U.S. patent application number 15/340840 was filed with the patent office on 2017-04-27 for ready-to-assemble sofa and method for packaging same.
The applicant listed for this patent is BILLY JOE GRIGGS, Jr.. Invention is credited to BILLY JOE GRIGGS, Jr..
Application Number | 20170112286 15/340840 |
Document ID | / |
Family ID | 58609321 |
Filed Date | 2017-04-27 |
United States Patent
Application |
20170112286 |
Kind Code |
A1 |
GRIGGS, Jr.; BILLY JOE |
April 27, 2017 |
READY-TO-ASSEMBLE SOFA AND METHOD FOR PACKAGING SAME
Abstract
A furniture system having a base frame, side pieces and a back
portion, that assembles quickly and disassembles into a
configuration that optimizes space when shipped.
Inventors: |
GRIGGS, Jr.; BILLY JOE;
(PULASKI, TN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GRIGGS, Jr.; BILLY JOE |
PULASKI |
TN |
US |
|
|
Family ID: |
58609321 |
Appl. No.: |
15/340840 |
Filed: |
November 1, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13846535 |
Mar 18, 2013 |
9480338 |
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15340840 |
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13423701 |
Mar 19, 2012 |
8480179 |
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13846535 |
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13293429 |
Nov 10, 2011 |
8408653 |
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13423701 |
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13045240 |
Mar 10, 2011 |
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13293429 |
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12824469 |
Jun 28, 2010 |
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13045240 |
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11580482 |
Oct 13, 2006 |
7744162 |
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12824469 |
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60726324 |
Oct 12, 2005 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47C 7/021 20130101;
A47C 7/18 20130101; B65B 31/00 20130101; A47C 4/028 20130101; A47C
17/00 20130101 |
International
Class: |
A47C 4/02 20060101
A47C004/02; A47C 7/18 20060101 A47C007/18; B65B 31/00 20060101
B65B031/00; A47C 7/02 20060101 A47C007/02 |
Claims
1. A piece of furniture, comprising: a horizontal seat support
frame with a plurality of panels, said panels defining a storage
cavity, said frame further comprising one or more movable support
members extending between two of more of side panels; one or more
back frame members attachable to said horizontal seat support frame
in an assembled configuration; and one or more arm members
attachable to said horizontal seat support frame or said one or
more back frame members, or combinations thereof, in said assembled
configuration; wherein at least one of said back frame members, or
one or more of said arm members, or combinations thereof, are
positioned in said storage cavity in a shipping configuration.
2. The furniture of claim 1, wherein said shipping configuration is
substantially rectangular.
3. The furniture of claim 1, wherein said horizontal support frame
comprises a back longitudinal frame member having a vertical
angular offset.
4. The furniture of claim 1, wherein said one or more arm members
comprise a base potion attachable to a portion of said horizontal
support frame.
5. The furniture system of claim 4, wherein said one or more arm
members comprise one half of a male-female connector for attachment
to a corresponding half of said male-female connector on said
horizontal support frame in said assembled configuration.
6. A method of shipping Ready to Assemble (RTA) furniture,
comprising the steps of: (a) providing RTA components of furniture
comprising: (i) a horizontal seat support frame with a plurality of
panels, said panels defining a storage cavity, said frame further
comprising one or more movable support members extending between
two of more of side panels; (ii) one or more back frame members
attachable to said horizontal seat support frame in an assembled
configuration; (iii) one or more arm members attachable to said
horizontal seat support frame or said one or more back frame
members, or combinations thereof, in said assembled configuration;
and (iv) one or more cushions; (b) assembling said RTA components
such that they form a shipping configuration, wherein at least one
of said back frame members, or one or more of said arm members, or
combinations thereof, are positioned in said storage cavity; and
(c) packaging the shipping configuration of the RTA components into
a conventional shipping container and substantially maximizing
utilization of available shipping space within said conventional
shipping container.
7. The method of claim 6, wherein said one or more cushions are
vacuum packaged to reduce volume of space needed for storage and
shipping.
8. An upholstered furniture system, comprising: at least two
horizontal seat support frames, each support frame with a front,
back, right and left panel, said panels defining a storage cavity
for each support frame; a back frame member for each support frame,
attachable with male-female fasteners to the back panel of each
said support frame in an assembled configuration; and one or more
arm members attachable with male-female fasteners to the right or
left panels of said horizontal seat support frames in said
assembled configuration; wherein at least one of said back frame
members, or one or more of said arm members, or combinations
thereof, are positioned in each said storage cavity in a shipping
configuration.
