U.S. patent application number 12/428132 was filed with the patent office on 2010-10-28 for system and method for compactly shipping and finally assembling an upholstered seat.
Invention is credited to Phillip C. Hood.
Application Number | 20100270844 12/428132 |
Document ID | / |
Family ID | 42991469 |
Filed Date | 2010-10-28 |
United States Patent
Application |
20100270844 |
Kind Code |
A1 |
Hood; Phillip C. |
October 28, 2010 |
SYSTEM AND METHOD FOR COMPACTLY SHIPPING AND FINALLY ASSEMBLING AN
UPHOLSTERED SEAT
Abstract
A method of compactly packaging an upholstered seat for shipment
includes providing an upholstered seat bottom including a base with
a top surface, a front edge, a rear edge, a first end, a second
end, a first upwardly extending side arm attached to the first end,
and a second upwardly extending side arm attached to the second
end. The method further includes providing an upholstered seat back
configured for secure attachment to the seat bottom after shipment,
and compactly arranging the seat bottom and the seat back within a
substantially rectilinear shipping carton. The upholstered seat can
include at least one bracket assembly for irremovably attaching the
seat back to the seat bottom after shipment.
Inventors: |
Hood; Phillip C.;
(Greensboro, NC) |
Correspondence
Address: |
WOMBLE CARLYLE SANDRIDGE & RICE, PLLC
ATTN: PATENT DOCKETING, P.O. BOX 7037
ATLANTA
GA
30357-0037
US
|
Family ID: |
42991469 |
Appl. No.: |
12/428132 |
Filed: |
April 22, 2009 |
Current U.S.
Class: |
297/440.15 ;
297/463.1; 53/467 |
Current CPC
Class: |
A47C 7/42 20130101; A47C
4/028 20130101; A47C 31/11 20130101 |
Class at
Publication: |
297/440.15 ;
297/463.1; 53/467 |
International
Class: |
A47C 7/00 20060101
A47C007/00; A47C 31/00 20060101 A47C031/00; B65B 5/06 20060101
B65B005/06 |
Claims
1. A method of compactly packaging an upholstered seat for
shipment, the method comprising: a. providing an upholstered seat
bottom comprising a base with a top surface, a front edge, a rear
edge, a first end, a second end, a first upwardly extending side
arm attached to the first end and having a first top, and a second
upwardly extending side arm attached to the second end and having a
second top; b. providing a separate upholstered seat back
configured for secure attachment to the seat bottom after shipment;
and c. compactly arranging the seat bottom and the separate seat
back within a substantially rectilinear shipping carton.
2. A method according to claim 1 wherein the step of compactly
arranging the seat bottom and the seat back within the shipping
carton comprises positioning the seat back below the seat
bottom.
3. A method according to claim 1 wherein the seat bottom comprises
a bottom cavity and wherein the step of compactly arranging the
seat bottom and the seat back within the shipping carton comprises
positioning the seat back below the seat bottom such that at least
a portion of the seat back is received within the bottom
cavity.
4. A method according to claim 1 wherein compactly arranging the
seat bottom and the seat back within the shipping carton comprises
placing the seat back above the top surface of the base and between
the first and second upwardly extending side arms such that no
substantial portion of the seat back extends forward of the front
edge, rearward of the rear edge, or above the first or second tops
of the first and second side arms.
5. A method according to claim 1 wherein the upholstered seat
bottom includes at least one first bracket and the upholstered seat
back includes at least one second bracket, wherein the first
bracket is configured to substantially irremovably engage the
second bracket when the seat back is attached to the seat bottom
after shipment.
6. A method according to claim 1 further comprising providing at
least one seat cushion or pillow, and placing the seat cushion or
pillow between the first and second upwardly extending side arms
such that no substantial portion of the seat cushion or pillow
extends forward of the front edge, rearward of the rear edge, or
above the first or second tops of the first and second side arms,
and enclosing the seat bottom, the seat back and the cushion or
pillow within the substantially rectilinear shipping carton.
