Patent Publication Number: US-2004041455-A1

Title: Collapsible furniture structure and assembly method

Description:
BACKGROUND OF THE INVENTION  
       [0001] This invention relates to furniture construction and more particularly a collapsible furniture structure having threaded crossbars that threadably insert into parallel side frames for assembly to chairs and other furniture.  
       [0002] Generally, chairs and similar furniture are assembled at a factory using dowels and glue in a permanent manner. Such items of furniture are usually shipped already assembled. Therefore, due to the size of the assembled furniture such is costly to ship. Also, the furniture cannot be disassembled for carrying, storage or shipping. Moreover, the assembly of furniture, whether it is done at the factory of after shipping, generally requires tools, glue and other equipment, which exposes an assembler to the toxic effects of the glue and possible injury during assembly.  
       [0003] Thus, there exists a need for a collapsible furniture structure and method which makes the assembly and disassembly of furniture possible without tools.  
       [0004] The prior art includes numerous patented articles of furniture and methods of assembly but none like the present invention. For instance, U.S. Pat. No. 4,563,040, issued to Alster on Oct. 15, 1982, discloses a furniture assembly which uses threaded strut rods with threaded rod caps to secure together side frames of the furniture. U.S. Pat. No. 1,932,794, issued to McArthur, Jr. on Oct. 31, 1933, discloses a furniture assembly that uses rods threaded at both ends to hold together several hollow pieces in a series with threaded ball end caps. Great Britain Patent No.1,508,585, issued to Pask, et al. on Apr. 26, 1978, teaches chairs using threaded dowels with socket nuts on each end. U.S. Pat. No. 4,146,269, issued to Beckley on Mar. 27, 1979, teaches furniture construction which uses dowel rungs with screws to secure the furniture. Great Britain Patent No. 2,093,688, issued to Bantock, discloses another chair that uses screws to hold pieces to dowel rungs. U.S. Pat. No. 5,407,250, issued to Prince, et al. on Apr. 18, 1995, discloses modular knockdown furniture which uses screws to secure each side frame to dowels. U.S. Pat. No. 5,649,742, issued to Liu on Jul. 22, 1997, discloses a leg assembly for chairs that uses nuts and bolts to connect struts to the side frames. Finally, U.S. Pat. No. 5,601,339, issued to Buiani on Feb. 11, 1997, discloses a system for making dismantable seats using pins, rods, and so forth.  
       [0005] Unlike the prior art, the present invention discloses a collapsible furniture structure and method of assembly having cross-pieces which are oppositely threaded at both ends which are threadably inserted simultaneously into threaded sockets in side frames of the furniture.  
       SUMMARY OF THE INVENTION  
       [0006] The primary object of the present invention is to provide a furniture structure which results in an article of furniture that is collapsible.  
       [0007] Another object of the present invention is to provide such a furniture structure that is easy to assemble and disassemble.  
       [0008] A further object of the present invention is to provide a furniture structure that can be assembled and disassembled without the need for tools, glue, or other equipment.  
       [0009] An even further object of the present invention is to provide such a furniture structure that is and less expensive and more convenient to ship, carry, and store.  
       [0010] The present invention accomplishes the above and other objects by providing an article of collapsible furniture having at least two parallel side frames each frame containing a plurality of positionably matching sockets, the sockets on each frame being oppositely threaded from the sockets on an opposing parallel frame. A plurality of crossbars having ends which are threaded in opposite directions for threadable insertion into the sockets on each frame, such that when the crossbars are rotated in one direction, the crossbars simultaneously become threadably inserted into each frame and form the article of furniture. The article of furniture may be provided with a fabric having a plurality of channels into which each crossbar can be inserted into the channel in the fabric to form a fabric seat and back. A method of assembling the article of collapsible furniture involves positioning one of the pair of frames on a planar surface with the threaded sockets facing upward, then inserting a matching end of the crossbar into each of the sockets so that the crossbars are perpendicular to the frame. Then, if desired, the fabric cover can be slid over the crossbars by inserting the crossbars into each channel of the fabric cover. Then, another like frame having oppositely threaded sockets from the first frame is aligned over the crossbars and each crossbar is rotated in a tightening direction so that it is simultaneously inserted in the two frames to form the article of furniture.  
       [0011] The above and other objects, features and advantages of the present invention should become even more readily apparent to those skilled in the art upon a reading of the following detailed description in conjunction with the drawings wherein there is shown and described illustrative embodiments of the invention. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0012] In the following detailed description, reference will be made to the attached drawings in which:  
     [0013]FIG. 1 is a front perspective exploded view of the components of the collapsible furniture structure of the present invention;  
     [0014]FIG. 2 is a perspective view of the cloth seat fabric usable on a chair having the collapsible furniture structure of the present invention;  
     [0015]FIG. 3 is a front view of a typical crossbar used in the collapsible furniture structure of the present invention;  
     [0016]FIG. 4 is a perspective view of the first step of the assembly of the collapsible furniture structure;  
     [0017]FIG. 5 is a perspective view of the second step of the assembly of the collapsible furniture structure;  
     [0018]FIG. 6 is a perspective view of the third step of the assembly of the collapsible furniture structure;  
     [0019]FIG. 7 is a is a perspective view of the fourth step of the assembly of the collapsible furniture structure; and  
     [0020]FIG. 8 is a perspective view of a fully assembled chair employing the collapsible furniture structure of the present invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS  
     [0021] For purposes of describing the preferred embodiment, the terminology used in reference to the numbered components in the drawings is as follows:  
                                      1.   right side of chair frame       2.   left side of chair frame       3.   top crossbars       4.   back crossbars       5.   seat crossbar       6a, b.   right legs       7a, b.   left legs       8a, b, c.   right threaded crossbar end       9a, b, c.   left threaded crossbar end       10a, b.   right/left seat       11a,b.   right/left back       12a, b, c.   right side threaded           sockets       13a, b, c.   left side threaded sockets       14.   cover       15.   cover back       16.   cover seat       17.   top channel       18.   back channel       19.   seat channel       20.   top sew line       21.   back sew line       22.   seat sew line       23.   crossbar (main section)       24.   right threaded end       25.   left threaded end                  
 
