Patent Publication Number: US-10779654-B2

Title: Chair, stool assembly, and system

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This is a division patent application of co-pending U.S. patent application Ser. No. 15/434,169, filed Feb. 16, 2017, which claims the benefit of U.S. Provisional Application No. 62/297,226, filed Feb. 19, 2016. The contents of these prior applications are incorporated herein by reference. In addition, this application is related to U.S. patent application Ser. Nos. 29/559,485 and 62/297,226, each filed Mar. 29, 2016, the contents of which are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention generally relates to furniture. The invention particularly relates to pieces of furniture having reduced storage footprints and systems for building custom pieces of furniture. 
     A current trend in furniture and interior decoration focuses on minimalist designs which use fewer building materials, result in limited environmental impact, have a reduced physical footprint suitable for smaller living spaces, and incorporate relatively simple designs. In addition, as many designers incorporate fewer pieces into their living spaces, their focus appears to be more directed toward unique and/or custom pieces. 
     Accordingly, there is an ongoing desire for pieces of furniture that embodies one or more of the above trends. 
     BRIEF DESCRIPTION OF THE INVENTION 
     The present invention provides chairs, stool assemblies, and systems for constructing furniture. 
     According to one aspect of the invention, a chair includes multiple rigid structural members having hinge joints at ends thereof pivotally coupling each of the structural members to one or more adjoining structural members. The hinge joints define parallel axes so that the structural members pivot relative to each other about the parallel axes. The chair is configured to be arranged in a collapsed configuration wherein all of the structural members are in the same plane and define a substantially planar shape. The chair is also configured to be arranged in an expanded configuration wherein a first group of the structural members defines a seat, a front set of support legs, and armrests of the chair, and a second group of the structural members define a rear set of support legs and leg braces connecting the front and rear set of support legs of the chair. The first group of structural members expands in a first outward direction relative to the plane of the structural members in the first configuration, and the second group of structural members expand in a second direction that is generally opposite the first outward direction. The structural members pivot about the parallel axes relative to the one or more adjoining structural members to transition between the first and second configurations. 
     According to another aspect of the invention, a stool assembly includes at least first and second stools each having a seat and legs configured to support a load applied to the seat. The second stool is shorter than the first stool and is configured to be stackably located under the first stool such that the seats of the first and second stools abut face to face and are parallel to each other. The first and second stools stack and in combination define a composite base that is configured to support a load applied to the seat of the first stool with the legs of both the first and second stools. 
     According to another aspect of the invention, a system for constructing furniture includes multiple joints each having slots configured to receive and retain structural members. The multiple joints are configured to be assembled with the structural members to form a piece of furniture, with the multiple joints defining corners of the piece of furniture. 
     Technical effects of the chair described above preferably include its ability to be deployed or expanded for use as a chair when desired, and to be collapsed for storage or shipping. Technical effects of the stool assembly described above preferably include the ability to disassemble the stools when more than one stool is desired, whereas when assembled together the stools effectively constitute a single stool that does not occupy more space than the largest of the stools. Technical effects of the system for constructing furniture as described above preferably include the ability to create custom furniture without extensive woodworking expertise, skills, or equipment. 
     Other aspects and advantages of the invention will be further appreciated from the following detailed description. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front perspective view schematically representing a nonlimiting embodiment of a collapsible chair in an expanded configuration in accordance with one aspect of the invention. 
         FIG. 2  is a front elevational view of the chair of  FIG. 1 . 
         FIG. 3  is a rear elevational view of the chair of  FIG. 1 . 
         FIG. 4  is a left elevational side view of the chair of  FIG. 1 , wherein the right elevational side view of the chair is a mirror image of the left elevational side view. 
         FIG. 5  is a top view of the chair of  FIG. 1 . 
         FIG. 6  is a bottom view of the chair of  FIG. 1 . 
         FIG. 7  is a front view of the chair of  FIG. 1  in a collapsed configuration. 
         FIGS. 8A, 8B, 8C, and 8D  are a series of images representing a process by which a model of a collapsible chair can be expanded from a relatively collapsed configuration ( FIG. 8A ) to an expanded configuration ( FIG. 8D ). 
         FIG. 9  represents a blank from which the collapsible chairs of  FIGS. 1 through 7  can be fabricated in accordance with certain aspects of the invention. 
