Abstract:
The present invention relates to kit for a patio bench utilizing injection molded plastic panels capable of being packaged and shipped in a knocked-down state and constructed into a secure patio bench. The patio bench may also include an integral storage box positioned beneath the bench seat. The panels utilized for assembling the patio bench are also constructed to allow a number of patio benches to be configured using common components.

Description:
FIELD OF THE INVENTION  
       [0001]    This invention relates generally to a patio bench. More specifically, the present invention relates to a snap-together patio bench constructed of molded structural plastic panels to be capable of packaging and shipment in a knocked-down state for assembly at a desired site. 
       BACKGROUND INFORMATION  
       [0002]    Modular furniture is known in the art, for example, U.S. Pat. No. 3,811,728 to Redemske discloses plastic modular furniture. The invention utilizes a plurality of plastic base modules having grooves formed on one face thereof. The base modules cooperate with various shells for sitting, sleeping, storage, and table tops. Each shell includes a perimetal edge for engaging the grooves on one of the base modules. 
         [0003]    U.S. Pat. No. 4,140,065 to Chacon discloses a number of wooden panels to cover the entire areas of a back, a seat, or an end of a sofa or chair. The panels have tabs or hooks which fit into slots. Wedge shaped pegs are then used to secure the furniture components together. 
         [0004]    U.S. Pat. Nos. 3,874,729 4,523,787, 4,932,720, 4,919,485 and 5,069,506 disclose various other embodiments of modular furniture. 
         [0005]    Modular benches are also known in the art. For example, U.S. Pat. No. 4,919,480 to Drew discloses a sectional bench. The bench includes two A-shaped support members, a seat section and a plurality of slats secured to the A-shaped support members. 
         [0006]    U.S. Pat. No. 3,748,012 to Abelman discloses a joining pedestal for benches assembled in a line. The pedestal has a lower post with a wide top to seat meeting end portions of adjoining bench seats. The end portions have setbacks to receive the shank of an upper pedestal portion. The upper pedestal extends rearwardly for attachment of a back portion. Before assembly of the pedestal, bench seat and back portion the joining areas are coated with an adhesive. 
         [0007]    U.S. Pat. No. 5,938,281 to Keils discloses a seating structure for a child. The seating structure includes a box constructed of blow molded panels. The panels are connected at the ends with a pin that slides through apertures oriented transversely with respect to the panels. A bench seat is positioned within the box. 
         [0008]    U.S. Pat. No. 3,463,546 to Geibel discloses a knockdown paperboard chair with a storage space. The paperboard chair is constructed from two blanks. One blank incorporates the back section and the side panels. Seat flaps are cut out from the side panels in such a way that the assembled chair resembles a swing chair and bottom flaps are interfolded together to form a base structure. A second blank forms a front section, a seat cover and a bottom flap. 
         [0009]    Other U.S. Patents that disclose seats having storage areas positioned below the seat include U.S. Pat. Nos. 5,458,395, 5,692,335, 5,727,844, 6,390,551, 6,664,523. 
         [0010]    Such prior art systems, while working well, have not met all of the needs of manufacturers to provide a product that can be easily manufactured, packaged and shipped or the needs of consumers requiring structural integrity combined with modularity, aesthetic appearance and ease of assembly. 
         [0011]    Paramount among such needs is a panel system which creates a patio bench which resists panel separation, buckling, racking and weather infiltration. Security is a further consideration, the storage box formed by the panels must tie into the side panels and base panel in such a way as to unify the entire enclosure. 
         [0012]    Also, from a versatility standpoint, a seat panel should be present which can be easily installed after assembly of the side and bottom components and which provides dependable security and pivoting access to the contents of the storage box. 
         [0013]    There are also commercial considerations that must be satisfied by any viable patio bench system or kit; considerations which are not entirely satisfied by state of the art products. The patio bench must be formed of relatively few component parts that are inexpensive to manufacture by conventional techniques. The patio bench must also be capable of being packaged and shipped in a knocked-down state. In addition, the system must be modular and facilitate the creation of a family of patio benches that vary in appearance and functionality but which share common, interchangeable components. 
