U.S. patent application number 10/854096 was filed with the patent office on 2005-10-13 for compactable furniture system.
Invention is credited to Ou, Shren Chu.
Application Number | 20050225153 10/854096 |
Document ID | / |
Family ID | 34775190 |
Filed Date | 2005-10-13 |
United States Patent
Application |
20050225153 |
Kind Code |
A1 |
Ou, Shren Chu |
October 13, 2005 |
Compactable furniture system
Abstract
A compactable furniture system having a seat back with front and
rear panels that are pivotally connected at the top of the front
and rear panels and removably connected at the bottom of the front
and rear panels with a pitch mechanism that fixes the seat back at
a pitch angle during assembly.
Inventors: |
Ou, Shren Chu; (Monterey
Park, CA) |
Correspondence
Address: |
SHELDON & MAK, INC
225 SOUTH LAKE AVENUE
9TH FLOOR
PASADENA
CA
91101
US
|
Family ID: |
34775190 |
Appl. No.: |
10/854096 |
Filed: |
May 25, 2004 |
Current U.S.
Class: |
297/440.1 ;
297/440.14; 297/440.15 |
Current CPC
Class: |
A47C 17/00 20130101;
A47C 4/028 20130101 |
Class at
Publication: |
297/440.1 ;
297/440.14; 297/440.15 |
International
Class: |
A47C 007/00 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 2, 2004 |
CN |
200420044284.6 |
Claims
What is claimed is:
1. A compactable furniture system comprising: a) a seat back having
a front panel and a rear panel, wherein the front panel and the
rear panel are: i) pivotally connected at a front panel top end and
a rear panel top end; and ii) removably connected at a front panel
bottom end and a rear panel bottom end; b) a pitch mechanism for
removably connecting the front panel bottom end and the rear panel
bottom end at a pitch angle; c) first and second side supports
attached to the seat back; d) a front rail attached to the first
and second side supports; and e) a seat deck disposed between the
seat back, the front rail, and the first and second side
supports.
2. The furniture system of claim 1 additionally comprising a seat
deck lock.
3. The furniture system of claim 2 wherein the seat deck lock
comprises a bracket and a plate having a joining pin.
4. The furniture system of claim 1 additionally comprising a center
bar interposed between the rear panel and the front rail.
5. The furniture system of claim 1 additionally comprising a hinge
lock.
6. The furniture system of claim 5 wherein the hinge lock comprises
first and second hinge plates and a hinge pin.
7. The furniture system of claim 1 additionally comprising first
and second legs attached to the first side support and third and
fourth legs attached to the second side support.
8. The furniture system of claim 1 wherein the pitch mechanism
comprises a slotted bracket having one or more notches.
9. The furniture system of claim 1 wherein the pitch mechanism
comprises a bar with two apertures.
10. The furniture system of claim 1 wherein the pitch mechanism
comprises a bar with an aperture and a hook.
11. The furniture system of claim 1 wherein the pitch mechanism
comprises a locking joint.
12. The furniture system of claim 1 wherein the front panel and the
rear panel are pivotally connected with one or more hinges.
13. A method for assembling compactable furniture comprising: a)
selecting a furniture system according to claim 1; b) attaching the
seat back to the first and second side supports; c) attaching the
front rail to the first and second side supports; d) inserting the
pitch mechanism and fixing the seat back at a pitch angle; and e)
inserting the seat deck between the seat back, the front rail, and
the first and second side supports.
14. A method according to claim 13 wherein the furniture system
additionally comprises a seat deck lock and the method additionally
comprises attaching the seat deck lock to at least one of the first
side support, the second side support or the front rail.
15. A method according to claim 13 wherein the furniture system
additionally comprises a hinge lock and the method additionally
comprises attaching at least one of the first and second side
supports to the front rail with a hinge lock.