         FIG. 10  is an exploded view representing various layers of a nonlimiting embodiment of the blank of  FIG. 9 . 
         FIG. 11  is a front perspective view schematically representing a nonlimiting embodiment of a stool assembly comprising three individual stools stacked and assembled with one another in accordance with another aspect of this invention. 
         FIG. 12  is a top view of the stool assembly of  FIG. 11 . 
         FIG. 13  is a bottom view of the stool assembly of  FIG. 11 . 
         FIG. 14  is a first elevational side view of the stool assembly of  FIG. 11 . 
         FIG. 15  is a second elevational side view of the stool assembly of  FIG. 11 , taken from a direction perpendicular to the first elevational side view of  FIG. 14 . 
         FIG. 16  is an exploded perspective view of the stool assembly of  FIG. 11  showing the three individual stools unstacked and disassembled with one another and positioned end to end. 
         FIG. 17  is an exploded side view of the stool assembly of  FIG. 11  showing the three individual stools unstacked and disassembled with one another and positioned end to end. 
         FIG. 18  is an exploded top view of the stool assembly of  FIG. 11  showing the three individual stools unstacked and disassembled with one another and positioned side by side. 
         FIG. 19  represents a nonlimiting embodiment of a joint having slots therein sized and shaped to receive structural members in accordance with another aspect of the invention. 
         FIGS. 20 through 23  are top, side, end, and perspective views, respectively, of a bench formed from joints and structural members of the types shown in  FIG. 19 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIGS. 1 through 8  represent nonlimiting embodiments of a collapsible chair  100 . The chair  100  is configured to be selectively folded or arranged into one of at least two configurations. The chair  100  preferably may be folded between a collapsed configuration having a relatively planar shape suitable for efficient storage and shipping, and an expanded configuration suitable for use as a chair in which a user may sit.  FIGS. 1-6 and 8D  represent the chair  100  in a fully expanded configuration,  FIG. 7  represents the chair  100  in a fully collapsed configuration, and  FIGS. 8A through 8C  represent the chair  100  in different partially collapsed stages between the fully collapsed and fully expanded configurations.  FIG. 9  represents a nonlimiting embodiment of a blank  101  from which the collapsible chair  100  of  FIGS. 1 through 8  can be fabricated, and  FIG. 10  is an exploded view representing certain preferred but nonlimiting exterior layers  102  and  104  and an interior layer  103  that may be bonded together to form the blank  101  of  FIG. 9 . 
     To facilitate the description provided below of the embodiments represented in  FIGS. 1 through 10 , relative terms, including but not limited to, “vertical,” “horizontal,” “side,” “upper,” “lower,” “longitudinal,” “lateral,” “above,” “below,” “right,” “left,” etc., may be used in reference to the perspective of an individual sitting in the chair  100  when in its expanded configuration, and therefore are relative terms that are useful to describe the chair  100  represented in  FIGS. 1 through 8 , but should not be necessarily interpreted as limitations to the construction and use of the chair  100 . 
       FIGS. 1 through 6  identify multiple rigid structural members  110 ,  112 ,  114 ,  116  and  118  of various shapes as members of the chair  100 , and represent each pair of adjoining structural members  110 ,  112 ,  114 ,  116  and  118  as connected by a revolute or hinge joint  106  that allows the adjoining pair to pivot relative to each other about a single axis of rotation. In the expanded configuration of  FIG. 1 , the structural members  110  define a seat, the structural members  112  define support legs, the structural members  114  define leg braces, the structural members  116  define armrests, and the structural members  118  define a back rest. It is within the scope of the invention that the chair  100  could have additional structural components suitable for maintaining the chair  100  in one or any of its configurations. For example,  FIG. 8D  represents the chair  100  as comprising an additional support brace  120 . It is also within the scope of the invention that the chair  100  may be of other shapes and sizes than those represented. 
