Patent Publication Number: US-2023135463-A1

Title: Fastener system for furniture

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Application No. 63/073,251, filed Sep. 1, 2020, which is hereby incorporated in its entirety. 
    
    
     TECHNICAL FIELD 
     The present invention pertains generally to furniture construction, and more particularly to fastener systems for slatted furniture. 
     BRIEF SUMMARY OF THE EMBODIMENTS 
     The embodiments of a fastener system described herein provide a way to quickly and easily assemble an article of slatted furniture. The fastener system joins multiple slats and connects a support, such as a leg, thereto. The fastener system may also join a support to a solid, non-slatted furniture member. The system is suitable for various types of furniture, such as a bench, table, stool, bed frame, shelf, or the like. 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 an article of slatted furniture, the furniture 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;   a notch in the stud positioned to align with the external aperture of the flange when the stud is inserted therethrough; and   wherein, 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, the notch is circumscribed around the stud. 
     According to one or more embodiments, the 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. 
     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. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Non-limiting and non-exhaustive embodiments of the fastener system for furniture are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified. 
         FIG.  1    is an upper perspective view of an article of slatted furniture including an embodiment of a fastener system. 
         FIG.  2    is a lower perspective view thereof. 
         FIG.  3    is an end view thereof. 
         FIG.  4    is a top view thereof. 
         FIG.  5    is a side view thereof. 
         FIG.  6    is a bottom view thereof. 
         FIG.  7    is an enlarged view of region VII of  FIG.  3   . 
         FIG.  8 A  is a reduced partially exploded view of an embodiment of an article of slatted furniture.  FIG.  8 B  is an enlarged view of region  8 B of  FIG.  8 A . 
         FIG.  9    is an enlarged perspective view of an embodiment of a flange of the fastener system. 
         FIG.  10    is an end view of the  FIG.  9    embodiment. 
         FIG.  11    is a side view of the  FIG.  9    embodiment. 
         FIG.  12    is a bottom view of the  FIG.  9    embodiment. 
         FIG.  13    is an enlarged perspective view of an embodiment of a stud of the fastener system. 
         FIG.  14    is an end view of the  FIG.  13    embodiment. 
         FIG.  15    is a side view of the  FIG.  13    embodiment. 
         FIG.  16    is a bottom view of the  FIG.  13    embodiment. 
         FIG.  17    is an enlarged perspective view of an embodiment of a rod of the fastener system. 
         FIG.  18    is an enlarged perspective view of an embodiment of a spacer of the fastener system. 
         FIG.  19    is an enlarged perspective view of another embodiment of a spacer of the fastener system. 
         FIG.  20    is an enlarged perspective view of an embodiment of a first slat of an article of slatted furniture. 
         FIG.  21    is a top view of the  FIG.  20    embodiment. 
         FIG.  22    is an enlarged perspective view of an embodiment of a second slat of an article of slatted furniture. 
         FIG.  23    is a side view of the  FIG.  22    embodiment. 
         FIG.  24    is an end view of the  FIG.  22    embodiment. 
         FIG.  25    is an enlarged perspective view of an embodiment of a middle slat of an article of slatted furniture. 
         FIG.  26    is a top view of the  FIG.  25    embodiment. 
         FIG.  27    is an enlarged end view of an embodiment of a support of an article of slatted furniture. 
         FIG.  28    is a side view of the  FIG.  27    embodiment. 
         FIG.  29    is an enlarged perspective view of an embodiment of a flange tool. 
         FIG.  30    is a top view of the  FIG.  29    embodiment. 
         FIG.  31    is a first side view of the  FIG.  29    embodiment. 
         FIG.  32    is an end view of the  FIG.  29    embodiment. 
         FIG.  33    is a second side view of the  FIG.  29    embodiment. 
         FIG.  34    is a perspective view of the flange tool in engagement with the flange. 
         FIG.  35    is an enlarged partial end view of another embodiment of the fastener system. 
     
    
    
     Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of various embodiments. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments. 
     