9. The system of claim 8, wherein each horizontal support frame is
constructed and arranged to detachably connect to the other in said
assembled configuration to form a single article of furniture.
10. The system of claim 9, wherein said detachable connection
comprises male-female connectors.
11. The system of claim 8m wherein each of said horizontal frames
in said assembled configuration is an independent article of
furniture.
Description
[0001] This application is a continuation of U.S. patent
application Ser. No. 13/846,535, filed Mar. 18, 2013, now U.S. Pat.
No. 9,480,338, issued Nov. 1, 2016, which is a continuation-in-part
of U.S. patent application Ser. No. 13/423,701, filed Mar. 19,
2012, now U.S. Pat. No. 8,480,179, issued Jul. 9, 2013, which is a
continuation-in-part of U.S. patent application Ser. No.
13/293,429, filed Nov. 10, 2011, now U.S. Pat. No. 8,408,653,
issued Apr. 2, 2013, which is a continuation-in-part of U.S. patent
application Ser. No. 13/045,240, filed Mar. 10, 2011 which is a
continuation-in-part of U.S. patent application Ser. No.
12/824,469, filed Jun. 28, 2010, which is a continuation of U.S.
patent application Ser. No. 11/580,482, filed Oct. 13, 2006, now
U.S. Pat. No. 7,744,162, issued Jun. 29, 2010, which claims benefit
of U.S. Provisional Pat. App. No. 60/726,324, filed Oct. 13, 2005,
the complete disclosures of which are incorporated herein by
specific reference for all purposes in their entireties.
FIELD OF INVENTION
[0002] The present invention relates generally to ready-to-assemble
("RTA") furniture. More specifically, the present invention relates
to RTA sofas, RTA love seats, RTA chairs and similar articles of
RTA furniture that are configured for rapid assembly from a
partially assembled state to a fully assembled state after shipping
and storage stages.
SUMMARY OF INVENTION
[0003] In various exemplary embodiments, the present invention
comprises an article of RTA furniture. Although a sofa is generally
described, the present invention is suitable for RTA chairs, love
seats, sofas, and the like, and includes a base assembly, a back
assembly and left and right arm assemblies that are constructed and
arranged for minimizing packaging volume in a partially assembled
state, and for rapid assembly from said partially assembled state
to a fully assembled state with minimal effort and tools.
[0004] In one embodiment, the invention comprises an upholstered
furniture system comprising a first assembled configuration for
seating, and a second unassembled configuration for storage and
shipping. The furniture comprises a horizontal seat support frame
having front and rear support frame members, wherein said rear
support member comprises at least two male fasteners for receiving
complementary female fasteners from a seat back frame; left and
right side support frame members, wherein said left and right side
support frame members each comprise at least two orifices for
receiving two male fasteners for interacting with complementary
female fasteners from a respective arm member; a back member,
having male fasteners for assembling with complementary female
fasteners secured to said horizontal seat support frame; and left
and right arm members, each of said left and right arm members
having a female fastener for receiving male fasteners attached to
said horizontal seat support frame; wherein said horizontal seat
support frame comprises a cavity to contain, in said unassembled
configuration, each of said arm members to be used with said
furniture system. The cavity may, in one embodiment, further
contain cushions used in said assembled configuration.
[0005] In the furniture system of the present invention, said
unassembled configuration is substantially rectangular. Previous to
construct a furniture system as per the present invention were
unsuccessful because those attempts did not account for storage of
arm portions. The present invention provides that in said
unassembled state, arm portions nest within a cavity formed within
the border of said horizontal seat support frame. Said arm portions
may interconnect in a dissembled state such that they nest within
the boundary of said cavity in said horizontal seat support frame.
Said back member is constructed and arranged to connect to said
horizontal seat support frame by a male-female connection.
[0006] In the furniture system, each of said left and right arm
members attach to said horizontal seat support frame by interacting
with male connection of placed through said frame with orifices on
each of said left and right arm members and said left and right arm
members are secured with hand tightening nuts, such as wing nuts.
This assembly system provides a process that allows assembly
without the use of tools.
[0007] Also contemplated is a method of shipping Ready to Assemble
(RTA) furniture, comprising the steps of:
[0008] a) providing RTA components of furniture comprising: a
horizontal seat support frame; left and right side pieces; a back
frame; and cushions;
[0009] b) assembling said RTA components such that they form a
rectangular configuration, wherein said rectangular configuration
provides said left and right side portions constructed and arranged
to nest within the underside of said horizontal seat support frame,
and said back portion nests on top of said frame; and
[0010] c) packaging said RTA furniture into a conventional shipping
container such that each unit forming said rectangular frame
efficiently utilizes the available shipping space within a
conventional shipping container.