         [0014]    Finally, there are ergonomic needs that a patio bench system must satisfy in order to achieve acceptance by the end user. The system must be easily and quickly assembled using minimal hardware and requiring a minimal number of tools. Further, the system must not require excessive strength to assemble or include heavy component parts. Moreover, the system must assemble together in such a way so as not to detract from the internal storage volume of the resulting storage box or otherwise negatively affect the utility of the patio bench. 
       BRIEF DESCRIPTION OF THE INVENTION  
       [0015]    The present invention provides a system, or kit, of injection molded panels having integrated connectors which combine to form a patio bench. The panels are formed of injection molded plastic to interlock with one another without the need for separate fasteners or I-beam connectors. The system incorporates a minimum number of components to construct a patio bench by integrally forming the connectors into the injection molded panels. This minimizes the need for separate extruded or molded connectors to assemble the patio bench and facilitates snap-together assembly of the bench. The integrated connection of the side wall, seat and bottom panel components also provides for a storage box beneath the pivoting bench seat. The storage box is fully enclosed with wall panels to provide dry storage for items kept therein. Injection molding allows the panels to be formed with integral cross-bracing, ribs and gussets for increased rigidity while maintaining a lightweight construction that can be easily assembled and moved. The extra rigidity substantially prevents the panels from bowing inwardly and/or outwardly to resist panel racking and separation over time to maintain an aesthetically pleasing water resistant enclosure. The same side wall and bottom panel components are used to create a variety of patio benches, and the assembly of the patio benches require minimal hardware and a minimum number of hand tools. 
         [0016]    The front and rear wall panels of the storage box have a combination of outwardly projecting locking posts and inwardly extending sockets for interlocking cooperative engagement with sockets and locking posts formed into the adjacent panels for locking the panels together in a substantially perpendicular relationship. The left and right end panels include integrally formed arm rests. In addition, the left and right end panels are constructed with inwardly extending contoured sockets for interlocking cooperative engagement with outwardly projecting locking posts on the ends of the front, rear and base panels. The engagement between the locking posts and the sockets serve to rigidly connect the components together without the need for additional fasteners. The back portion of the patio bench arm rests are formed hollow to accept a structural block which cooperates with the seat back, end panels and seat panel to provide additional rigidity and weight capacity to the assembled bench structure. The system further includes a seat panel which slides into place after the front, rear, side and bottom panels have been fully assembled. The seat panel is pivotally mounted to allow the storage compartment to be easily accessed, further increasing the utility of the patio bench. Integral formation of the connectors, via injection molding, permits connection to panels formed by other means such as blow molding and/or vacuum forming without the need for separate connectors. In this manner, a low cost yet structurally robust snap together patio bench can be constructed. Prior art assemblies that utilize extruded panels require separate connectors to attach the panels together, increasing the number of components and connections required to assemble a bench, thereby increasing the complexity and cost of assembly. 
         [0017]    Accordingly, it is an objective of the present invention to provide a patio bench construction system wherein the patio bench components include integrated connectors for creating various patio benches which snap together using common components. 
         [0018]    A further objective is to provide a patio bench with storage wherein the panels used for construction include integrated connectors accommodated by the process of injection molding. 
         [0019]    Yet a further objective is to provide a bench assembly which includes a storage box wherein the side walls, cover, and bottom panel of the storage box are integrally interlocked without separate connectors or fasteners. 
         [0020]    Another objective is to provide a bench assembly constructed of modular components having a pivotally mounted bench seat which provides access to an integral storage box. 
         [0021]    Yet another objective is to provide a kit for a bench that is capable of being packaged and shipped in a knocked-down state and snapped together into a robust bench assembly. 
