Patent Publication Number: US-11649842-B2

Title: System for interchangeable furniture bases with interlock connections

Description:
This application is a continuation-in-part application of U.S. application Ser. No. 15/343,563, filed Nov. 4, 2016, which is a continuation-in-part application of U.S. application Ser. No. 15/049,767, filed Feb. 22, 2016, which is a continuation of U.S. application Ser. No. 14/167,249, filed Jan. 29, 2014, which claims benefit of and priority to U.S. Provisional Application No. 61/758,231, filed Jan. 29, 2013, by Billy Joe Griggs Jr., and is entitled to those filing dates for priority. This application also claims priority to and benefit of U.S. Provisional Applications Nos. 62/380,932, and 62/380,933, filed Aug. 29, 2016, and U.S. Provisional Application No. 62/490,226, filed Apr. 26, 2017, and is entitled to those filing dates for priority. The specifications, figures, appendices and complete disclosures of U.S. Provisional Applications Nos. 61/758,231; 62/380,932; and 62/490,226; and U.S. application Ser. Nos. 14/167,249; 15/049,767; and 15/343,563 are incorporated herein in their entireties by specific reference for all purposes. 
    
    
     FIELD OF INVENTION 
     This invention relates to a mechanism and system for interchangeable furniture bases with interlocking connections. More particularly, this invention relates to a mechanism and system for quickly and easily interchanging various furniture bases with various furniture seats or seat boxes by means of an interlocking connection, such as a multi-part cam assembly. 
     BACKGROUND OF THE INVENTION 
     Ready to assemble furniture is very popular because it can be easier to assemble and relatively inexpensive as compared to fully assembled furniture. However, there are pieces of furniture that have been proven to be exceedingly difficult to provide as ready to assemble furniture. 
     Reclining furniture with rocker, glider, swivel and other mechanisms create particular problems when used in ready to assemble furniture. In fact the precision of preparing the interlocking parts is typically beyond the ability of the average person working with ready to assemble furniture. The present invention addresses this deficiency and provides a system for quickly and easily interchanging various furniture bases with various furniture seats or seat boxes by means of an interlocking connection, such as a multi-part cam assembly. The multi-piece cam further provides a configuration that is more easily disassembled and serviced in the field. 
     SUMMARY OF INVENTION 
     In various embodiments, the present invention comprises a system for quickly and easily interchanging various furniture bases with various furniture seats or seat boxes by means of an interlocking connection, such as a multi-part cam assembly. A furniture base can be quickly and easily detached from a particular seat box, and replaced by a different style of furniture base. 
     The present invention further comprises a mechanism for assembling and connecting a furniture base to a piece of furniture. The assembly comprises a furniture base having a first cam piece, configured with a first cam interlock, associated therewith; a furniture frame having a second cam piece, configured with a second cam interlock, associated therewith; with each of said first cam and second cam interlocks configured to mate and interlock one to another to form a cam. In an alternative configuration, the first cam piece and second cam piece are a first connector piece and a second connector piece, with interlocks configured to mate and interlock one to another to form a connector. 
     The mechanism, whether in cam or connector form, is configured to be used with a multitude of furniture bases and seats or seat boxes, including, but not limited to recliner mechanism bases, rockers, gliders, swivels, swivel rockers, swivel gliders, twin sleepers, full sleepers, queen sleepers, king sleepers, or combinations thereof. 
     In one embodiment, the first cam piece is a system including two or more cam units or sub-pieces. In another embodiment, the second cam piece is a system including two or more cam units or sub-pieces. The first cam piece may have two or more first cam interlocks, and the second cam piece may have two or more second cam interlocks. 
     In one exemplary embodiment, the first cam interlock is integrated onto said first cam piece. Similarly, the second cam interlock may be integrated onto said second cam piece. In several embodiments, the first cam interlock and said first cam piece are constructed of a unitary piece. The second cam interlock and said second cam piece also may be constructed of a unitary piece. The first cam interlock and said second cam interlock connect in a snap-fit locking arrangement. 