[0011] In another embodiment the present invention is an
upholstered furniture system comprising a first assembled
configuration for seating, and a second unassembled configuration
for storage and shipping, comprising: a horizontal seat support
seat support frame having front and rear support frame members,
wherein said rear support member comprises at least two male
fasteners for receiving complementary female fasteners from a seat
back frame; left and right side support frame members, wherein left
and right side support frame members each comprise a pair of male
fasteners for receiving complementary female fasteners from a
respective arm member; a back member, having male fasteners for
assembling with complementary female fasteners secured to said
horizontal seat support frame; and left and right arm members, each
of said left and right arm members having an female fastener for
receiving male fasteners attached to said horizontal seat support
frame; wherein said horizontal seat support frame comprises a
cavity to contain each of said arm members and cushions to be used
with said furniture system.
[0012] The cavity may, in one embodiment, further contain cushions
used in said assembled configuration. In the furniture system of
the present invention, said unassembled configuration is
substantially rectangular. Previous attempts at providing RTA
furniture and systems to maximize shipping space did not account
for storage of arm portions.
[0013] The present invention provides that in said unassembled
state, arm portions nest within a cavity formed within the border
of said horizontal seat support frame. Said arm portions may
interconnect in a dissembled state such that they nest within the
boundary of said cavity in said horizontal seat support frame. Said
back member is constructed and arranged to connect to said
horizontal seat support frame by a male-female connection. In the
furniture system of the present invention, each of said left and
right arm members attach to said horizontal seat support frame by
interacting with a male connection placed through said frame with
orifices on each of said left and right arm members and said left
and right arm members are secured with wing nuts, or hand
tightening nuts. Thus assembly is without the use of tools.
[0014] The base assembly includes a base frame having a storage
cavity for receiving the left and right arm assemblies for storage
during shipment and storage of the article of furniture. Use of
movable supports transversing the storage cavity facilitates
storage of the arm assemblies when the supports are moved out of
the way and provides needed strength and rigidity when the supports
are moved into a support position during final assembly of the
article of RTA furniture. This novel feature of storing the arms in
the base cavity allows for a significant reduction of shipping
volume per unit of furniture, which in turn greatly reduces
shipping and handling costs. Conventionally, the RTA arms would be
shipped in a shipping box separate from the box housing the base
and back assemblies. In addition to the saving in reduction of
volume, handling costs and inventory losses are reduced because
shipping is consolidated to a single shipping box.
[0015] In one preferred embodiment, the base frame is a box frame
having a base front frame portion, a base rear frame portion, and
right frame portion and left frame portion. Upon final assembly,
one or more movable support members transverse the storage cavity
to provide structural support of the base assembly during use of
the article of furniture. In one preferred embodiment, the moveable
support members comprise swing gates. The base frame also includes
right and left base extensions for receiving the left and right arm
assemblies for rapid assembly of the RTA article of furniture. The
frame extensions each include a lower arm mounting assembly upon
which an upper arm mounting assembly of the respective arm assembly
is received. Fast operating fastener components pre-mounted upon
the upper and lower arm mounting assemblies allow for rapid
attachment of the arm to the base frame extension. In one preferred
embodiment, wing-nut fastener assemblies are used. In another
preferred embodiment snap-in fasteners are used.
[0016] The base assembly also includes base cushions and a cushion
support, such as interwoven webbing or box springs. The base
assembly further includes upholstery covering portions of the base
frame. One advantage of this assembly is that the right and left
base extensions are not upholstered while the front, the outside,
the top and the inside portions of the arm assemblies are fully
upholstered. This provides a small vertical crevasse between the
upholstered arm and the upholstered front of the base assembly.
This is characteristic of conventionally manufactured furniture.
The arm fronts of prior art RTA furniture have only the upper
portion upholstered while the front face of the base assembly is
fully upholstered. This creates an elongated horizontal crevasse
along the front of each arm.
[0017] The base assembly further has a quick connecting bracket
either receiving or being received by the opposite gendered bracket
of the back assembly. The base cushions and the back cushions (if
detachable) are vacuum packed and stacked between the base assembly
(with the arms placed in the storage cavity) and the back assembly
in a minimal volume configuration. The RTA article is optionally
compressed further and placed in a storage container such as a
shipping box.