         [0022]    Still yet another objective is to provide a combination of injection molded panels wherein connectors are integrally formed onto the edges thereof for connection to injection molded, extruded and/or blow molded panels to construct a bench assembly. 
         [0023]    Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES  
         [0024]      FIG. 1  is a top perspective view of one embodiment of the instant invention; 
           [0025]      FIG. 2  is a bottom perspective view of one embodiment of the instant invention; 
           [0026]      FIG. 3  is an exploded perspective view of the snap-together bench embodiment shown in  FIG. 1 ; 
           [0027]      FIG. 4  is a front elevational view of one embodiment of the instant invention; 
           [0028]      FIG. 5  is a rear elevational view of one embodiment of the instant invention; 
           [0029]      FIG. 6  is a side elevational view of one embodiment of the instant invention; 
           [0030]      FIG. 7  is a section view along lines  7 - 7  of the bench embodiment shown in  FIG. 4  illustrating the overlapping interlocking engagement between the panels constructing the bench assembly; 
           [0031]      FIG. 8  is a top elevational view of one embodiment of the instant invention; 
           [0032]      FIG. 9  is a bottom elevational view of one embodiment of the instant invention; 
           [0033]      FIG. 10  is a top perspective view of one embodiment of the instant invention illustrating the bench seat in an open position to provide access to the storage box. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0034]    While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated. 
         [0035]      FIGS. 1-10  which are now referenced illustrate perspective, exploded and sectioned views of the patio bench, generally referenced as  10 , according to a preferred embodiment of the present invention. The patio bench is made up of a base panel  100 , left side panel  200 , right side panel  300 , front panel  400 , rear panel  500 , backrest panel  550 , and bench seat panel  600 . In the preferred embodiment, the panels comprising the assembly are formed of, but not limited to, a suitable polymeric material such as plastic, through the process of injection molding. Injection molding offers significant versatility, strength and stability advantages over materials and processes as utilized in the prior art. The result is that the panels comprising the patio bench  10  are formed as single wall unitary panels with integral connectors, cross bracing, surface texture and the like. Strengthening ribs  202  and gussets  204  are formed within the inner surfaces of the panels in order to enhance rigidity of the panels while leaving the external surface in a generally smooth condition for aesthetic purposes. The ribs  202  and gussets  204  increase the structural integrity of the patio bench  10  by preventing the panels  200 ,  300 ,  400 ,  500  and  550  from bowing or bending inwardly or outwardly, and thus, adversely affecting the appearance or operation of the patio bench  10 . In this manner the patio bench of the instant invention is capable of handling a significant amount of weight while providing a lightweight construction that can be shipped in a knocked down condition for snap-together assembly upon a desired site. 
         [0036]    Referring to  FIGS. 1-7 , the front and rear panels  400  and  500  are each configured having a first end  408 ,  508  and a second end  412 ,  512 , an upper end  414 ,  514  and a lower end  416 ,  516 . Both the first and second ends include an integrally formed attachment means illustrated herein as an elongated post  410 . The posts  410  are generally constructed and arranged to cooperate with the sockets  208  provided in either end of the left  200  and right panels  300 . The lower ends  416 ,  516  of the front and rear panels include an integrally formed socket  115  constructed and arranged to cooperate with the base panel in an interlocking overlapping manner. Integrally formed spring clips  126  provide additional engagement between adjacent panels by snapping into an aperture or depression formed into the adjacent panel to prevent the panels from separating. The upper end  514  of the rear panel  500  is constructed and arranged to include a plurality of integrally formed posts  518 , each post including an integrally formed spring lock  126  for engaging an aperture formed into the socket(s)  560  ( FIG. 7 ) of the backrest panel  550 . Also included on the upper end of the back panel  500  is a drip rail  520 . The drip rail extends along the length of the rear panel and is preferably positioned below a lower surface of the bench seat panel  600 . In this manner, water or moisture from the bench seat  600  and backrest  550  panels is channeled away from the storage box  522  ( FIG. 10 ) formed by the assembled panels. 