     As noted above,  FIG. 10  is an exploded view representing two exterior layers  102  and  104  and an interior layer  103  of the blank  101  shown in  FIG. 9 . The blank  101  is represented as comprising multiple longitudinal slots  108  that are present in and may entirely pass through each of the layers  102 ,  103  and  104  to delineate the structural members  110 ,  112 ,  114 ,  116  and  118  of the chair  100 , and specifically the longitudinal edges of the members  110 ,  112 ,  114 ,  116  and  118 . The exploded view of  FIG. 10  further shows lateral slots  109  that are present in and may entirely pass through the interior layer  103 , but preferably are not present in and do not pass through the two exterior layers  102  and  104 . As a result of the slots  108  and  109 , the interior layer  103  defines discrete structural elements  107  that are located within and secured to one another through the exterior layers  102  and  104 , but might not otherwise directly touch each other as a result of being separated by one or more longitudinal slots  108  and one or more lateral slots  109 . The exterior layers  102  and  104  form the joints  106  at the lateral slots  109 , and therefore the joints  106  may be referred to as lateral joints. In other words, each structural element  107  formed with the interior layer  103  is preferably entirely surrounded on all sides by combinations of the longitudinal slots  108 , the lateral joints  106 , and the outer perimeter of the chair  100  as is schematically represented in  FIG. 7 . As a result, the structural elements  107  are only interconnected with other structures of the chair  100  through the lateral joints  106 . 
     According to one nonlimiting embodiment, the chair  100  may be produced by providing the interior layer  103  (e.g., wood), forming the longitudinal slots  108  and lateral slots  109  in the interior layer  103  to define the structural elements  107 , and then locating the structural elements  107  between the two exterior layers  102  and  104  (e.g., leather), and sewing the two exterior layers  102  and  104  along edges of structural elements  107  of the interior layer  103 . Portions of the two exterior layers  102  and  104  within the structural elements  107  may then be cut and removed to form the longitudinal slots  108 , with the result that the structural elements  107  are entirely encased by the two exterior layers  102  and  104  and the structural members  110 ,  112 ,  114 ,  116  and  118  are integral components of the chair  100 . Optionally, each of the two exterior layers  102  and  104  may be continuous over a respective side of the chair  100 , that is, each of the layers  102  and  104  is formed of a single portion of material rather than multiple portions of material, for example, sewn together. It is foreseeable that the chair  100  may comprise additional layers, for example, a cushioning layer (not shown) between the interior layer  103  and one or both of the exterior layers  102  and  104 . 
     As a result of the construction described above, the individual structural members  110 ,  112 ,  114 ,  116  and  118  are preferably only connected to adjacent structural members  110 ,  112 ,  114 ,  116  and  118  at longitudinal ends thereof by the exterior layers  102  and  104 , which define the revolute or hinge joints  106  that have lateral orientations and allow for pivoting about a single axis of rotation. Consequently, the structural members  110 ,  112 ,  114 ,  116  and  118  pivot relative to adjoining structural members  110 ,  112 ,  114 ,  116  and  118  exclusively about laterally-oriented and parallel axes (joints  106 ), as do the seat, support legs, leg braces, arm rests, and back rest of the chair  100  formed by these structural members  110 ,  112 ,  114 ,  116  and  118 . The hinge joints  106  provide the ability of the chair  100  to be collapsed and expanded between its collapsed and expanded configurations, and therefore the exterior layers  102  and  104  that define the joints  106  are preferably formed of flexible materials capable of reliably interconnecting unsupported portions of the structural elements  107  of the interior layer  103  between longitudinal ends thereof. Although this hinge function is represented herein as being provided solely by the flexibility of the exterior layers  102  and  104 , it is within the scope of the invention that this function could be achieved by other means. For example, the structural members  110 ,  112 ,  114 ,  116  and  118  could be connected to adjacent structural members  110 ,  112 ,  114 ,  116  and  118  at longitudinal ends thereof with other types of mechanical hinges that allow pivoting therebetween. 
     In the fully collapsed configuration shown in  FIG. 7 , all of the structural members  110 ,  112 ,  114 ,  116  and  118  are preferably in the same plane and define a substantially planar shape.  FIGS. 8A through 8D  show a series of images representing a process by which the chair  100  can be expanded from a partially collapsed configuration ( FIG. 8A ) to a fully expanded configuration ( FIG. 8D ). It should be understood that the chair  100  may be folded into the collapsed configuration by reversing the steps of  FIGS. 8A through 8D . During the expanding/collapsing process, the structural members  110 ,  112 ,  114 ,  116  and  118  pivot relative to adjacent structural members  110 ,  112 ,  114 ,  116  and  118  to transition between the configurations. During the transition between configurations, a first group of the structural members  110 ,  112  and  116  that define the seat, front set of support legs, and armrests of the chair  100  pivot and expand in a first outward direction relative to the plane of the collapsed chair  100  (to the right in  FIGS. 8A-8D ), and a second group of the structural members  112  and  114  that define the rear set of the support legs and the leg braces of the chair  100  pivot and expand in a direction that is generally opposite the first (to the left in  FIGS. 8A-8D ). 