[0018] It is another object of the present invention to provide a
ready to assemble furniture system that assembles without the use
of tools.
[0019] In one embodiment, the present invention comprises an
upholstered furniture system comprising: (a) a first assembled
configuration for seating; (b) a second unassembled configuration
for storage and shipping, said upholstered furniture system
comprising: (i) a horizontal seat support frame, said frame having
opposing front and rear panels and opposing side panels, said
panels arranged fixedly and continuously to define a rectangular
storage cavity, said frame further comprising a fixed support
members extending generally perpendicularly between said front and
rear panels and within said cavity, said support members has
opposing vertical sides that are parallel and adjacent to an inner
surface of each of said front and rear panels and is positioned
within said cavity and extend in a perpendicular orientation
between each of said front and rear panels, said support member
defines a portion of said cavity into at least two subcavities,
wherein each subcavity receives arm members and cushions configured
to nest in said sub cavity in said unassembled configuration; (ii)
a back frame member; (iii) left and right arm members; (iv) wherein
said rear support panel connects with said back frame through
male-female fasteners; (v) wherein said left and right side support
frame panels connect to respective arm member utilizing male-female
connectors; and wherein in said second unassembled configuration
said arm members and a plurality of cushions to be used in said
system are positioned in said cavity each in a subcavity.
[0020] And further the present invention, in one embodiment is a
method of shipping Ready to Assemble (RTA) furniture comprising the
steps of: (a) providing RTA components of furniture comprising: i)
a horizontal seat support frame, said frame having opposing front
and rear panels and opposing left and right side panels, said
panels arranged fixedly and continuously to define a rectangular
storage cavity, said frame further comprising a fixed support
members extending generally perpendicularly between said front and
rear panels and within said cavity, said support members has
opposing vertical sides that are parallel and adjacent to an inner
surface of each of said front and rear panels and is positioned
within said cavity and extend in a perpendicular orientation
between each of said front and rear panels, said support member
defines a portion of said cavity into at least two subcavities,
wherein each subcavity receives arm members and cushions configured
to nest in said sub cavity in said unassembled configuration; (ii)
a back frame member; (iii) left and right arm members; (iv) wherein
said rear support panel connects with said back frame through
male-female fasteners; (v) wherein said left and right side support
frame panels connect to respective arm member utilizing male-female
connectors; and wherein in said second unassembled configuration
said arm members and a plurality of cushions to be used in said
system are positioned in said cavity each in a subcavity; (b)
assembling said RTA components such that they form a rectangular
configuration, wherein said rectangular configuration provides said
left and right arm members; nest within the rectangular storage
cavity of said horizontal seat support frame when said movable
support members are moved in a swivel motion about a said pin, to a
horizontal orientation relative to said frame, to facilitate
storage of said RTA components in said horizontal seat support
frame, and said back portion nests on top of said frame; (c)
packaging the rectangular configuration of the RTA components into
a conventional shipping container and substantially maximizing
utilization of available shipping space within said conventional
shipping container.
[0021] In another embodiment, the present invention is an
upholstered furniture system comprising: (a) a first assembled
configuration for seating; (b) a second unassembled configuration
for storage and shipping, said upholstered furniture system
comprising: (i) a horizontal seat support frame, said frame having
opposing front and rear panels and opposing side panels, said
panels arranged fixedly and continuously to define a rectangular
storage cavity, said frame further comprising a movable support
member extending generally perpendicularly between said front and
rear panels and within said cavity, said support is positioned
within said cavity and extend in a perpendicular orientation
between each of said front and rear panels, said support member
swivels on a pivot incorporated with each horizontal portion of
said frame, said support member defines a portion of said cavity
into at least two subcavities, wherein each subcavity receives arm
members and cushions configured to nest in said sub cavity in said
unassembled configuration; (ii) a back frame member; (iii) left and
right arm members; (iv) wherein said rear support panel connects
with said back frame through male-female fasteners; (v) wherein
said left and right side support frame panels connect to respective
arm member utilizing male-female connectors; and wherein in said
second unassembled configuration said arm members and a plurality
of cushions to be used in said system are positioned in said cavity
each in a subcavity.
[0022] The horizontal frame is substantially rectangular. The
rectangular configuration is defined by horizontal planes
corresponding to upper and lower sides of said horizontal seat
support frame when said frame is resting on a surface in an
environment of use. Arm portions interconnect in a dissembled state
such that said arm portions nest within the boundary of a single
subcavity in said horizontal seat support frame. The horizontal
support frame supports a back longitudinal frame member having a
vertical angular offset.