         [0037]    Still referring to  FIGS. 1-7 , a backrest panel  550  is illustrated. The backrest panel includes a top end  552 , a bottom end  554 , a left end  556  and a right end  558 . Sockets  560  are integrally formed along the bottom end  554  for interlocking cooperation with posts  518  of the back panel. The top end  552  of the backrest panel includes a removable and replaceable backrest cover member  562 . The backrest cover member includes an integrally formed socket  564  constructed and arranged to cooperate with a top end  552  of the backrest  550  in a snap-together arrangement. The backrest cover socket includes integrally formed spring locks  126  which cooperate with apertures  118  in the top end of the backrest panel. The left and right ends  556 ,  558  of the backrest panel include integrally formed posts  518  depending downwardly from the top end  552  for interlocking cooperation with the armrest portion  212  of the side panels  200 ,  300 . In a most preferred embodiment, the locking posts include spring locks  126  to engage the side panel and/or structural blocks  250 ,  350  positioned in the armrest portion of the left and right side panels. 
         [0038]    Referring to  FIGS. 1-10 , the patio bench includes a left side panel  200  and a right side panel  300  each having integrally formed legs  210  and armrests  212 . The rear portion of the armrests  214  are formed hollow to accept a structural block  250 ,  350 . Each structural block includes at least one integrally formed socket  560  for snap-together interlocking engagement with a left end or a right end respectively of the backrest panel. The structural block further includes a hinge pin aperture  566  constructed and arranged to cooperate with a hinge pin  602  formed to each distal end  604 ,  606  respectively of the bench seat panel. The hinge pin aperture  566  aligns with an aperture  260  formed into the inner wall of the armrest  212 . 
         [0039]    The left and right side panels  200 ,  300  include integrally formed sockets  208  for interlocking engagement with the front and the rear panels  400 ,  500  in a substantially perpendicular arrangement. In a most preferred embodiment, the armrests  212  include removable and replaceable armrest cover members  262 . The armrest cover members are preferably formed hollow to include integrally formed connectors constructed and arranged to cooperate with an upper surface of each of the left and right armrest. The internal portion of the armrest covers include spring locks constructed and arranged to cooperate with apertures  118  for interlocking engagement between the armrest covers and the armrests. 
         [0040]    Each of the left and right panels include a drip rail  264  secured along the length of an inner surface of each respective panel. The drip rails are positioned to be below a lower surface of the bench seat panel, whereby water contacting an upper surface of the bench seat panel is directed to at least one of the drip rails to be channeled away from an interior area of the storage box. The drip rails include integrally formed C-shaped spring locks  266  which are arranged to cooperate with elongated apertures  268  formed into the inner surface of the left and right side panels. For engagement the C-shaped spring locks are directed through the apertures  268  and thereafter the drip rail is slid rearwardly to engage the spring locks and interlock the drip rail to the respective side panel. 
         [0041]    Referring to  FIGS. 3 ,  4 ,  7  and  10 , a bench seat panel  600  is illustrated. The bench seat panel includes an upper surface  608 , a lower surface  610 , a left end  604 , a right end  606 , a front end  612  and a rear end  614 . A hinge pin  602  is integrally formed onto each of the left and right ends to allow the bench seat panel  600  to be pivotable about a central axis A of the hinge pins to enclose the top portion of the storage box and to provide ingress into and egress from the storage box  522 . The front portion of the bench seat panel  600  includes an integrally formed latch member illustrated herein as a spring-catch  616  for releasably securing the cover in a closed position that is relatively parallel with respect to the ground surface. The spring-catch is constructed and arranged to cooperate with a catch plate  618  integrally formed to the front panel for releasable engagement between the bench seat panel  600  and the front panel  400 , whereby the bench seat panel is releasable upon pulling upward on a front portion thereof. The lower surface includes integrally formed ribs  202  and gussets  204  to add rigidity and weight capacity to the seat panel. 