     [0022] The collapsible furniture structure and assembly method of the present invention is described with respect to a patio chair illustrated in the drawings. FIG. 1 shows a chair having a pair of side frames, a right frame  1  and a left frame  2  each frame having a pair of legs  6   a  and  6   b  and  7   a  and  7   b,  respectively, and a back  11   a  and  11   b,  respectively. Each side frame has a plurality of sockets  12   a,    12   b,  and  12   c,  for the right side frame  1  and  13   a,    13   b,  and  13   c  for the left side frame  2 . The sockets on each side frame are oppositely threaded from the sockets on the opposite side frame. A plurality of crossbars with  3 ,  4 , and  5  for threadable insertion into each side frame  1  or  2  having ends  8   a,    9   a,    8   b,  and  9   b,    8   c,  and  9   c,  respectively, are threaded for insertion into each socket.  
     [0023] If desired, the particular article of furniture to be constructed may have a fabric seat comprising a cover  14  having a back portion  15  and seat portion  14  and channels  17 ,  18 , and  19  made by overlapping the fabric and sewing it along sew lines  20 ,  21 , and  22 , respectively is provided. The number of channels in the cover  14  are equal to the number of crossbars to be used in the particular piece of furniture.  
     [0024]FIG. 3 shows a typical crossbar of the collapsible furniture structure having a main smooth cylindrical section  23  and two threaded ends,  24  and  25 , which are oppositely threaded.  
     [0025] The method of assembling the collapsible furniture structure of the present invention is illustrated in FIGS.  4 - 7 . FIG. 4 shows the first step in the method which involves positioning one of the pair of frames on a planar surface with the sockets facing upward. FIG. 5 illustrates the second step in the method which involves inserting a matching end of a crossbar into each of the sockets in a cross frame so that the crossbars are perpendicular to the frame.  
     [0026]FIG. 6 shows the next step in the method of assembly when a fabric seat is desired. In this step, the fabric cover is slipped over the crossbars by inserting each crossbar into each channel of the fabric cover. FIG. 7 shows the final two steps in the assembly process which involves aligning the frames  1  and  2  over the crossbars  3 ,  4 , and  5  so the end of each crossbar is aligned with a socket  12   a,    12   b,    12   c  and  13   a,    13   b  and  13   c  in that frame and rotating each crossbar one at a time or intermittently in the appropriate direction so that each crossbar becomes simultaneously threadably inserted into the sockets of both frames to form the article of furniture.  
     [0027] In order to disassemble the furniture, the opposite steps of the method are employed. The collapsible furniture structure of this invention provides an article of furniture that can be easily and quickly assembled as necessary for use, carrying storage and shipment. This furniture structure would be particularly useful for patio and beach furniture as one could carry a chair to the beach in a flat condition and merely assemble it by inserting the threaded cross pieces without the need for tools or glue. The collapsible furniture structure of the present invention could be employed to make not only chairs as illustrated, but larger articles of furniture, such as sofas, by using more than two side frames with crossbars threadably inserted between each frame.  
     [0028] Although only a few embodiments of the present invention have been described in detail hereinabove, all improvements and modifications to this invention within the scope or equivalents of the claims are included as part of this invention.