     The present invention further contemplates a method of connecting a furniture base to furniture, said method comprising the steps of: providing a first cam piece and second cam piece according to any of the configurations or combinations disclosed herein; associating said first cam piece with a furniture base; connecting said second cam piece to either a furniture seat box or a reclining mechanism; positioning said first and second cam pieces to align respective interlocks; and interlocking each of said first and second cam pieces one to another. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1 A  is a side perspective view of a two-piece cam assembly configuration in a separated position. 
         FIG.  1 B  is a side perspective view of a two-piece cam assembly configuration in a separated position. 
         FIG.  1 C  is a side perspective view of a four-piece cam assembly configuration in a separated position. 
         FIG.  2    is a side perspective view of a two-piece cam assembly configuration in a connected position. 
         FIG.  3    is a partial cross-section from  FIGS.  1 A and  1 B  with directional arrow indicating direction of connection of separate cam components. 
         FIG.  4    is a partial cross-section from  FIGS.  1 A,  1 B, and  3    with separate cam components in a connected position. 
         FIG.  5    is a side perspective view of another example of a two-piece cam assembly configuration in a separated position. 
         FIG.  6    is a side perspective view of the assembly of  FIG.  5    in a connected position. 
         FIG.  7    is an outer side view of the assembly of  FIG.  5    in a separated position 
         FIG.  8    is an outer side view of the assembly of  FIG.  5    in a connected position. 
         FIG.  9    is an inner side view of the assembly of  FIG.  5    in a separated position 
         FIG.  10    is an inner side view of the assembly of  FIG.  5    in a connected position. 
         FIG.  11    is a side perspective sectional view of the connected assembly of  FIG.  6    along A-A′. 
         FIG.  12    is a top sectional view of  FIG.  11   . 
         FIG.  13    is a side perspective view of another example of a two-piece cam assembly configuration in a separated position. 
         FIG.  14    is a side perspective view of the assembly of  FIG.  13    in a connected position. 
         FIG.  15    is an outer side view of the assembly of  FIG.  13    in a separated position 
         FIG.  16    is an outer side view of the assembly of  FIG.  13    in a connected position. 
         FIG.  17    is an inner side view of the assembly of  FIG.  13    in a separated position 
         FIG.  18    is an inner side view of the assembly of  FIG.  13    in a connected position. 
         FIG.  19    is a side perspective sectional view of the connected assembly of  FIG.  14    along B-B′. 
         FIG.  20    is a top sectional view of  FIG.  19   . 
         FIG.  21    is an inner side perspective view of another example of a lower or receiving cam piece from a two-piece cam assembly configuration. 
         FIG.  22    is an outer side perspective view of the cam piece of  FIG.  21   . 
         FIG.  23    is a top view of the cam piece of  FIG.  21   . 
         FIG.  24    is an outer side perspective view of another example of an upper cam piece from a two-piece cam assembly configuration with the lower cam piece of  FIG.  21   . 
         FIG.  25    is an inner side perspective view of the cam piece of  FIG.  24   . 
         FIG.  26    is an outer side view of the cam piece of  FIG.  24   . 
         FIG.  27    is an inner side view of the cam piece of  FIG.  24   . 
         FIG.  28    is a top view of the cam piece of  FIG.  24   . 
         FIG.  29    is an end view of the cam piece of  FIG.  24   . 
         FIG.  30    is a perspective view of a fixed base with two-piece cam assembly. 
         FIG.  31    is a side view of  FIG.  30   . 
         FIG.  32    is a top view of  FIG.  30   . 
         FIG.  32    is a front view of  FIG.  30   . 
         FIG.  34    is a perspective view of a glider base with two-piece cam assembly. 
         FIG.  35    is a side view of  FIG.  34   . 
         FIG.  36    is a top view of  FIG.  34   . 
         FIG.  37    is a front view of  FIG.  34   . 
