Abstract:
A ready-to-assemble (RTA) furniture system includes a collection of identically configured side panels, with sets of the side panels having different aesthetic and/or functional features, a collection of base panels and back panels spanning between pairs of side panels, the collection of base and back panels being provided in different sets of lengths and configurations to permit construction of different types of furniture. The panels are interconnected through a series of slots and notches. A locking member is provided that can be wedged into a slot to lock the entire RTA furniture item together. A second locking member can be provided to be wedged into a slot in the back panel to provide additional support for a base panel. A wide variety of furniture items are show that can be constructed using the two locking members.

Description:
CLAIM OF BENEFITS  
       [0001]     This application claims the benefits of Provisional Application No. 60/568,113 filed May 3, 2004. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     The present invention relates generally to articles of furniture. More specifically, the invention concerns furniture that is “ready-to-assemble” or knockdown.  
         [0003]     Knock-down or ready-to-assemble (“RTA”) furniture is substitute for the traditional, one-piece, articles of furniture. RTA furniture is often significantly less expensive than its already assembled counterpart. Less expensive, durable and serviceable makes it an attractive alternative to already assembled furniture. Moreover, RTA furniture provides a wide range of configurations.  
         [0004]     RTA furniture is not a new concept. RTA furniture relies upon interlocking tabs and notches and maintaining a tight fit between spliced tabs and notches to keep the article of furniture solid. 
     
    
     DESCRIPTION OF THE DRAWINGS  
       [0005]     These needs are met by a novel RTA furniture array that is reflected in the following written description together with the accompanying figures.  
         [0006]      FIG. 1  is a top plan view of one structural element of a piece of RTA furniture in accordance with one embodiment of the present invention.  
         [0007]      FIG. 2  is a top plan view of another structural element of a piece of the article of RTA furniture to be constructed in accordance with the present invention.  
         [0008]      FIG. 3  is plan view of still another structural element of the article of RTA furniture to be constructed in accordance with the present invention.  
         [0009]      FIG. 4  is a plan view of another structural element, which is a mirror image of element shown in  FIG. 4 , of the article of RTA furniture to be constructed in accordance with the present invention.  
         [0010]      FIG. 5  is a front view of a further structural element of the article of furniture to be constructed in accordance with the present invention.  
         [0011]      FIG. 6  is a perspective view of a key which is used to retain the elements of  FIGS. 1 through 5  of the article of RTA furniture constructed in accordance with the invention.  
         [0012]      FIG. 7  is a front perspective view of the article of RTA furniture constructed in accordance with the invention.  
         [0013]      FIG. 8  is a rear perspective view of the article of RTA furniture constructed in accordance with the invention. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0014]     To facilitate further understanding of the invention, reference will now be made to the embodiments illustrated in the drawing and described in the following written specification.  
         [0015]     The article of RTA furniture described as providing the environment for construction using the principles of the present invention is a chair.  
         [0016]     Referring to  FIG. 1 , one structural element comprising a flat panel seat  10  includes a primary load supporting area  12 , oppositely extending support tabs  14  and  16 , and a rearwardly extending tab  18 . The oppositely extending tabs  14  and  16  define with the load supporting area  12  notches  15  and  17 .  
         [0017]     The structural elements shown in  FIG. 2  are flat panel arm supports  20  and  30 . The arm supports  20  and  30  are for use on the left and right sides of the article of RTA furniture to be constructed in accordance with the present invention.  
         [0018]     The arm supports  20  and  30  include support areas  22  and  32 . Also, the support areas  22  and  32  include notches  24  and  34  and  26  and  36  that are provided to support the arm supports on the structural elements of  FIGS. 3 and 4  as will be described hereinafter. The arm supports  20  and  30  also include tabs  28  and  38  which are used to help secure and stabilize the arm supports when the RTA furniture is assembled in accordance with this invention. As with the notches  24  and  34 , the function of the tabs  28  and  38  will be described hereinafter. The structural elements shown in  FIGS. 4 and 5  are flat panel sides  40  and  50  that provide the support for the primary load supporting member  10  of  FIG. 1  and the chair assembled in accordance with the present invention. The sides  40  and  50  include front and rear legs and feet  42 ,  44  and  52 ,  54 .  