7. A bracket assembly for irremovably attaching a first portion of
an upholstered article of furniture to a second portion of the
upholstered article of furniture, the bracket assembly comprising:
a. a male bracket comprising: i. an elongated end having a first
side wall and an opposed second side wall; ii. a first protrusion
outwardly extending from the first side wall, and a second
protrusion outwardly extending from the second side wall; and iii.
at least one mounting flange for attaching the male bracket to the
first portion of article of furniture; b. a female bracket
comprising: i. a top end and an opposed bottom end; ii. a first
side and an opposed second side defining an elongated channel
therebetween, the channel extending from the top end to the bottom
end and being configured to receive the elongated end of the male
bracket; and iii. a first recess in the first side and a second
recess in the second side; and iv. at least one flange for
attaching the female bracket to the second portion of article of
furniture; c. wherein when the elongated end of the male bracket is
received in the channel of the female bracket, the first protrusion
is received in the first recess and the second protrusion is
received in the second recess such that the first and second
protrusions resist extraction of the end of the male bracket from
the channel of the female bracket.
8. A bracket assembly according to claim 7 wherein the first side
wall of male bracket is parallel to the second side wall of the
male bracket.
9. A bracket assembly according to claim 7 wherein the first side
of the female bracket is parallel to the second side of the female
bracket.
10. A bracket assembly according to claim 7 wherein the channel is
wider at the top end of the female bracket than at the bottom end
of the female bracket.
11. A bracket assembly according to claim 7 wherein the mounting
flange of the male bracket includes a lower edge, and wherein the
lower edge is proximate to the top end of the female bracket when
the elongated end of the male bracket is received in the channel of
the female bracket, the first protrusion is received in the first
recess and the second protrusion is received in the second
recess.
12. A bracket assembly according to claim 11 wherein the lower edge
contacts the top end of the female bracket when the elongated end
of the male bracket is received in the channel of the female
bracket, the first protrusion is received in the first recess and
the second protrusion is received in the second recess.
13. A bracket assembly according to claim 7 wherein the first
protrusion and the second protrusion have substantially
semi-spherical shapes.
14. A bracket assembly according to claim 7 wherein the first
protrusion is integrally formed on the first sidewall and the
second protrusion is integrally formed on the second side wall.
15. A bracket assembly according to claim 7 wherein the first
recess and the second recess have substantially semi-spherical
shapes.
16. A bracket assembly according to claim 7 wherein the first
recess is formed by a first opening in the first side of the female
bracket, and the second recess is formed by a second opening in the
second side of the female bracket.
17. A bracket assembly according to claim 7 wherein the elongated
end of the male bracket is non-tapered.
18. A bracket assembly according to claim 7 wherein the male
bracket is constructed of a continuous piece of material.
19. A bracket assembly according to claim 7 wherein the female
bracket is constructed of a continuous piece of material.
20. A sofa, chair or couch comprising the bracket assembly of claim
7.
21. An upholstered sofa, chair or couch comprising: a. a back
portion having a first end, an opposed second end, and a middle
portion; b. a bottom portion having a first upwardly extending side
arm with a first inside surface, and an opposed second upwardly
extending side arm with a second inside surface; c. a first male
bracket on the first end and a second male bracket on the second
end, the first and second male brackets each including an elongated
portion having at least outwardly extending protrusion thereon; and
d. a first female bracket on the first inside surface and a second
female bracket on the second inside surface, the first and second
female brackets each including an elongated channel defined by a
plurality of walls, at least one wall of each of the first and
second female brackets including a recess therein; e. wherein when
the elongated portions of the first and second male brackets are
each received in the channel of one of the first and second female
brackets and the protrusions of the first and second male brackets
are each received in the recess of one of the first and second
female brackets, the back portion is substantially irremovably
attached to the bottom portion.