         FIG.  38    is a perspective view of a rocker base with two-piece cam assembly. 
         FIG.  39    is a side view of  FIG.  38   . 
         FIG.  40    is a top view of  FIG.  38   . 
         FIG.  41    is a front view of  FIG.  38   . 
         FIG.  42    is a perspective view of a stationary swivel base with two-piece cam assembly. 
         FIG.  43    is a side view of  FIG.  42   . 
         FIG.  44    is a top view of  FIG.  42   . 
         FIG.  45    is a front view of  FIG.  43   . 
         FIG.  46    is a perspective view of a swivel glider base with two-piece cam assembly. 
         FIG.  47    is a side view of  FIG.  46   . 
         FIG.  48    is a top view of  FIG.  46   . 
         FIG.  49    is a front view of  FIG.  46   . 
         FIG.  50    is a perspective view of a swivel rocker base with two-piece cam assembly. 
         FIG.  51    is a side view of  FIG.  50   . 
         FIG.  52    is a top view of  FIG.  50   . 
         FIG.  53    is a front view of  FIG.  50   . 
     
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     In various embodiments, the present invention comprises a system for quickly and easily interchanging various furniture bases with various furniture seats or seat boxes by means of an interlocking connection, such as a multi-part cam assembly. A furniture base can be quickly and easily detached from a particular seat box, and replaced by a different style of furniture base. The present system suitable for all furniture, reclining or non-reclining, where connection is desired, such as, but not limited to, sofas, loveseats, chairs, sectional pieces, ottomans, rockers, gliders, swivels, swivel rocker, sleepers, and the like, each with their respective seat boxes and bases. The present invention allows the furniture seat boxes and bases to be disconnected and connected in various combinations as desired, by the consumer, the retail store, or others, as described above. 
       FIGS.  30 - 53    shows detailed views of various furniture bases  510 ,  520 ,  530 ,  540 ,  550 ,  560  with a two-piece cam assembly  500  (examples of which are described below) in place. The lower piece of the cam assembly is affixed or fastened to the respective bases as shown (e.g., fixed base  510 , glider base  520 , rocker base  530 , stationary swivel base  540 , swivel glider base  550 , swivel rocker base  560 ), while the upper piece of the cam assembly, which is shown in interlocking position with the lower piece of the cam assembly, is affixed or fastened to the seat box or seat or upper furniture component (as seen in  FIG.  1 A ). A base is detached from the seat box or seat or upper furniture component by disengaging the pieces of the cam assembly from each other. A replacement base, with its own pair of cam assembly lower pieces, is positioned to align the lower pieces with the upper pieces on the seat box or seat or upper furniture component, and then pushed together to interlockingly connect. In several embodiments, the interlocking connections are designed so all bases have lower cam pieces that can interlock with all corresponding upper cam pieces on all seat boxes, seats or upper furniture components. 
     In several embodiments, the present invention enables a glider base (in various forms) to be attached to a rocker scissor mechanism attached to a seat box or seat. This avoids the requirement for a glider side assembly mechanism to be separately attached to the scissor mechanism, as is the case with prior art rocker gliders. The present invention thus allows a rocker to be converted to a rocker-glider or a glider without the need of a separate glider side assembly mechanism, thereby reducing parts and costs. 
     In several further embodiments, two or more cross tubes extend laterally between the two sides of the bases (in the embodiments shown, the cross tubes extend between the right and left lower pieces of the cam assembly). The cross tubes may be bent or curved, as shown. This allows the cross tubes to pack efficiently around the drive tube, when the base is packed with a seat box, seat or upper furniture component. 
     The present invention further comprises a multi-piece cam assembly for furniture. The figures are demonstrative and the invention contemplates multiple configurations including, but not limited to two, three, four, and five cam component systems. 
     As generally understood, ready to assemble furniture is constructed such that an ordinarily skilled consumer can assemble the furniture. Reclining mechanisms are typically exceedingly complex and furthermore locking mechanisms are often excluded from ready to assemble furniture products. 