Description
BACKGROUND
[0001] Traditionally, large furniture seating items such as sofas,
loveseats, chairs, and sleepers are fully constructed and assembled
in a factory and then shipped, in the assembled state, to a desired
destination, either a retailer or directly to a consumer. A major
manufacturing cost for producing these items is the cost of
shipping (i.e., freight costs). In addition, these bulky furniture
items require a large amount of space to warehouse and store, which
is also costly.
[0002] Furniture that can be manufactured and shipped, and then
fully assembled by an end user, such as a retailer or consumer, is
currently known. An example of such a furniture system can be found
in U.S. Pat. No. 5,423,596. Disadvantageously, however, this
furniture system has many components and assembly/disassembly of
the finished product can be difficult for the end user.
[0003] In addition, many consumers live in homes or apartments that
have narrow doors or stairways that cannot be navigated by
traditional bulky furniture. This can require removing windows or
doors, and/or hoisting large furniture items through upper story
windows to place large furniture in these homes or apartments.
Removing the furniture from the dwelling requires the same arduous
process.
[0004] Therefore, there is a need for a furniture system that can
be compacted into a small space for shipping, storage, and moving.
It would also be advantageous if this furniture system can be
easily assembled and disassembled by a retailer or consumer.
SUMMARY
[0005] According to the present invention, there is provided a
compactable furniture system with a pitch mechanism that removably
connects a front and rear panel of a seat back at a pitch angle.
The compactable furniture system also has first and second side
supports attached to the seat back and a front rail attached to the
first and second side supports. A removable seat deck is disposed
between the seat back, the front rail, and the first and second
side supports.
[0006] The furniture system can additionally have a seat deck lock,
which has a bracket, and a joining pin with a plate that can
provide support for the seat deck. The furniture system can
additionally have a center bar interposed between the rear panel
and the front rail to provide support for the seat deck. A hinge
lock can be used to join the front rail and the first and second
side supports. The hinge lock can also have a hinge plate to
provide support for the seat deck. Further, the furniture system
can additionally have a set of legs that are attached to the first
and second side supports.
[0007] In one embodiment, the pitch mechanism comprises a slotted
bracket having one or more notches. The furniture system of claim 1
wherein the pitch mechanism comprises a bar with two apertures. The
furniture system of claim 1 wherein the pitch mechanism comprises a
bar with an aperture and a hook. The furniture system of claim 1
wherein the pitch mechanism comprises a locking joint. The
furniture system of claim 1 wherein the front panel and the rear
panel are pivotally connected with one or more hinges.
[0008] In another embodiment according to the present invention,
there is provided a method for assembling compactable furniture. In
one embodiment, a furniture system according to the present
invention is selected. Then, the seat back and the front rail are
attached to the first and second side supports. The pitch mechanism
is then inserted into the seat back and the seat back is fixed a
pitch angle. The seat deck is then inserted between the seat back,
the front rail, and the first and second side supports. In a
preferred embodiment, the furniture system additionally has a seat
deck lock, and the seat deck lock is attached to at least one of
the first side support, the second side support, or the front rail.
In another preferred embodiment, the furniture system additionally
has a hinge lock, at least one of the first and second side
supports is attached to the front rail with the hinge lock.
FIGURES
[0009] These and other features, aspects and advantages of the
present invention will become better understood from the following
description, appended claims, and accompanying figures where:
[0010] FIG. 1 is a front side perspective view of a compactable
furniture system, shown unassembled;
[0011] FIG. 2 is a front side perspective view of a compactable
furniture system, shown partially assembled;
[0012] FIG. 3A is a front perspective view of a front seat deck
lock;
[0013] FIG. 3B is a front perspective view of a side seat deck
lock;
[0014] FIG. 4A is a front perspective view of a hinge lock, shown
in an assembled form;
[0015] FIG. 4B is a front perspective view of a hinge lock, shown
in an unassembled form;
[0016] FIG. 5A is an outer side perspective view of one embodiment
of a pitch mechanism having a slide pitch lock;
[0017] FIG. 5B is an inner side perspective view of the embodiment
of the pitch mechanism shown in FIG. 5A;
[0018] FIG. 6A is an outer side perspective view of another
embodiment of a pitch mechanism having a bolted pitch lock;
[0019] FIG. 6B is an inner side perspective view of the embodiment
of the pitch mechanism shown in FIG. 6A;
[0020] FIG. 7A is an outer side perspective view of another
embodiment of a pitch mechanism having a hooked pitch lock;
[0021] FIG. 7B is an inner side perspective view of the embodiment
of the pitch mechanism shown in FIG. 7A, attached to the front seat
back by a bolting mechanism;
[0022] FIG. 7C is an outer side perspective view of the embodiment
of the pitch mechanism shown in FIG. 7A, attached to the front seat
back by a pin and groove mechanism;
[0023] FIG. 7D is an inner side perspective view of the embodiment
of the pitch mechanism shown in FIG. 7C;
[0024] FIG. 8A is an outer side perspective view of another
embodiment of a pitch mechanism having a locking joint; and
[0025] FIG. 8B is an inner side perspective view of the embodiment
of the pitch mechanism shown in FIG. 8A.