         [0019]     The sides also include a tab  46 ,  56  for cooperating with the notches  24  and  34  supporting and stabilizing the arm supports  20  and  30 . A further tab  48  and  58  is provided on the sides  40  and  50  that will be used to support a back panel of the chair when the RTA furniture is assembled as shown in  FIGS. 7 and 8 . Also, the sides  40  and  50  include mirror image L-shaped notches  49  and  59 . The notches  49  and  59  cooperate with the tabs  14  and  16  and notches  15  and  17  on the primary load support  10  to secure and stabilize the support  10  and sides  40  and  50  when the RTA furniture is assembled in accordance with the present invention.  
         [0020]      FIG. 5  shows a flat panel back support member  60  for the RTA furniture of the present invention. The back support member  60  includes vertical notches  62  and  64  and a horizontal notch  66 . The horizontal notch  66  accepts the rearwardly extending tab  18  of the primary load support  10 , and the horizontal notches  62  and  64  slide over the sides  40  and  50  to provide a back support member  60  for the RTA furniture to be assembled in accordance with the present invention.  
         [0021]     The vertical notches  62  and  64  also include small, horizontally extending notches  63  and  65 . The notches  63  and  65  accept the tabs  28  and  38  of the arm supports  20  and  30  shown in  FIG. 2 . The cooperation of the notches  63  and  65  with the tabs  28  and  38  help to secure and stabilize the arm supports  20  and  30  when the RTA furniture is assembled in accordance with the present invention.  
         [0022]      FIG. 6  shows a C-shaped locking key  70  defining a notch  72 . The function of the key  70  will be described below in reference to  FIG. 8 .  
         [0023]      FIG. 7  shows a front perspective of the article of RTA furniture assembled in accordance with the present invention.  
         [0024]      FIG. 8  shows a rear perspective view of the article of RTA furniture assembled in accordance with the present invention.  FIG. 8  shows the C-shaped key  70  in place in the notches  49  and  59 . The notch  72  in the key  70  fits snuggly over the flat panel side  40  and  50 . The key  70  serves to hold all of the structural elements, i.e., the support  10 , the sides  40  and  50 , the back  60  together.  
         [0025]     The drawings represent one possible embodiment of the ready-to-assemble article of furniture of the present invention. In this embodiment, the furniture is a chair  100  that is formed from the several components shown in the drawing. Specifically, the chair  100  is formed by a pair of side panels  40  and  50 , a back panel  60 , a base panel  10  and a pair of locking members  70 .  
         [0026]     Each of the components is preferably formed of wood, either as solid wood elements or as pressed-wood or wood composite elements. The components are designed to be cut, preferably by means of a laser cutter, from standard sized sheet material. Alternatively, the components can be formed of new or recycled composites, elastomers, plastic or other suitable materials. In order to maintain the ready-to-assemble attributes of the chair  100 , the material of the components should be sufficiently rigid and strong, yet lightweight to facilitate the construction of the type of furniture contemplated.  
         [0027]     As shown in more detail in  FIGS. 7 and 8 , the chair components include pre-cut or pre-formed features for ornamental and functional attributes of the chair  100 . For instance, as is shown in  FIGS. 7 and 8 , the side and back panels  40 ,  50  and  60  exhibit a generally trapezoidal configuration with decorative cut-outs, and each defines a pair of legs  42 ,  44  and  52 ,  54  for supporting the article of furniture.  
         [0028]     The side panels  40  and  50  in this embodiment are identically configured, each including a closed L-shaped notch  49  and  59  and a back tab  49  and  58  formed near the top of each panel. The notch  49 ,  59  is contained within the interior of the panel  40 ,  50  and can be oriented at an angle with respect to horizontal, as depicted in  FIGS. 3 and 4 . Alternatively, the notch  49 ,  59  can run generally parallel with the lower edge of the legs  42 ,  44  and  52 ,  54 , so that the support  10  will sit horizontal in the assembled article of furniture. In the illustrated embodiment, the notch  49 ,  59  is angled such that the support member  10  has a small angle that makes sitting more comfortable.  