     In one embodiment, the two-piece cam is suitable for assembling a furniture base to the seat box portion of furniture. It is further contemplated that the present invention is suitable for connection of reclining mechanisms to a base in ready to assemble furniture. Reclining furniture is without limitation and includes, but is not limited to, a rocker, glider, swivel, swivel rocker, swivel glider, power variations of all of the above, sleepers, or any piece of furniture that utilizes reclining mechanism. However, the multi-piece cam assembly is suitable for all furniture, reclining or non-reclining, where connection is desired, such as, but not limited to, sofas, loveseats, chairs, sectional pieces, ottomans, rockers, gliders, swivels, swivel rocker, sleepers, and the like, each with their respective seat boxes and bases. The present invention allows the seat boxes and bases to be disconnected and connected in various combinations as desired, by the consumer, the retail store, or others, as described above. 
     In one embodiment, the two-piece cam is particularly well suited for connecting a furniture frame to a base. Although the drawings demonstrate a first cam piece as a locking cam connected to a furniture frame and a second or receiving cam piece connected to a base, the locking/receiving configurations are interchangeable. 
     First cam piece, configured as a receiving cam  20  is constructed and arranged with a locking orifice  24 . Orifice  24  is constructed and arranged to interact with locking tab  34  on locking cam piece  32 . 
     Receiving cam piece  20  has formed thereon a horizontal support receiver  22  which is constructed and arranged to receive horizontal supports  36  of the present invention. In one embodiment, as seen in  FIG.  1 A , receiving cam piece  20  is constructed arranged with a curved lower surface  26  that interacts with the upper surface  28  of furniture base  30 . In another embodiment, as seen in  FIG.  1 B , receiving cam piece  20  is flat and secured to base  30 . In the latter embodiment, the cam pieces may be referred to as connector pieces, i.e., receiving connector piece  20  and locking connector piece  32 , which combine to form a connector. 
     The locking cam piece  32  of the present invention is constructed and arranged to affix to the seat box or scissor/main assembly of a reclining mechanism of a piece of furniture. In one embodiment, locking cam piece  32  is affixed to the seat box. In another embodiment, the seat box frame or recliner frame is formed with a cam portion integral therewith. Since locking cam piece  32  is affixed to the underside of an article of furniture it is positioned above receiving cam piece  20  whereby locking tab  34  interacts with locking tab  24  in order to removably interconnect locking cam piece  32  with receiving cam piece  20 . 
     Either or both of the cam pieces can in turn be provided in two or more separate sub-pieces. For example, in the embodiment of  FIG.  1 C , receiving cam pieces  20  are provided in pairs. However, locking cam pieces may also be provided in pairs, and either may be provided in multiple sub-pieces. 
     In use, receiving cam piece  20  is positioned over a prepared upper surface  28  of furniture base  30 . When locking cam piece  32  is positioned and locked onto receiving cam piece  20  the article of furniture attached thereto will be able to rock along base  30 . Base  30  is constructed and arranged to have two main base portions each being 30 that are interconnected by transverse supports  38 . Cam piece  20  has receiving socket  42  configured to mate with positioning tab  40  of locking cam piece  32 . 
     In one embodiment the invention is a mechanism for a piece of furniture comprising: two or more locking cam pieces, constructed and arranged with at least one locking mechanism on each cam piece; two or more receiving cam pieces, said receiving cam pieces are constructed and arranged to receive said locking mechanism, said interconnected cam pieces are configured to be used in reclining furniture and sleepers to include, but not limited to, rockers, gliders, swivels, swivel rockers, swivel gliders, twin sleepers, full sleepers, queen sleepers, king sleepers. In addition, this mechanism assembly covers power reclining variations. 