DESCRIPTION
[0026] According to the present invention a compactable furniture
system is provided. The furniture system is a "knock-down" seating
system where the furniture can be manufactured remotely in
unassembled pieces that can be shipped, stored, or moved in compact
form and later assembled by the end user. The compactable furniture
system has a pitch mechanism that allows the seat back to fold flat
for shipping, storage, and moving. When the compactable furniture
is assembled by the end user, the seat back is positioned for
proper seating by inserting the pitch mechanism into place and
locking, which adjusts the seat back to a desired pitch angle. The
compactable furniture system according to the present invention
allows approximately double the number of sofas to be shipped in a
conventional shipping container, substantially lowering
manufacturing costs. The compactable furniture system has the added
advantage of having few detachable components for ease of assembly
by the end user.
[0027] In one embodiment, the present invention is a compactable
furniture system having a pitch mechanism. Referring to FIG. 1 and
FIG. 2, there is shown a compactable furniture system 10 according
to the present invention. FIG. 1 shows an unassembled compactable
furniture system and FIG. 2 shows a partially assembled compactable
furniture system comprising a seat back 12 having a front panel 14
and a rear panel 16. The front panel 14 and the rear panel 16 are
pivotally connected at a front panel top end 18 and a rear panel
top end 20. The front panel 14 and the rear panel 16 are removably
connected at a front panel bottom end 22 and a rear panel bottom
end 24 with a pitch mechanism 26 and 28. A first side support 30
and second side support 32 are attached to the seat back 12 and a
front rail 34. A seat deck 36 is disposed between the seat back 12,
the front rail 34, and the first and second side supports 30 and
32.
[0028] Referring again to FIG. 1, in one embodiment the furniture
system 10 can additionally comprise support rails 38 and 40 (not
shown) to support the seat deck 36. The furniture system 10 can
additionally comprise a center bar 42 interposed between the rear
panel 16 and the front rail 34 to further support the seat deck
36.
[0029] Referring to FIG. 3A and FIG. 3B, and referring again to
FIG. 2, in another embodiment, the furniture system 10 additionally
comprises a front seat deck lock 44, and a side seat deck lock 46
and 48 (not shown). As shown in FIG. 3A, an expanded front
perspective view of the front seat deck lock 44, the front seat
deck lock 44, has a front bracket 50 and a front plate 52 with a
joining pin 54. As shown in FIG. 3A, the front bracket 50 is
attached to the front rail 34. The joining pin 54 inserts into the
front bracket 50. The front plate 52 rests on top of the front
bracket 50 and can provide support for the seat deck 36. As shown
in FIG. 3B, an expanded front perspective view of the side seat
deck lock 46, the side seat deck lock 46, has a side bracket 56, a
side plate 58, and a joining pin 60. The side bracket 56 attaches
to the side support 30 and the joining pin 60 inserts into the side
bracket 56. The side plate 60 rests on top of the side bracket 56
and can provide support for the seat deck 36. In a preferred, but
not required embodiment, the seat deck 60 additionally can have a
back stop 62. In another embodiment, the side plate 60 additionally
can have an insert pin that inserts into the seat deck 36 to
immobilize the seat deck 36, that is, to keep the seat deck 36 in a
desired position when it is inserted in the compactable furniture
system 10.