       
         
           
               
             
               
                   
               
               
                 LIST OF DRAWING REFERENCE NUMERALS 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
            
               
                 20 
                 fastener system 
               
               
                 30 
                 stud 
               
               
                 32 
                 end 
               
               
                 33 
                 exterior surface 
               
               
                 34 
                 stud head 
               
               
                 35 
                 recess 
               
               
                 36 
                 notch 
               
               
                 38a, 38b 
                 sidewalls 
               
               
                 39 
                 floor 
               
               
                 40 
                 flange 
               
               
                 42 
                 longitudinal channel 
               
               
                 44 
                 transverse channel 
               
               
                 45 
                 slot 
               
               
                 46 
                 external aperture 
               
               
                 48 
                 distal end 
               
               
                 49 
                 flange head 
               
               
                 50 
                 proximal end 
               
               
                 60 
                 rod 
               
               
                 62 
                 rod end 
               
               
                 70 
                 spacer 
               
               
                 72 
                 central aperture 
               
               
                 80 
                 retainer 
               
               
                 90 
                 flange tool 
               
               
                 92 
                 blade 
               
               
                 94 
                 shank 
               
               
                 96 
                 tongue 
               
               
                 500 
                 slatted furniture 
               
               
                 510 
                 support 
               
               
                 512 
                 threaded region 
               
               
                 520 
                 exterior slat 
               
               
                 522 
                 through hole 
               
               
                 530 
                 second slat 
               
               
                 532 
                 through hole 
               
               
                 534 
                 retainer hole 
               
               
                 540 
                 slat 
               
               
                 542 
                 through hole 
               
               
                 580 
                 solid member 
               
               
                   
               
            
           
         
       
     