     It is within the scope of the invention that the chair  100  could have additional structural components suitable for maintaining the chair  100  in one or any of its configurations. For example,  FIG. 8D  represents the chair  100  as comprising an additional support brace  120  that spans interior corners of the chair  100  defined by the seat (members  110 ), legs (members  112 ), and leg braces (members  114 ). It is also within the scope of the invention that the chair  100  may be of other shapes and sizes than those represented. 
       FIGS. 11 through 18  represent nonlimiting embodiments of a multi-piece stool assembly  200  that is configured for use as a single seat ( FIGS. 11-15 ) or as multiple individual seats ( FIGS. 16-18 ). The assembly  200  comprises multiple individual stools  210 ,  212 , and  214  ( FIGS. 16-18 ) that can be individually used as seats, but also configured to be selectively arranged for assembly by stacking to construct the stool assembly  200 , resulting in a more compact configuration for storing. In the nonlimiting embodiment of  FIGS. 11-18 , each stool  210 ,  212  and  214  comprises a seat  204  and three legs  202  secured to its seat  204  and configured to support a load applied to the seat  204 , for example, a person sitting on the seat  204  of the stool  210 ,  212 , or  214 . 
       FIGS. 11 through 18  show the stools  210 ,  212 , and  214  as differing in height, size and shape, with the stool  210  being the tallest, the stool  214  being the shortest, and the stool  212  being intermediate the stools  210  and  214  in height to enable the stool  212  to be stacked between the stools  210  and  214  with their respective seats  204  parallel and face to face as evident from  FIGS. 11, 14, and 15 . As used herein, the faces of the stools  210 ,  212 , and  214  are the upper surface of a seat  204  that is intended for an individual to sit on and the lower surface oppositely disposed the upper surface, and face to face refers to a configuration wherein a lower surface of the seat  204  of one of the upper stools  210  or  212  is abutting an upper surface of the seat  204  of one of the lower stools  212  or  214 . To achieve these differences in height, the legs  202  of the tallest stool  210  are longer than those of the other stools  212  and  214 , the legs  202  of the shortest stool  214  are shorter than those of the other stools  210  and  212 , and the legs  202  of the intermediate stool  212  have lengths that are intermediate those of the other stools  210  and  214  and, more particularly, differ in length by a distance approximately equal to the thickness of its seat  204 . In contrast,  FIGS. 11 through 18  represent the legs  202  of all three stools  210 ,  212  and  214  as having substantially equal widths and thicknesses (as measured in the lateral/horizontal directions). 
     When the stools  210 ,  212  and  214  are assembled as shown in  FIGS. 11 through 15 , the stool assembly  200  comprises what may be described as a single composite base made up of the legs  202  of the individual stools  210 ,  212 , and  214 , which are interdigitated or nested together to create a generally frustoconical shape for the composite base of the stool assembly  200 . The composite base is able to support a load applied to the seat  204  of the tallest stool  210 , which serves as the seat for the stool assembly  200 . With this arrangement, a load applied to the seat  204  of the stool assembly  200 , for example, a person sitting on the seat  204  of the tallest stool  210 , will preferably be supported by the legs  202  of all three of the stools  210 ,  212 , and  214 . Although not shown, less than all of the individual stools  210 ,  212 , and  214  could be stacked to form a partially combined configuration. Preferably, longitudinal edges of the legs  202  of the individual stools  210 ,  212  and  214  contact each other when assembled as the single composite base. Alternatively, gaps (not shown) may be provided between the legs  202  of one or more of the stools  210 ,  212  and  214 . 
     As evident from  FIGS. 11 through 15 , the assembly  200  can have relatively uniform and continuous exterior surfaces. To achieve this shape, the seat  204  and legs  202  of each stool  210 ,  212  and  214  are uniquely configured to enable the stools  210 ,  212  and  214  to be assembled via stacking to construct the assembly  200 . For example, whereas  FIGS. 11, 12, 16, and 18  represent the seat  204  of the tallest stool  210  as having an uninterrupted circular perimeter, the seat  204  of the intermediate stool  212  has a perimeter interrupted by recesses  206  located between its legs  202  so that each recess  206  can accommodate one of the legs  202  of the tallest stool  210 , and the seat  204  of the shortest stool  214  has a perimeter interrupted by wider recesses  208  located between its legs  202  so that each recess  208  can accommodate one leg  202  of each of the tallest and intermediate stools  210  and  212 . 