[0030] Referring again to FIG. 1, in a preferred, but not required
embodiment, the compactable furniture system additionally comprises
legs 64, 66, 68, and 70. As shown in FIG. 1, legs 64 and 66 are
attached to the side support 30 and legs 68 and 70 are attached to
the side support 32 by screws, as shown in FIG. 1, or can be
attached by other attachment means as will be understood by those
of skill in the art with reference to this disclosure. As also
shown in FIG. 1, the legs 64, 66, 68, and 70 can be triangular
shaped, or can have other leg shapes such as bun feet, turned legs,
cylinders, squares, or can have other shapes as will be understood
by those of skill in the art with reference to this disclosure. The
legs can be manufactured from wood or other suitable material such
as plastic and can be upholstered or not upholstered as also will
be understood by those of skill in the art with reference to this
disclosure.
[0031] Referring again to FIG. 1, the first side support 30 and the
second side support 32 can be attached to the front rail 34 with an
L bracket 72 and an L bracket 74 and bolts 76. The first side
support 30 and the second side support 32 can be directly attached
to the seat back 12 with bolts 78. Now referring to FIGS. 4A and
4B, and referring again to FIG. 2, in a preferred but not required
embodiment, the first side support 30 and the second side support
32 can be attached to the front rail 34, with a hinge lock 80 and
90. FIG. 4A shows a front perspective view of the hinge lock 80, in
an assembled form, and FIG. 4B shows a front perspective view of
the hinge lock 80, in an unassembled form, according to the present
invention. As shown in FIG. 4A, and FIG. 4B, the hinge lock 80 has
a first hinge bracket 82 and a second hinge bracket 84. The first
hinge bracket 82 and the second hinge bracket 84 are joined by
inserting hinge pin 86 into the first and second hinge bracket 82
and 84. Optionally, hinge pin 86 can have a hinge plate 88 that can
provide support for the seat deck 36 when the seat deck 36 is
inserted in the compactable furniture system 10.
[0032] Now referring to FIG. 5A and FIG. 5B; FIGS. 6A and 6B; FIG.
7A, FIG. 7B, FIG. 7C, and FIG. 7D; and FIGS. 8A and 8B, variations
of the pitch lock mechanism 26 according to the present invention
are shown. As shown in FIG. 5A and FIG. 5B, in a preferred but not
required embodiment, the pitch mechanism 26 is a slide lock 92.
FIG. 5A is an outer side perspective view of the slide lock 92, and
FIG. 5B, is an inner side perspective view of the slide lock 92
shown in FIG. 5A. The slide lock 92 is a slotted bracket 94 having
one or more notches 96 and a pitch lock 98. As shown in FIG. 5B,
the slide lock 92 is attached to the seat back 12 by attaching the
front panel 14 to the end of the slide lock 92 when the pitch lock
98 is in an unextended position. A bolt 100 joins the slotted
bracket 94 and the rear panel 16 of the seat back 12. As shown in
FIG. 5A, the front panel 14 is then extended to a desired pitch
angle and the slide lock 92 is straightened, thereby locking the
pitch lock 98 in place. When more than one notch 96 is provided in
the slide lock 92, the seat back can be adjustably locked in
different positions.
[0033] Referring again to FIG. 6A and FIG. 6B, in another
embodiment, the pitch mechanism 26 is a bolted pitch lock 102. FIG.
6A is an outer side perspective view of the bolted pitch lock 102,
and FIG. 6B, is an inner side perspective view of the bolted pitch
lock 102 shown in FIG. 6A. As shown in FIG. 6A and FIG. 6B, the
bolted pitch lock 102 is a bar 104 having first and second
apertures 106 and 108. The bolted pitch lock 102 is attached to the
seat back 12 by attaching the rear panel 16 to the bolted pitch
lock 102 through the first aperture 106 with a bolt 110. The front
panel 14 is then extended and the bolted pitch lock 102 is attached
to the front panel 14 through the second aperture 108 and a bolt
112, thereby locking the pitch mechanism 26 in place.