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring initially to  FIGS.  1 - 6   , there are illustrated upper and lower perspective, end, top, side, and bottom views, respectively, of an article of slatted furniture generally designated  500 . Slatted furniture  500  includes an embodiment of a fastener system designated  20 . In general, fastener system  20  connects multiple slats to form a slatted surface, also referred to herein as a deck. Fastener system  20  connects a furniture support  510  to the deck. Support  510  may 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 system  20  are shown in the end view of  FIG.  7   , where hidden elements are shown in dashed lines, and in the exploded views of  FIGS.  8 A and  8 B . In the shown embodiment, furniture  500  is a slatted bench having four supports  510 , which are legs. Multiple slats (e.g.,  520 ,  530 ,  540 ) are connected in spaced apart relation along rods  60 . In the shown embodiment, four rods are present, offset from one another along the major dimension of the deck. Spacers  70  (see also  FIG.  18 - 19   ) may be interposed between the slats. The deck is assembled by inserting each rod  60  alternately through a through hole ( 522 ,  532 ,  542 ) in a slat and through a central aperture  72  of a spacer, forming a deck sub-assembly. 
       FIGS.  9 - 12    are enlarged perspective, end, side, and bottom views, respectively, of a flange  40  of the fastener system. Flange  40  is shaped and dimensioned to be inserted into a through hole  522  of an exterior slat  520 , and may extend through one or more additional slats (e.g. into a through hole  532  of a second slat  530 ). A distal end  48  of flange  40  is configured to mate with a rod end  62  of rod  60  (see also  FIG.  17   ). 
     During assembly (refer to  FIGS.  7 ,  8 A , &amp;  8 B), rod  60  is inserted into through holes  542  of multiple slats  540 . Twelve of slat  540  are present in the shown embodiment (see also  FIGS.  25 - 26   ), although more or fewer slats may be used depending on the desired size of furniture. Flange  40  is inserted into exterior slat  520 , through second slat  530 , and distal end  48  of flange  40  mates with rod end  62  (shown internal to slat  540  in  FIG.  7   ). In the shown example, distal end  48  has an internal thread sized to mate with an external thread of rod end  62 , although other mating configurations may be used. 
     Flange  40  has a flange head  49 . The flange head  49  may include a slot  45  suitable for insertion of a screwdriver or a custom driver, such as flange tool  90  discussed below. The shown flange head  49  has a flat exterior face configured to fit within a counter-bore of through hole  522 , visible in  FIGS.  20 - 21   . The counter-bore provides a smooth exterior surface when flange  40  is assembled in exterior slat  520 , and allows the surfaces of leg  510  and exterior slat  520  to closely contact one another (see  FIG.  7   ). 
     Flange  40  has a longitudinal channel  42  dimensioned to receive the stud through a proximal end  50 . Flange  40  also has a transverse channel  44  which opens to longitudinal channel  42 . Transverse channel  44  has an external aperture  46  configured to align with a hole in bottom of one of the slats, such as retainer hole  534  of second slat  530  (shown in  FIGS.  22 - 24   ). Flange  40  may be rotated within the slats to align external aperture  46  with retainer hole  534 . In the shown embodiment the transverse channel goes through the entire diameter of the flange, and may therefore be aligned with retainer hole  534  in either of two positions (rotated about  180  degrees apart from one another). 
       FIGS.  13 - 16    are enlarged perspective, end, side, and bottom views, respectively, of an embodiment of a stud  30 . Stud  30  is connectable to leg  510 , for example in threaded region  512 , shown in  FIGS.  27 - 28   . An end  32  of the shown stud has an external thread configured to mate with a threaded region  512  of leg  510 . Alternative ways of mating the stud with the leg could be used, such as providing a shaft at end  32  to be mated with a hole in leg  510 , with or without adhesive. A stud head  34  has a recess  35  suitable for inserting a driver. In the shown embodiment, recess  35  is 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 studs  30  are assembled to each of four legs  510  by screwing threaded ends  32  into corresponding threaded regions  512 . A screwdriver may be inserted into recess  35  and 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. 
     Stud  30  further includes a notch  36 , shown revolved around the body of stud  30  (i.e., notch  30  may be rotationally symmetric about a longitudinal axis of the stud). Notch  36  is configured to align with external aperture  46  of the flange when the stud is inserted into the flange (see  FIG.  7   ). The notch has angled sidewalls  38   a,    38   b  which taper inwardly from an exterior surface  33  of 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 floor  39  of the notch. As shown, sidewalls  38   a,    38   b  taper 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 stud  30  into the longitudinal channel  42  of one flange  40  to a depth where notch  36  of the stud aligns with external aperture  46  of the flange. A retainer  80 , such as a set screw, is inserted through retainer hole  534  and external aperture  46  to contact floor  39  or sidewalls  38   a,    38   b  of the notch. In the shown embodiment, transverse channel  44  is threaded for mating with a threaded retainer  80 . Angled sidewalls  38   a,    38   b  guide retainer  80  toward the narrow floor  39  of notch  36 , while drawing the support sub-assembly inward to contact the deck sub-assembly. 
       FIGS.  29 - 33    are views of a flange tool  90  which may be provided with fastener system  20 . Flange tool  90  may be used to rotate flange  40  within the deck sub-assembly, for the purpose of aligning external aperture  46  with retainer hole  534 . In the shown embodiment, flange tool  90  has a blade  92  sized to engage slot  45  of the flange head. The tool also includes a tongue  96  which is sized to engage the flange through the longitudinal channel  44  (see  FIGS.  9 - 12   ). A shank  94  is provided on the opposite side from blade  92 , and may be used to grip or drive the flange tool, such as with pliers, a drill, or a bit driver.  FIG.  34    illustrates how flange tool  90  may engage flange  40 . 
       FIG.  35    shows components of another embodiment of fastener system  20 , for joining a support (e.g. leg  510 ) to a solid member  580  of the article of furniture. Solid member  580  may be, for example, a bench top, a chair seat, or a shelf. Stud  30  is connected to support  510  in the manner described above. Flange  40  is inserted into a complementary shaped hole in solid member  580 , and may have features and a shape as described above. External aperture  46  of the flange is aligned with a hole in solid member  580 . To join the solid member to the support, stud  30  is inserted into flange  40  and a retainer is inserted into external aperture  46  to contact notch  36  of the stud. In this manner the support is drawn inwardly to contact solid member  580 . While the  FIG.  35    embodiment shows support  510  being 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 member  580 . 
     The following dimensions for elements of fastener system  20  provide an exemplary embodiment suitable for a slatted bench. Flange  40  may have a length of about  3  inches and a diameter of about  0 . 75  inches. Stud  30  may 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. Spacers  70  may have an outer diameter of about  1  inch and an inner diameter (of central aperture  72 ) 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 furniture. 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 (legs  510 ) 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 leg  510 . 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 studs  30  of 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. 
     Further provided is an article of furniture, wherein fastener system  20  is packaged with the slats, supports, and other components of an article of furniture. In other embodiments, the components of the fastener system may be packaged independently of the other furniture pieces. Embodiments may optionally include a flange tool. 
     In terms of use, a method of assembling an article of slatted furniture includes: (refer to  FIGS.  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 hole  534 ;   b. providing a support  510 ;   c. providing a fastener system  20  including:
           i. a stud  30  configured for connection to the support;   ii. a flange  40  configured for insertion into at least one of the plurality of slats, the flange having: a longitudinal channel  42  having a proximal end  50  dimensioned to receive the stud therethrough and an opposing distal end  48 ; a transverse channel  44  oriented substantially orthogonally to the longitudinal channel and opening thereto; and an external aperture  46  opening to the transverse channel;   iii. a rod  60  configured to connect two or more of the plurality of slats, the rod having a rod end  62  which is configured to mate with the distal end of the flange; and   iv. a notch  36  in 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; and   i. fastening the support sub-assembly and deck sub-assembly to one another by inserting a retainer  80  through 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 spacers  70 ; 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 driver  90 ; in (c)(ii), the flange having a flange head  49  configured 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.