22. An upholstered sofa, chair or couch according to claim 21
further comprising at least one bolt connecting the middle portion
of the back to the bottom.
23. An upholstered sofa, chair or couch according to claim 21
wherein the first male bracket, the second male bracket, the first
female bracket, and the second female bracket are each constructed
of a continuous piece of material.
Description
FIELD OF THE INVENTION
[0001] The invention generally relates to furniture, and more
particularly relates to an upholstered seat which can be compactly
packaged in a partially disassembled state, and which includes a
bracket assembly for quickly and substantially irremovably
connecting separate portions of the upholstered seat after
shipment.
BACKGROUND
[0002] Traditional upholstered seats include a usually wooden frame
having a bottom portion, a back portion, and side arm portions. As
used herein, the term "seat" is used to generally refer to an
upholstered chair, sofa, couch, and the like. The bottom portion,
back portion, and side arm portions of such frames are permanently
connected together to provide rigid support structures for the
seats Spring supports can be provided on the bottom portions of the
frames, and padding and fabric at least partially cover the frame.
Cushions can be provided atop the spring supports and/or against
the backs of the seats.
[0003] When such traditional upholstered seats are to be
transported long distances on ships, for example, the seats are
typically stowed in large shipping containers. Due to the irregular
shapes of such seats, it can be difficult to compactly arrange the
seats in a shipping container in a manner that minimizes the amount
of unoccupied and wasted space within the container. Accordingly,
it can advantageous to ship the seats in unassembled parts which
can be more compactly arranged within a shipping container. Once
such seats arrive at their final destinations, the parts must be
assembled together to provide a complete article of furniture.
Unfortunately, such seats can include a substantial number of
unassembled parts or portions and loose connecting hardware that
must be finally assembled after shipment, thus complicating final
assembly of the seats.
[0004] Accordingly, there is a need for an upholstered seat which
can be arranged in a partially unassembled and compact
configuration, and which permits the partially unassembled and
compactly arranged seat to be packaged in a single shipping carton
or container in a manner that minimizes the amount of wasted space
within the carton or container. In addition, there is a need for a
method and device for quickly and securely assembling the
unassembled portions of the upholstered seat together after
shipment.
SUMMARY OF THE INVENTION
[0005] One embodiment of the invention includes a method of
compactly packaging an upholstered seat for shipment. The method
includes providing an upholstered seat bottom including a base with
a top surface, a front edge, a rear edge, a first end, a second
end, a first upwardly extending side arm attached to the first end
and having a first top, and a second upwardly extending side arm
attached to the second end and having a second top. The method
further includes providing a separate upholstered seat back
configured for secure attachment to the seat bottom after shipment,
and compactly arranging the seat bottom and the separate seat back
within a substantially rectilinear shipping carton.
[0006] In another embodiment, a bracket assembly for irremovably
attaching a first portion of an upholstered article of furniture to
a second portion of the upholstered article of furniture includes a
male bracket and a female bracket. The male bracket can include an
elongated end having a first side wall and an opposed second side
wall, a first protrusion outwardly extending from the first side
wall, and a second protrusion outwardly extending from the second
side wall, and at least one mounting flange for attaching the male
bracket to the first portion of article of furniture. The female
bracket can include a top end and an opposed bottom end, a first
side and an opposed second side defining an elongated channel
therebetween, the channel extending from the top end to the bottom
end and being configured to receive the elongated end of the male
bracket, a first recess in the first side and a second recess in
the second side, and at least one flange for attaching the female
bracket to the second portion of article of furniture. When the
elongated end of the male bracket is received in the channel of the
female bracket, the first protrusion is received in the first
recess and the second protrusion is received in the second recess
such that the first and second protrusions resist extraction of the
end of the male bracket from the channel of the female bracket.