     Although a particular embodiment is demonstrated, the multi-piece cam is contemplated to connect and disconnect in a male-female interlock arrangement. The two-piece cam represents a significant and unforeseen improvement in furniture design and construction by providing a construction element that improves ease of assembly and disassembly. The multi-piece cam assembly is suitable not only for rocking, reclining, and gliding assemblies, but for all furniture in which there is the attachment of a mechanism to a frame base. The multi cam configurations provide additional benefit relating to simplification of the assembly process. 
       FIGS.  5 - 20    show additional exemplary embodiments of a multi-piece cam assembly, comprising a receiving (i.e., a first or lower) cam piece  120  and a locking (i.e., a second or upper) cam piece  130 . In this embodiment, the interlocks,  140   a, b ,  142   a, b , are positioned at one or both ends of the cam pieces, thereby providing enhanced stability when the cam pieces are locked together. One or more positioning elements, as described below, also may be used to provide assistance in assembly and overall stability and strength of the cam pieces when locked together to form the multi-piece cam. 
     An end interlock mechanism comprises one or more end tabs  140   a, b  extending from the end or ends of a cam piece, and a corresponding slot or groove  142   a, b , with or without walls or tabs of its own, on the inside of the end or ends of the other cam piece, the slot or groove  142   a, b  adapted to receive the corresponding one or more end tabs  140   a, b . A locking tab or tabs  150  in the end interlock mechanism on one cam piece engages a corresponding hole, opening, slot, groove or tab  152  in the end interlock mechanism on the other cam piece to removably secure the one or more end tabs  140   a, b  within the corresponding slot or groove  142   a, b . To separate the cam pieces, a tool or instrument, such as, but not limited to, a screw-driver, may be inserted into an opening in the end interlock mechanism to release the locking tab or tabs  150 . In several embodiments, the end interlock mechanisms also serve as positioning elements in addition to locking or connection elements. 
     While  FIG.  5    shows the end tabs  140   a, b  on the upper or locking cam piece  130 , and the receiving slots or grooves  142   a, b  on the lower or receiving cam piece  120 , it should be noted that one or both end tabs may located on the lower or receiving cam piece, and the corresponding slot or groove located on the upper or locking cam piece. Similarly, the locking tabs  150  may be located on either the lower or receiving cam piece or the upper or locking cam piece, with the corresponding hole, opening, slot, groove or tab located on the other cam piece element. 
       FIGS.  5 - 20    further show a plurality of positioning elements that may be used to assist in assembly of the multi-piece cam. One or more vertical ribs, ridges or rectilinear elements  160  may be located along a side of a cam piece, extending to the bottom or top, respectively, of the cam piece, with a corresponding slot, groove or channel  162  on a corresponding side of the other cam piece element provided to receive the corresponding vertical rib, ridge or rectilinear element  160 . The top of the vertical ribs, ridges or rectilinear elements may be angled  166  for ease of insertion. As seen in  FIG.  5   , the vertical rib, ridge or rectilinear extends to the bottom  122  of the lower cam piece. The bottom of the lower cam piece may be solid, or hollow in sections or parts to reduce weight. 
     Similarly, one or more rectilinear elements or blocks,  170   a, b ,  180   a, b ,  190 , may be positioned along a side of the receiving or locking cam (and may be positioned along or near the top of the particular cam element), with a corresponding receiving hole or slot,  172   a, b ,  182   a, b ,  192 , located along or in a corresponding side of the other cam piece element. These elements may be of substantial size, and thus provide additional support and strength to the cam when assembled. For example, the sides of rectilinear elements  170   a, b  may comprise channels  174  adapted to receive corresponding tabs or ribs  176  along the inside of the corresponding receiving slot or hole,  172   a, b . Further, one or more of these elements may incorporate or include one or more of the horizontal support receivers  22 . 