         [0029]     Likewise, each side panel  40 ,  50  can be configured so that the back panel  60 , when assembled onto the side panels  40 ,  50  will be non-vertical to provide a comfortable seating position.  
         [0030]     The back panel  60  defines a pair of side notches  62  and  64  at opposite sides of the panel. The notches  62  and  64  permit the side panels  40  and  50  to be inserted therethrough. The back panel  60  is supported by the tabs  48 ,  58  on the side panels  40  and  50  and by the side panels  40 ,  50 .  
         [0031]     The back panel  60  also defines a pair of notches  63 ,  65  perpendicular to the notches  62 ,  64  that interlock with the ends of the tabs  28 ,  38  in the arm support panels  20 ,  30 .  
         [0032]     All notches in the various components are sized for an appropriate interference fit to help provide tightness, rigidity and stability to the final RTA furniture assembly.  
         [0033]     The final component of the article of furniture is the locking member  70 . The key  70  is sized to slide into the short leg of the L-shaped notch  49 ,  59 .  
         [0034]     This assembly of the RTA chair  100  is not shown in any figure of the drawing, but can be described as follows: 
        a) side panels  40  and  50  are inserted into the notches  62  and  64  in the back panel  60  until the back panel  60  engages the upwardly extending arms on the side panels  40  and  50 ,     b) the side panels  40  and  50  are spread apart somewhat to allow the insertion of the primary support element  10  with the rearwardly extending tab  18  inserted into the horizontal notch  66  in the back panel  60 ,     c) the side panels  40  and  50  are moved to a position so that the notches  49  and  59  engage the laterally extending tabs  14  and  16  on the primary support element  10 ,     d) the arm support elements  20  and  30  are installed on the side panels  40  and  50  so that rearwardly extending tabs  28 ,  38  fit into the horizontal notches  63 ,  65  and the upwardly extending tabs  46 ,  56  of the side panels  40 ,  50  engage notches  26 ,  36  thereby securing the arm support elements  20  and  30 .     e) a C-shaped keys  70  is inserted in the L-shaped notch  49  and  59  and moved downwardly over the side panels  40 ,  50  to secure the RTA furniture in its fully assembled condition.        
 
         [0040]     The construction of the components of the chair  100  using the above described sequence and technique are firmly inter-engaged to establish a rigid and solid piece of furniture. The locking function is achieved by interlocking notches and by an interference provided by the key  70 .  
         [0041]     Hence although the invention has been described in respect of one type of RTA furniture, i.e., a chair, the design and assembly techniques are applicable to a wide variety of articles of furniture that can be created using the same principles as have been described herein with respect to the chair.  
         [0042]     The invention can be used to design a bookcase, larger or smaller chairs, tables, benches, office partitions, ottoman and the like. In designing and constructing such other types of furniture, the side panels  40 ,  50 , back panel  60  and primary support panel  10  can include the same array of tabs and notches as with the chair  100  illustrated in the drawing.  
         [0043]     The RTA furniture concept of the present invention offers an easy and uniform construction technique over a wide range of furniture designs and types.  
         [0044]     The design techniques and locking member provides a solid and lasting assembly of RTA furniture panels. the design locks all panels so that all panels are, in effect, inter-engaged with each other. This feature provides a rigid, reliable and long lasting construction.  
         [0045]     The design techniques and the locking member of this invention yield solid furniture construction, but allows easy and quick disassembly of the furniture if desired. Furniture made in accordance with the present invention can be simply disassembled by dislodging the arm supports  20 ,  30  and locking key  70  from the notch  49 ,  59 . This frees the components for easy disassembly.  
         [0046]     While the invention has been illustrated and described in detail in the drawing and foregoing description, the same should be considered as illustrative and not limiting or restrictive. It is understood that only a preferred embodiment has been presented and that all changes, modifications and applications that come within the spirit of the invention are to be protected. It is further understood that the present invention includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the invention as would normally occur to one skilled in the art to which this invention pertains.