shown in  FIGS. 13-14 , according to an embodiment, the upper support assembly  14  can further comprise a fabric layer  64  and a support network  66 . As depicted, the support network  66  comprises a plurality of interwoven metal strips, but can comprise slats or any other conventional means of support users seated on the furniture item. According to an embodiment, the upper support assembly  14  can further comprise at least one Velcro strip for engaging seat cushions or seating elements that are placed on the upper support assembly  14 . 
         [0049]    According to an embodiment, the interface plates  16 ,  22 ,  50 ,  54  can be covered by a fabric layer  68 . The fabric layer can prevent damage to the interface surfaces and provide friction to prevent sliding of the subcomponents relative to each other. 
         [0050]    According to an embodiment, the arm rest  10  can further comprise at least one an alignment bracket  70  positioned on the interface plate  50 . The alignment bracket  70  can comprise an track  72  having v-shaped walls  74 . In this configuration, the seat box  4  and the back rest  6  can each comprise a corresponding alignment bracket  76  positioned on the interface plates  16 ,  22 . The corresponding alignment brackets  76  each comprise an track  78  having v-shaped walls  80 . The v-shaped walls  74  are sized slide between v-shaped walls  80  to lock the alignment brackets  70  and  76  together. The interlocking alignment brackets  70 ,  76  serve as a guide for improving the respective alignment of the seat box  4 , the back rest  6  and arm rests  10 . 
         [0051]    In  FIG. 23 , a representative set of instructions for assembling the furniture item  2  is depicted. The instructions provide for tool-less assembly of the furniture item  2 . 
         [0052]    While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and described in detail. It is understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.