[0007] In a further embodiment, an upholstered sofa, chair or couch
includes a back portion having a first end, an opposed second end,
and a middle portion, and a bottom portion having a first upwardly
extending side arm with a first inside surface, and an opposed
second upwardly extending side arm with a second inside surface. A
first male bracket can be provided on the first end, and a second
male bracket can be provided on the second end. The first and
second male brackets can each include an elongated portion having
at least outwardly extending protrusion thereon. A first female
bracket can be provided on the first inside surface and a second
female bracket can be provided on the second inside surface. The
first and second female brackets can each include an elongated
channel defined by a plurality of walls, at least one wall of each
of the first and second female brackets including a recess therein.
When the elongated portions of the first and second male brackets
are each received in the channel of one of the first and second
female brackets and the protrusions of the first and second male
brackets are each received in the recess of one of the first and
second female brackets, the back portion is substantially
irremovably attached to the bottom portion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a top perspective view of one embodiment of a sofa
according to the invention.
[0009] FIG. 2 is a bottom perspective view of the sofa shown in
FIG. 1.
[0010] FIG. 3 is another bottom perspective view of the sofa shown
in FIGS. 1 and 2.
[0011] FIG. 4A shows a first packaging arrangement for a sofa like
that shown in FIGS. 1-3.
[0012] FIG. 4B shows a second packaging arrangement for a sofa like
that shown in FIGS. 1-3.
[0013] FIG. 5 is a perspective view of one embodiment of a female
bracket for attaching a seat back to a seat bottom to produce the
sofa shown in FIGS. 1-3.
[0014] FIG. 6 is a perspective view of one embodiment of a male
bracket for attaching a seat back to a seat bottom to produce the
sofa shown in FIGS. 1-3.
[0015] FIG. 7 is a perspective view showing the male bracket of
FIG. 6 received in the female bracket shown in FIG. 4.
[0016] FIG. 8 is a cross sectional view taken along line 8-8 in
FIG. 7 showing the male bracket of FIG. 6 received in the female
bracket shown in FIG. 5.
[0017] FIG. 9 is a front elevation view of the female bracket shown
in FIGS. 5, 7 and 8.
[0018] FIG. 10 is a bottom plan view of the female bracket shown in
FIGS. 5 and 7-9.
DETAILED DESCRIPTION
[0019] FIG. 1 shows one embodiment of a sofa 10 having a separate
upholstered back 20 which can be compactly packaged with the sofa's
bottom 30 for shipment. As discussed in detail below, the separate
back 20 and bottom 30 can be compactly packaged in a single
shipping carton, and compactly stowed within a large shipping
container with other similarly packaged sofas 10 such that wasted
space within the shipping carton and the shipping container is
minimized. Once the sofa 10 arrives at a final destination, a user
can assemble the back 20 to the bottom 30 in a manner like that
described below. Once the back 20 is assembled to the bottom 30,
the sofa 10 has the appearance of a traditional upholstered sofa
having a continuous wooden frame and a permanently attached and
inseparable back and bottom.
[0020] As shown in FIG. 1, the sofa 10 can include an upholstered
back 20 having a lower edge 24 and first and second opposed ends
22, 26. As also shown in FIG. 1, the bottom 30 can include an
upholstered base 31 having a substantially planar upper surface 32,
a first upholstered side arm 34 affixed to one end of the base 31,
and a second upholstered side arm 36 affixed to an opposite end of
the base 31. In the embodiment shown, the base 31 and side arms 34,
36 combine to provide the bottom 30 with an elongated U shape. The
separate upholstered back 20 can be assembled to the bottom 30 as
indicated by the directional arrow 12 in FIG. 1. The back 20 can be
lowered between rear portions of the opposed side arms 34, 36 until
the lower edge 24 of the back 20 rests upon or is proximate to a
rear portion of the upper surface 32 of the base 31.
