Abstract:
A furniture assembly system and method useful for assembling furniture provided in disassembled pieces. The system and method can securely and permanently connect two or more pieces of furniture with a furniture element connector without the use of separate tools. The furniture element connector can remain with the furniture while the furniture is in use.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application Ser. No. 61/529,547, titled Furniture Assembly System and Method, filed Aug. 31, 2011, the contents of which are hereby incorporated by reference. 
     
    
     FIELD 
       [0002]    The invention generally relates to systems and methods for assembling furniture. 
       BACKGROUND 
       [0003]    Furniture is frequently sold as a disassembled set of pieces or elements for assembly by a customer. Generally, such furniture is packaged along with fasteners, such as screws, bolts, and nuts, which are used to connect the various pieces together. These fasteners are actuated by the customer with separate tools, such as screwdrivers and wrenches. Unfortunately, many customers may not have these tools, or the correct sizes and configurations of these tools, immediately at hand when attempting to assemble the furniture. 
       SUMMARY 
       [0004]    Embodiments of the invention include a furniture assembly system and method useful for assembling furniture provided in disassembled pieces. In some embodiments, the system and method can securely and permanently connect two or more pieces of furniture without the use of any separate tools. Embodiments of the invention include furniture, such as desks, tables, stands, shelving assemblies, and the like, assembled with the system, and the methods of assembly themselves. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]    The following drawings are illustrative of particular embodiments of the present invention and therefore do not limit the scope of the invention. The drawings are not to scale (unless so stated) and are intended for use in conjunction with the explanations in the following detailed description. Embodiments of the present invention will hereinafter be described in conjunction with the appended drawings, wherein like numerals denote like elements. 
           [0006]      FIG. 1  includes a side plan view with a cut-away portion of assembled furniture in accordance with an embodiment of the invention. 
           [0007]      FIG. 2  includes a perspective disassembled view of furniture elements in accordance with an embodiment of the invention. 
           [0008]      FIG. 3  includes a perspective assembled view of the furniture elements of  FIG. 2 . 
           [0009]      FIG. 4  includes a side plan view of a furniture element connector depicted in first and second positions in accordance with an embodiment of the invention. 
           [0010]      FIG. 5  includes a front plan view of the furniture element connector of  FIG. 4 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0011]    The following detailed description is exemplary in nature and is not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the following description provides some practical illustrations for implementing exemplary embodiments of the present invention. Examples of constructions, materials, dimensions, and manufacturing processes are provided for selected elements, and all other elements employ that which is known to those of ordinary skill in the field of the invention. Those skilled in the art will recognize that many of the noted examples have a variety of suitable alternatives. 
         [0012]    Embodiments of the invention include assembled furniture, such as a desk, table, stand, shelving assembly, or the like. In some embodiments, as shown in  FIGS. 1-3 , the furniture  10  includes a first furniture element  20  and a second furniture element  30 . The first and second furniture elements can be generally planar and each include a front surface  22  and  32 , respectively, defining a front plane, a back surface  24  and  34 , respectively, defining a back plane, a perimeter  26  and  36 , respectively, defining a perimeter plane generally perpendicular to the front and back planes, and a thickness (which may be different or equal). In some embodiments, the front surface  22  of the first furniture element can be a generally horizontal work surface when the furniture elements are assembled and the furniture is properly positioned for use. As shown, the second furniture element can be spaced from and parallel to the first furniture element. 
         [0013]    In some embodiments, the furniture includes an elongate furniture element  40  in apposition with the first furniture element  20  and the second furniture element  30 . The elongate furniture element is useful for positioning the first and second furniture elements at a predetermined distance from each other, as it can include a compression portion  42  that will be in compression between the first and second furniture elements when the furniture is assembled. In some embodiments, the compression portion has a first surface  44  generally parallel to and in apposition to the back surface  24  of the first furniture element and a second surface  46  parallel to and in apposition to the front surface  32  of the second furniture element  30 . In some embodiments, the elongate furniture element is a “leg” of furniture. Further, it can also include a foot portion  50  extending beyond (e.g., beneath) the first or second furniture elements when assembled, as shown in  FIGS. 1 and 3 . 
         [0014]    Embodiments of the invention also include a furniture element connector  60  useful for permanently and rigidly connecting the first and second furniture elements. An exemplary embodiment of such a furniture element connector is shown in  FIGS. 4-5 . As used herein, “permanent” means the furniture element connector is not removed before the furniture is placed into service, and does not mean the furniture cannot be disassembled when desired. In some embodiments, the furniture element connector extends between the first furniture element and the second furniture element to provide the rigid connection. 
         [0015]    As shown best in  FIG. 1 , the furniture element connector  60  can have a first end  70  rigidly connected to either the first furniture element  20  or the second furniture element  30 . As shown, the first end can be rigidly connected proximate the back surface  24  of the first furniture element  20 . The furniture element connector  60  can also have a second end  80  in compressive engagement with the other of the first furniture element  20  or the second furniture element  30 . As shown, the second end can be in compressive engagement with the back surface  34  of the second furniture element  30 . In some embodiments, the furniture element connector has an elongate shaft  90  (e.g., having a longitudinal axis and a generally circular cross-section) extending through an aperture  92  defined in second furniture element  30  and an aperture  94  defined by the elongate furniture element  40  and extending through the compression portion  42  and between the first and second furniture elements. In certain embodiments, the first end  70  of the furniture element connector includes a threaded portion  110  that is received within a threaded portion of an aperture  100  defined by the first or second furniture element to form the rigid connection. 