     The stools  210 ,  212  and  214  may be formed of any material, and each of the stools  210 ,  212  and  214  may be formed of the same or different materials. One or more of the stools  210 ,  212  and  214  may have a different surface texture, color, ornamental pattern, etc. in order to provide different appearances between the stools  210 ,  212  and  214 , as well as an aesthetically interesting appearance for the assembly  200 . It is within the scope of the invention that the assembly  200  may comprise any number of individual stools  210 ,  212  and  214 , each of the stools  210 ,  212  and  214  may have any shape, and each of the stools  210 ,  212  and  214  may be formed of any material. Although not shown in the drawings, it is foreseeable that the assembly  200  may comprise a means for securing one or more of the stools  210 ,  212  and  214  in a combined or a partially combined configuration (e.g., including two of the three stools  210 ,  212 , and  214 ). 
       FIGS. 19 through 23  represent nonlimiting embodiments of systems suitable for constructing or assembling furniture. In particular, the system may include multiple joints  300  having openings or slots  302  configured to slidably receive and/or retain rigid structural members  304  therein. When assembled with structural members  304 , the system can be used to define apiece of furniture having the joints  300  located at corners of the piece of furniture. In practice, a user may easily create a custom sized and shaped piece of furniture without the necessity of the user having extensive woodworking (or other craftsman) knowledge and skill that may ordinarily be necessary for creating a custom piece of furniture. Preferably, the system includes multiple joints  300  which may be assembled with structural members  304  that are included with the system, or provided separately by the user. 
     As a nonlimiting example,  FIGS. 20-23  represent a bench  310  formed of eight structural members  304  (for example, wood boards) secured with four joints  300 . Each of the joints  300  includes three openings or slots  302  into which ends of the structural members  304  are inserted. Although each of the structural members  304  in this embodiment have identical widths and thicknesses, their lengths are varied to define the shaped and structure of the desired bench  310 . The system may be made available as a kit that includes the structural members  304  precut to desired lengths, or the members  304  may be separately obtained and cut to length by the user. 
     Optionally, the joints  300  may define corners having any desired shape, but do not require complicated cuts to the ends of the structural members  304 . For example,  FIG. 19  represents the joint  300  as defining a rounded, chamfered or beveled corner for a piece of furniture, through the structural members  304  to be inserted in the slots  302  of the joint  300  have simple flat ends formed at ninety degrees to the longitudinal sides of the members  304 . 
     The joints  300  may include holes  306  for insertion of fasteners to secure the structural members  304  after assembly. Alternatively, the slots  302  of the joints  300  may be configured to secure the structural members  304  by an integral retention feature, interference fit, or any other suitable means. 
     It is within the scope of the invention that the joints  300  may have any shape, and/or the system may comprise multiple types of joints  300  such that various types of custom furniture may be built. The joints  300  may include designs, cutouts, protrusions, indentations, shaped portions, etc., in order to provide ornamental and/or secondary functional features. For example, the joints  300  of  FIGS. 19-23  include an array of through holes having various sizes and shapes that define an ornamental pattern. The joints  300  may be formed of any material suitable for securing the structural members  304  to form the furniture, including but not limited to polymers, metals, composites, etc. The structural members  304  may be formed of any material including, but not limited to, woods, polymers, composites, and metals. 
     While the invention has been described in terms of specific or particular embodiments, it is apparent that other forms could be adopted by one skilled in the art. For example, the chair  100 , assembly  200 , joints  300 , and their respective components could differ in appearance and construction from the embodiments described herein and shown in the drawings, functions of certain components of the chair  100 , assembly  200 , joints  300  could be performed by components of different construction but capable of a similar (though not necessarily equivalent) function, and various materials could be used in the manufacturing of the chair  100 , assembly  200 , joints  300 , and their components. Accordingly, it should be understood that the invention is not limited to any embodiment described herein or illustrated in the drawings. It should also be understood that the phraseology and terminology employed above are for the purpose of describing the illustrated embodiments, and do not necessarily serve as limitations to the scope of the invention. Therefore, the scope of the invention is to be limited only by the following claims.