[0021] As shown in FIG. 1, the back 20 can include a first male
bracket 50 on its first end 22. Though not visible in FIG. 1, the
back 20 can similarly include a second male bracket 50 on its
opposite end 26. As also shown in FIG. 1, a female bracket 40 can
be provided on a rear portion of the inside surface 38 of the
second side arm 36. Though not visible in FIG. 1, another female
bracket 40 can be similarly provided on a rear portion of the
inside surface 39 of the first side arm 34. As described below,
each male bracket 50 can be arranged to engage an aligned female
bracket 40 when the back 20 is assembled to the bottom 30 as
described above. During assembly, the weight of the back 20 assists
in insertion of the male brackets 50 into the female brackets 40.
Once the back 20 is fully received by the bottom 30 and the male
brackets 50 are fully engaged with their mating female brackets 40,
the male brackets 50 and female brackets 40 can cooperate to
substantially irremovably affix the ends 22, 26 of the back 20 to
the side arms 34, 36. As also shown in FIG. 1, a flap 80 can
downwardly extend from the back 20. In one embodiment, the flap 80
is a portion of a continuous sheet of fabric that downwardly
extends from a top edge 21 of the back 20 to a lower edge 82 of the
flap 80.
[0022] As shown in FIG. 2, a bolt 60 can be used to connect a
mid-span portion of the back 20 to a mid-span portion of the base
31. The bolt 60 can include an elongated rod 69 including a
threaded portion 62 and a head 64. As shown in FIG. 2, the head 64
can include tabs or wings 67 configured to permit the head 64 to be
gripped by a person's fingers as the bolt 60 is manually rotated by
the person. The bolt 60 can be inserted through an opening 33 in a
rear portion of the base 31 such that the threaded portion 62 of
the bolt 60 upwardly extends through the base 31. Though not shown
in the drawings, the back 20 can include an aligned opening in its
lower edge 24 for receiving part of the e threaded portion 62 of
the bolt 60 that upwardly extends above the upper surface 32 of the
base 31. The aligned opening in the back 20 can include internal
threads for threadably receiving the bolt 60. Alternatively, a nut
(not shown) can be provided on the threaded end of the bolt 60 for
securing the back 20 to the base 31. As shown in FIG. 2, a washer
66 and a lock washer 68 can be disposed between the head 64 of the
bolt 60 and a bottom surface 35 of the base 31. When the bolt 60 is
threadably engaged with the aligned opening in the back 20 and the
bolt 60 is tightened such that the head 64 and washers 66, 68 are
seated against the bottom surface 35 of the base 31 as shown in
FIG. 3, the bolt 60 substantially prevents a mid-span portion of
the assembled base 20 from moving or flexing relative to the base
31 when a rearward force is applied to the mid-span portion of the
back 20, such as a rearward force applied by the back of person
seated on the sofa 10. In an alternative arrangement, the bolt 60
can downwardly extend from the back 20 and through the opening 33
in the base 31, and can receive a nut on its lower end for securing
the back 20 to the base 31. Once the back 20 is assembled to the
bottom 30, one or more cushions (not shown) can be placed on the
upper surface 32 of the base 31 to form a cushioned seating
surface.
[0023] As shown in FIG. 3, the flap 80 on the back 20 can
downwardly extend behind a rear portion of the base 31 and between
the opposed side arms 34, 36. The forward face of the lower edge 82
of the flap 80 can include a first hook-and-loop fastening
material, such as Velcro.RTM. or the like. The bottom of an
adjacent rear edge 37 of the base 31 can include a second
hook-and-loop fastening material for engagement with the first
hook-and-loop fastening material on the lower edge 82 of the flap
80. As shown in FIG. 3, the lower edge 82 of the flap 80 can be
folded under the adjacent rear edge 37 of the base 31 and secured
in that folded position by the first and second hook-and-loop
fastening materials. The flap 80 can cover the juncture between the
back 20 and the base 31, thereby providing the rear of the sofa 10
with a finished appearance. As shown in FIGS. 2 and 3, the bottom
30 can include a cavity 11 defined by the side arms 34, 36, the
rear edge 37 of the base 31, a forward edge 13 of the base 31, and
the bottom surface 35 of the base 31.