[0034] Referring again to FIG. 7A, in another embodiment, the pitch
mechanism 26 is a hooked pitch lock 114. Figure A is an outer side
perspective view of the hooked pitch lock 114, having a bar 116, an
aperture 118, and a hook 120. One embodiment of the hooked pitch
lock 114 is shown in FIG. 7B, an inner side perspective view of the
hooked pitch lock 114 shown in FIG. 7A, where the hooked pitch lock
114 is attached to the seat back 12 by attaching the rear panel 16
to the hooked pitch lock 102 through the aperture 118 with a bolt
122. According to this embodiment, the front panel 14 of the seat
back 12 is placed in an extended position and the hooked pitch lock
114 is attached to the front panel 14 by attaching the hook 120 to
a bolt 124, thereby locking the pitch mechanism 26 in place.
Another embodiment of the hooked pitch lock 114 is shown in FIG. 7C
and FIG. 7D, an inner side perspective view, and an outer side
perspective view, respectively, of the hooked pitch lock 114 shown
in FIG. 7A. According to this embodiment, the front panel 14 of the
seat back 12 is placed in an extended position and the hooked pitch
lock 114 is attached to the front panel 14 by connecting the hook
120 to a pin 126 contained within a front panel groove 128, thereby
locking the pitch mechanism 26 in place.
[0035] Referring again to FIG. 8A and FIG. 8B, in another
embodiment, the pitch mechanism 26 is a locking joint 130. FIG. 8A
is an outer side perspective view of the locking joint 130, and
FIG. 8B, is an inner side perspective view of the locking joint 130
shown in FIG. 8A. As shown in FIG. 8A and FIG. 8B, the locking
joint 130 is a bar 132 having first and second apertures 134 and
136 and a lock 138. The locking joint 130 is attached to the seat
back 12 by attaching the front panel 14 and the rear panel 16 to
the first and second apertures 134 and 136 of the locking joint
130. According to this embodiment, the front panel 14 is extended,
rotating the lock 138, until the locking joint 130 is substantially
straightened, thereby locking the pitch mechanism 26 in place.
[0036] Referring again to FIG. 2, the front panel 14 and the rear
panel 16 are pivotally connected at a front panel top end 18 and a
rear panel top end 20. In a preferred, but not required embodiment,
the front panel 14 and the rear panel 16 are pivotally connected
with one or more hinges 140, 142, and 144. However, the front panel
14 and the rear panel 16 are not necessarily connected with
hardware such as a hinge and can be otherwise connected, or
affixed, such as with fabric, cord, or plastic, or other suitable
materials as will be understood by those of skill in the art with
reference to this disclosure.
[0037] In another embodiment, the present invention is a method for
assembling compactable furniture. In one embodiment, the method
comprises selecting a furniture system according to the present
invention. Then, the seat back 12 is attached to the first side
support 30 and the second side support 32. Next, the front rail 34
is attached to the first side support 30 and the second side
support 32. Next, the pitch mechanism 26 and 28 is inserted into
the seat back 12 and the seat back 12 is locked at a pitch angle.
Next, the seat deck 36 is inserted between the seat back 12, the
front rail 34, and the first and second side supports 30 and
32.
[0038] In another embodiment, the method additionally comprises
attaching a front seat deck lock 44 to the front rail 34, and
attaching a side seat deck lock 46 and 48 to the first and second
side supports 30 and 32, respectively. In another embodiment, the
method additionally comprises attaching the first side support 30
and the second side support 32 to the front rail 34 with a hinge
lock 80 and 90.
[0039] Although the present invention has been discussed in
considerable detail with reference to certain preferred
embodiments, other embodiments are possible. Therefore, the scope
of the appended claims should not be limited to the description of
preferred embodiments contained herein.
* * * * *