         [0042]    Referring to  FIGS. 3 and 7 , the base panel  100  has a top surface  104 , bottom surface  106  ( FIG. 2 ), like-constructed front and rear edges  108  and  110 , and like-constructed left and right edges  112  and  114 . Extending along the edges of the base panel are a plurality of posts  206 . The posts are constructed and arranged to enter and mateably engage with sockets  115  formed along the lower portion of the left, right, front and rear panels in an overlapping interlocking fashion securing the panels together in a substantially perpendicular arrangement. The base panel also includes apertures  118  or indentations (not shown) for interlocking cooperation with spring locks  126  integrally formed into the sockets  115 . It should be noted that while the base panel is preferably constructed through the process of injection molding, the base panel may be formed by other suitable methods which may include, but should not be limited to, blow molding, vacuum forming or compression molding without departing from the scope of the invention. The integrally formed connectors, e.g. the sockets, facilitate connecting the injection molded panels to panels formed by other methods without the need for separate connectors and/or fasteners. 
         [0043]    It will be appreciated that the purpose of the posts  410 ,  518  and  206  are to align two panels in a substantially perpendicular or axially alined relationship and to facilitate their mechanical connection. The perpendicular panels are brought into an overlapping relationship wherein the posts enter the corresponding sockets  208 ,  560 ,  115 . The result is a mechanically secure connection between the panels. The overlapping edges between the panels as described above provides a secure connection and offers several advantages. First, the design allows the panels to be connected without the need for separate connectors or fasteners. Second, the design creates a positive lock that prevents separation of the panels. Third, the design maintains alignment of the panels in the same plane and prevents bowing or bending of either panel relative to one another. The resultant patio bench created by the combination of the interlocking panels benefits from high structural integrity and reliable operation. 
         [0044]    It should be noted that the positions of the posts and sockets on respective panels can be reversed without departing from the scope of the invention. It should also be noted that while the posts and sockets are illustrated as having a substantially rectangular shape, both the posts and sockets may be configured in any shape and/or combination of shapes suitable for interlocking engagement between the adjacent panels; such shapes may include, but should not be limited to, polygons, cylinders, ovals, D-shapes and the like. 
         [0045]    Referring generally to the FIGS., the front and rear panels  400 ,  500  are attached to the base panel  100  by sliding the locking posts  206  along the edges  108 ,  110  into the corresponding sockets  115 . The sockets  115  in the bottom portion of the front and rear panels correspond in shape and size to that of the locking posts  206 , and spring tabs  126  integrally formed into the sockets  115  align with apertures  118  in the locking posts  206  to engage the front and rear panels  400  and  500 . The result is a positive mechanical connection between the front and rear panels  400 ,  500 , and the base panel  100 . 
         [0046]    The left and right side panels  200 ,  300  are attached to the front, rear, and base panels  400 ,  500 ,  100  by inserting the posts  410 ,  206  into contoured sockets  208 ,  115  until the spring tabs  126  integrally formed into the sockets engage the apertures  118  in the posts. The result is a positive mechanical connection between the left and right panels  200 ,  300 , and the front  400 , back  500  and base panel  100 . 
         [0047]    The backrest panel  550  is secured to the left, right and back panels  200 ,  300 ,  500  by sliding the socket  560  over posts  518  while simultaneously inserting posts  518  into sockets  560  in the upper portion of the armrest until the spring locks  126  engage the apertures  118 . The result is a positive mechanical connection between the backrest panel  550 , the back panel  500 , the left panel  200 , the right panel  300  and the structural blocks  250 ,  350 . 
         [0048]    The bench seat panel  600  is secured to the left and right panels by placing one of the hinge pins  602  into a respective aperture  260  of an armrest to engage the structural block aperture  566 . Thereafter the opposite end of the bench seat panel is slid downwardly until the other hinge pin engages the apertures in the side panel and structural block at the other end of the bench. 
         [0049]    All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference. 
         [0050]    It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification. 
         [0051]    One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.