[0024] FIG. 4A shows one embodiment of a shipping arrangement 100
which can be used to compactly package a sofa 10 like that
described above within a substantially rectilinear shipping carton
190. A shown in FIG. 4A, the unassembled back 20 can be laid
substantially flat and positioned below the base 31. In one
embodiment in which the back 20 is appropriately sized and shaped,
at least a portion of the back 20 is received within a cavity under
the bottom 30 like the bottom cavity 11 shown in FIGS. 2 and 3, for
example. Loose pillows, cushions, or the like (not shown) can also
be stowed within the cavity 11 as space permits. As shown in FIG.
4A, one or more seat cushions 71, 72 can be situated atop the base
31 and between the opposed side arms 34, 36. As also shown in FIG.
4A, one or more unattached pillows 75, 77 can also be positioned
between the opposed side arms 34, 36. Once so arranged, the back
20, the bottom 30 and any cushions 71, 72 and/or pillows 75, 77 can
be compactly packaged within the rectilinear shipping carton 190
such that there is a minimal amount of unoccupied or wasted space
within the carton 190. The carton 190 can be stacked and compactly
arranged with other similar cartons within a larger shipping
container for long-distance transport, such as on a ship, for
example. Though not shown in FIG. 4A, the shipping arrangement 100
can include additional packaging materials for securing the sofa 10
within the carton 190 and for protecting the sofa 10 against damage
during shipment or handling. Once the package 100 arrives at a
final destination, the sofa 10 can be unpacked from the carton 190
and the back 20 can be quickly assembled to the bottom 30 as
described above.
[0025] FIG. 4B shows another embodiment of a shipping arrangement
200 which can be used to compactly package a sofa 10 like that
described above within a substantially rectilinear shipping carton
90. A shown in FIG. 4B, the unassembled back 20 can be laid
substantially flat and positioned above the base 31 and between the
upright side arms 34, 36 of the bottom 30. In FIG. 4B, the back 20
is situated atop a pair of cushions 71, 72 which rest on the base
31 and are also positioned between the opposed side arms 34, 36. In
an alternative arrangement, the back 20 can be placed directly on
the base 31 without cushions 71, 72 disposed therebetween. In a
further alternative arrangement, the back 20 can be placed directly
on the base 31 and the cushions 71, 72 can be stacked atop the back
20, for example. Other associated items such as additional
cushions, pillows, or the like can also be compactly arranged with
the back 20 between the side arms 34, 36 when available space
permits. As shown in FIG. 4B, the back 20 and bottom 30 can be
configured such that when the unassembled back 20 is compactly
stowed between the side arms 34, 36, no substantial portion of the
back 20 extends above the side arms 34, 36, no substantial portion
of the back 20 extends forward of the base 31, and no substantial
portion of the back 20 extends rearward of the base 31. As also
shown in FIG. 4B, the compactly arranged back 20, bottom 30 and any
cushions 71, 72 can be packaged within the rectilinear shipping
carton 90 such that there is a minimal amount of unoccupied or
wasted space within the carton 90. The carton 90 can be stacked and
compactly arranged with other similar cartons within a larger
shipping container for long-distance transport, such as on a ship,
for example. Though not shown in FIG. 4B, the shipping arrangement
200 can include additional packaging materials for securing the
sofa 10 within the carton 90 and for protecting the sofa 10 against
damage during shipment or handling. Once the package 200 arrives at
a final destination, the sofa 10 can be unpacked from the carton 90
and the back 20 can be quickly assembled to the bottom 30 as
described above.