     In several embodiments, a central positioning element  190 ,  192  is provided to provide additional strength and security for the assembled cam pieces. Positioning element  190  may be a simple block or flat extension, or may be L-shaped in cross-section, with a outermost element  194  that latches over or slides into a groove or slot  196  in the corresponding positioning element. This positioning element also may serve as an additional central interlock mechanism as described above, providing three or more interlock points in conjunction with the two 
     In several embodiments, one or more horizontal attachment tabs or elements  200   a, b  are located along or near the top of the upper cam piece  130 , the horizontal attachment tabs or elements comprising bolt holes or slots  204  for attaching one or more mechanisms or furniture components to the cam. piece. The horizontal attachment tabs  200   a, b  also may comprise or be an extension of a positioning element, such as blocks  180   a, b , as described above, and fit within corresponding grooves or channels  182   a, b  in the lower cam piece  120 . In the embodiment shown in  FIGS.  13 - 20   , the block positioning elements  180   a, b  and corresponding grooves or channels  182   a, b  also may comprise an additional tab  210  and slot or groove  212  on respective elements to help position and secure the respective cam pieces when connected. 
     As seen in several of the figures, when assembled or connected, sections of the top of the lower cam piece  120  are level with the top of the of the upper cam piece  130 . Due to the nature and placement of the positioning elements, however, in several sections the top of the upper cam piece  130  extends over the corresponding top section of the lower cam piece  120 . The connected cam assembly thus provides multi-axis strength and durability, with resistance to movement of the cam pieces with respect to each other after connection, which can lead to breakdown or failure of one or more of the cam pieces during use. 
       FIGS.  21 - 29    show additional exemplary embodiments of a flat-sided multi-piece cam assembly, comprising a receiving (i.e., a first or lower) cam piece  320  and a locking (i.e., a second or upper) cam piece  230 . In this embodiment, the interlocks,  140   a, b ,  142   a, b , are positioned at one or both ends of the cam pieces as described above, thereby providing enhanced stability when the cam pieces are locked together. One or more positioning elements, as described above, also may be used to provide assistance in assembly and overall stability and strength of the cam pieces when locked together to form the multi-piece cam. 
     In this embodiment, there are no elements of either cam piece extending outward from the sides of either cam piece, individually or in a conjoined configuration (i.e., the sides are “flat”). Horizontal supports are inserted into one or more cavities, orifices or openings  322  in the side of a cam piece, and which may extend through some or all of the width of the cam piece. The configuration has the advantage of a simpler efficient design without exposing any extended elements to damage or breakage during shipping or assembly. 
     Fastening means, such as a hole  312   a, b , on the interior of the orifice  322  may be used to receive a spring-based tab or extension element on the horizontal support to hold the horizontal support securely in place. The fastening means can be released by pushing the tab or extension down or inwards. In other embodiments, the horizontal support may comprise a hole extending therethrough proximate to the end, and configured to align with matching holes  310   a, b  extending vertically through the cam piece and opening into the corresponding orifices  322 . A screw or bolt may then be inserted into the holes  310   a, b  and through the corresponding holes in the horizontal support when inserted into the orifice. 
     The embodiments shown in  FIGS.  5 - 29    also possess a significant advantage in shipping of the respective furniture pieces or components with the respective cam pieces attached, as it has no positioning elements extending outward from the top or bottom of the respective cam pieces or components, or, in the case of  FIGS.  21 - 29   , from the sides of the respective cam pieces or components. For example, a positioning tab or element extending from the bottom of the upper or locking cam piece can be damaged or bent during shipping, thereby interfering or preventing the proper functioning of the cam elements and assembly. 
     While the invention has been described in its preferred form or embodiment with some degree of particularity, it is understood that this description has been given only by way of example and that numerous changes in the details of construction, fabrication, and use, including the combination and arrangement of parts, may be made without departing from the spirit and scope of the invention. Thus, it should be understood that the embodiments and examples described herein have been chosen and described in order to best illustrate the principles of the invention and its practical applications to thereby enable one of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as are suited for particular uses contemplated. Even though specific embodiments of this invention have been described, they are not to be taken as exhaustive. There are several variations that will be apparent to those skilled in the art.