         [0016]    On a second end  80  opposite the first end  70 , the furniture element connector  60  can include a pivoting lever  120  pivotably connected to the elongate shaft  90  (e.g., via a hinge). The pivoting lever  120  can include a cam member  122  with an eccentric shape.  FIG. 4  depicts movement of the pivoting lever  120  and cam member between an open, upward position and a closed, downward position. In such embodiments, the cam member provides the compressive engagement a furniture element, optionally via a washer as described below. The pivoting lever can also act like a handle with a turn radius greater than the radius of the elongate shaft to rotate the elongate shaft to threadingly engage it with the furniture element. In some embodiments, the compression portion  42  of the elongate furniture member has a length generally corresponding to the length of the elongate shaft  90  such that the first and second furniture elements are compressed against it when the cam is pivoted to a closed position. 
         [0017]    Accordingly, in some embodiments, after assembly, from the bottom up, the furniture will include lever  120 , cam member  122  acting against the back surface  34  of second furniture element  30 , shaft  90  will extend through aperture  92  in second furniture element  30  through the aperture  94  extending through compression portion  42  of elongate furniture element  40 , and threaded portion  110  of shaft  90  will be threadingly received within a threaded portion of an aperture  100  defined by back surface  24  of the first furniture element  20 . 
         [0018]    Note that  FIG. 1  shows only one side in cut away such that only one furniture element connector is depicted. However, it should be noted that in some embodiments furniture  10  can include two, three, or four furniture element connectors and associated two, three, or four elongate furniture elements. In some embodiments, furniture  10  includes first, second, third, and fourth furniture element connectors and associated first, second, third, and fourth elongate furniture elements respectively placed proximate the perimeters of the first and second furniture elements (e.g., one each proximate each corner in embodiments having generally rectangular first and second furniture elements).  FIGS. 2 and 3  identify additional apertures  92  and  100  to further illustrate exemplary positions of additional furniture element connectors. In such embodiments, all the furniture elements included within the furniture may be assembled with only the furniture element connectors, such that separate tools are not required to assemble the furniture elements. 
         [0019]    In some embodiments, the furniture does not include the second furniture element  30 . In such embodiments the cam member  122  acts against the second surface  46  of compression portion  42 . 
         [0020]    The furniture element connector  60  can also include a washer  130  that receives the elongate shaft  90  and is movable along a longitudinal axis of the elongate shaft. As shown, the washer is in contact with the eccentric shape and is moved along the elongate shaft as the cam member is pivoted with respect to the elongate shaft. The washer is useful for spreading the compressive forces provided by the cam over a larger area on the furniture element, such as back surface  34  of the second furniture element  30 . 
         [0021]    As noted above, in some embodiments the elongate furniture element  40  can include a foot portion  50  extending beyond the portion of the elongate furniture element that is compressed between the first and second furniture elements (e.g., beneath the back surface  34  of the second furniture element when assembled). Such a foot portion is useful for shielding the pivoting lever  120  and cam member  122 . In other embodiments, the foot portion is not integral with the elongate furniture element, but is rather attached to it or the second furniture element to shield the pivoting lever  120  and cam member  122 . 
         [0022]    The various furniture elements and the furniture element connector can include any desirable materials. In some embodiments, the furniture elements include wood and/or press board and the furniture element connector includes metal. 
         [0023]    The invention also includes methods of assembling furniture. In some embodiments, the method includes the step of rigidly connecting a first end of a furniture element connector to a first furniture element. The method can also include the step of positioning a second furniture element or a surface of a compression portion in a desired position spaced from the first furniture element. In some embodiments, the method includes the steps of applying compressive force to the second furniture element or surface of a compression portion with the second end of the furniture element connector (e.g., via a cam member). 
         [0024]    In certain embodiments, the elongate shaft is inserted through an aperture defined by an elongate furniture element separating the first and second furniture elements. A threaded end of the elongate shaft is threadingly connected with a threaded portion provided by one of the furniture elements. In some embodiments, the pivoting lever can be used as a handle to provide the rotational force. When snug, the cam member provided by the pivoting lever can be pivoted with respect to the elongate shaft to provide a compressive force on a furniture element, optionally through a washer positioned between the cam member and the furniture element. This process can be repeated as necessary (e.g., three more times) until the furniture is fully assembled. The furniture connecting elements are not removed before the furniture is placed into service, such that they become part of the furniture after it is assembled. In such embodiments, a customer is able to rigidly and permanently assemble furniture without the use of separate tools. 
         [0025]    Thus, embodiments of the invention are disclosed. Although the present invention has been described in considerable detail with reference to certain disclosed embodiments, the disclosed embodiments are presented for purposes of illustration and not limitation and other embodiments of the invention are possible. One skilled in the art will appreciate that various changes, adaptations, and modifications may be made without departing from the spirit of the invention and the scope of the appended claims.