[0026] Details of one embodiment of a female bracket 40 for use in
securing the ends of the back 20 to the side arms 34, 36 of the
sofa 10 is shown in FIGS. 5, 9 and 10. As shown in FIGS. 5 and 9,
the bracket 40 can include a front wall 41, opposed first and
second side walls 43a, 43b, opposed first and second mounting
flanges 47a, 47b, an upper end 42, and a lower end 44. The front
wall 41 and opposed first and second side walls 43a, 43b form an
elongated channel 45 extending between the upper end 42 and the
lower end 44. Each of the mounting flanges 47a, 47b can include one
or more holes 49 for receiving screws or the like for securely
attaching the female bracket 40 on an inside surface 38, 39 of a
side arm 34, 36 as shown in FIG. 1. As best seen in FIG. 9, the
female bracket 40 can further include opposed first and second
upper sidewalls 46a, 46b. The upper sidewalls 46a, 46b can be
spaced farther apart than the first and second side walls 43a, 43b
such that the channel 45 shown in FIG. 5 is at least slightly wider
at the upper end 42 than at the lower end 44. As described below,
the wider upper portion of the channel 45 facilitates insertion of
a portion of a mating male bracket 50 into the channel 45 as the
back 20 is assembled to the bottom 30 of the sofa 10 as shown in
FIG. 1 and discussed above.
[0027] As best seen in FIGS. 9 and 10, a first recess 70a is formed
in an inside surface of the first side wall 43a, and a second
recess 70b is formed in an inside surface of the second side wall
43b. In one embodiment, the first recess 70a and the second recess
70b are directly opposite each other on opposed sides of the
channel 45. In the embodiment shown in FIGS. 9 and 10, the recesses
70a, 70b are substantially semi-spherical dimples or indentations
formed in their respective side walls 43a, 43b. The recesses 70a,
70b can also have other shapes and configurations not shown in the
drawings. For example, the recesses 70a, 70b can be formed by
openings that extend through the respective side walls 43a, 40b,
such as circular holes or the like. Other configurations are also
possible. In one embodiment, the female bracket 40 is constructed
of metal, such as steel, aluminum, or the like, and is constructed
in a single continuous piece. In another embodiment, the female
bracket 40 is constructed of a continuous, strong and durable
molded plastic material, or the like. Other materials can also be
used to construct the female bracket 40.
[0028] Details of one embodiment of a male bracket 50 for use in
securing the ends of the back 20 to the side arms 34, 36 of the
sofa 10 are shown in FIG. 6. In this embodiment, the male bracket
50 includes a back wall 51, opposed first and second side walls
53a, 53b, opposed first and second mounting flanges 57a, 57b, and
upper end 52, and a lower end 54. The mounting flanges 57a, 57b are
disposed proximate to the upper end 52, and have lower edges 55a,
55b that are located substantially above the lower end 54 of the
male bracket 50. Each of the mounting flanges 57a, 57b can include
one or more holes 59 for receiving screws or the like for securely
attaching the male bracket 50 on an end 22, 26 of the back 20 as
shown in FIG. 1. As shown in FIG. 6, the first side wall 53a can
include a first protrusion 58a that outwardly extends from an outer
surface of the first side wall 53a. Similarly, the second side wall
53b can include a second protrusion 58b that outwardly extends from
an outer surface of the second side wall 53b. In the embodiment
shown in the drawings, the first and second protrusions 58a, 58b
are substantially semi-spherical blisters or buttons formed in the
respective side walls 53a, 53b. The first and second protrusions
58a, 58b can also have other shapes and configurations not shown in
the drawings. For example, the protrusions 58a, 58b can be tabs
that outwardly extend from the side walls 53a, 53b, or the like. In
one embodiment, the male bracket 50 is constructed of metal, such
as steel, aluminum, or the like, and is formed as one continuous
piece. In another embodiment, the male bracket 50 is constructed of
a continuous, strong and durable molded plastic material, or the
like. Other materials can also be used to construct the male
bracket 50.
[0029] FIGS. 7 and 8 show the lower end 54 of the male bracket 50
received in the channel 45 of the female bracket 40. As shown in
FIG. 7, when the male bracket 50 is fully inserted in the female
bracket, the lower edges 55a, 55b of the mounting flanges 57a, 57b
of the male bracket 50 can rest upon or be closely proximate to the
upper end 42 of the female bracket 40, and the lower end 54 of the
male bracket 50 can be proximate to the lower end 44 of the female
bracket 40. The mounting flanges 57a, 57b on the male bracket 50
and the mounting flanges 47a, 47b on the female bracket 40 are
arranged such that the male bracket 50 can be inserted into the
female bracket 40 when the male bracket 50 is attached to an end
22, 26 of the back 20 and the female bracket 40 is attached to an
inside surface 38, 39 of a side arm 34, 36 of the sofa 10 as shown
in FIG. 1.
[0030] As shown in FIG. 8, when the male bracket 50 is inserted
into the channel 45 of the male bracket, the opposed side walls
53a, 53b of the male bracket 50 are closely proximate to the
respective opposed sidewalls 43a, 43b of the female bracket 40.
Preferably, the lateral clearances between the opposed side walls
53a, 53b of the male bracket 50 and the respective opposed
sidewalls 43a, 43b of the female bracket 40 are sufficiently small
to substantially prevent relative lateral movement between the
mated brackets 40, 50, but are also sufficiently large to permit
the male bracket 50 to be inserted into the female bracket 40 when
the brackets 40, 50 are not perfectly aligned with each other. As
described above, the opposed upper side walls 46a, 46b of the
female bracket 40 are spaced farther apart than the side walls 43a,
43b of the female bracket 40 and the channel 45 of the female
bracket 40 is wider at the upper end 42 of the female bracket 40
than at the lower end 44. Accordingly, the lower end 54 of the male
bracket 50 can enter the upper end 42 of the female bracket 40 even
though there may be some lateral misalignment between the male
bracket 50 and the female bracket 40.
[0031] As shown in FIG. 8, when the male bracket 50 is fully
inserted into the channel 45 of the female bracket 40, each of the
protrusions 58a, 58b on the side walls 53a, 53b of the male bracket
50 are received within a corresponding recess 70a, 70b in the side
walls 43a, 43b of the female bracket 40. Once so engaged, the
protrusions 58a, 58b substantially prevent the male bracket 50 from
being extracted from the mated female bracket 4. Accordingly, the
mated brackets 40, 50 combine to provide a substantially permanent
attachment between the back 20 and bottom 30 of the sofa 10 shown
in FIG. 1 and described above, and permit a person to assemble the
back 20 to the bottom 30 without tools and with no loose
hardware.
[0032] Because the opposed protrusions 58a, 58b on the male bracket
50 are wider than the channel 45 of the female bracket, the
protrusions 58a, 58b can interfere with insertion of the male
bracket 50 into the narrower channel 45. Preferably, the side walls
53a, 53b of the male bracket 50 are sufficiently flexible to permit
the side walls 53a, 53b and protrusions 58a, 58b to resiliently
deflect inwardly as the male bracket 50 is inserted into the
channel 45. In addition, the opposed side walls 43a, 43b of the
female bracket 40 can be sufficiently flexible to be at least
slightly resiliently wedged apart by the protrusions 58a, 58b as
the male bracket 50 is inserted into the female bracket 40. The
semi-spherical shape of the protrusions 58a, 58b shown in the
drawings can assist in resiliently wedging the side walls 43a, 53a
and the side walls 43b, 53b apart as the male bracket 50 is
inserted into the female bracket 40.
[0033] The above descriptions of various embodiments of the
invention are provided to illustrate and highlight particular
aspects and features of the invention, and not to limit the
invention thereto. Persons of ordinary skill in the art will
recognize that various changes and modifications can be made to the
specifically described embodiments without departing from the scope
of the invention. All such changes and modifications are intended
to be within the scope of the appended claims.
* * * * *