[0023] Each arm member is constructed and arranged providing each
arm member, in said assembled configuration, has a base portion
that affixes to the uppermost portion of said support frame. There
may be an extending portion along the front of the furniture in the
assembled configuration, but the connecting of the arms is the
planer base connecting to the top of the support frame. That is to
say, each arm member has a base portion that generally forms a
horizontal plane, wherein said horizontal plane is positioned
directly upon an upper surface of said support frame when said
frame is on a generally flat surface for use. Each arm member, in
said unassembled configuration, is provided with padding,
upholstery, and unobstructed access to said male-female connectors
for assembly to said assembled configuration.
[0024] The present invention is comprise also a method of shipping
Ready to Assemble (RTA) furniture comprising the steps of: (a)
providing RTA components of furniture comprising: i) a horizontal
seat support frame, said frame having opposing front and rear
panels and opposing side panels, said panels arranged fixedly and
continuously to define a rectangular storage cavity, said frame
further comprising a movable support member extending generally
perpendicularly between said front and rear panels and within said
cavity, said support is positioned within said cavity and extend in
a perpendicular orientation between each of said front and rear
panels, said support member swivels on a pivot incorporated with
each horizontal portion of said frame, said support member defines
a portion of said cavity into at least two subcavities, wherein
each subcavity receives arm members and cushions configured to nest
in said sub cavity in said unassembled configuration; (ii) a back
frame member; (iii) left and right arm members; (iv) wherein said
rear support panel connects with said back frame through
male-female fasteners; (v) wherein said left and right side support
frame panels connect to respective arm member utilizing male-female
connectors; and wherein in said second unassembled configuration
said arm members and a plurality of cushions to be used in said
system are positioned in said cavity each in a subcavity; (b)
assembling said RTA components such that they form a rectangular
configuration, wherein said rectangular configuration provides said
left and right arm members; nest within the rectangular storage
cavity of said horizontal seat support frame when said arm members
nest within within a subcavity bounded by said fixed support
member, to facilitate storage of said RTA components in said
horizontal seat support frame, and said back portion nests on top
of said frame; (c) packaging the rectangular configuration of the
RTA components into a conventional shipping container and
substantially maximizing utilization of available shipping space
within said conventional shipping container. Preferably, the
cushions are vacuum packaged to reduce volume of space needed for
storage and shipping.
[0025] The present invention also includes an upholstered furniture
system comprising: (a) a first assembled configuration for seating;
(b) a second unassembled configuration for storage and shipping,
said upholstered furniture system comprising: (i) two horizontal
seat support frames, said frames having opposing front and rear
panels and opposing side panels, said panels arranged fixedly and
continuously to define a rectangular storage cavity, said frames
each defining a storage cavity, wherein each cavity receives arm
members and cushions configured to nest in said cavity in said
unassembled configuration; (ii) a back frame member for each frame;
(iii) at least one arm member; (iv) wherein said rear support panel
connects with said back frame through male-female fasteners; (v)
wherein said left and right side support frame panels connect to
respective arm member utilizing male-female connectors; and wherein
in said second unassembled configuration said arm members and a
plurality of cushions to be used in said system are positioned in
said cavity each in a cavity. Each horizontal support frame is
constructed and arranged to detachably connect to the other in an
assembled configuration to form a single article of furniture. The
detachable connection is through male-female connectors.
[0026] In a configuration utilizing two or more frames, the
horizontal frames may be either detachably connected one to
another, or each frame, in an assembled configuration, is an
independent article of furniture.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIGS. 1A-B show a perspective view of the assembled (A) and
unassembled (B) configurations.
[0028] FIGS. 2A-B show perspective (A) and side views (B) of one
embodiment of the sofa packaged for shipping.
[0029] FIGS. 3A-C show close up views of the male-female connectors
(A) for the back frame and the connected arrangement (B) and the
disconnected arrangement (C) for the back frame portion of the sofa
to the frame.
[0030] FIGS. 4A-B show close up views (A) and (B) depicting the
attachment of the back and side portions to the frame.
[0031] FIG. 5 shows an alternative embodiment whereby side pieces
and cushions nest within a cavity on the underside of the frame for
shipping. The cushions are vacuum packaged to reduce volume of
space needed for storage and shipping.
[0032] FIG. 6 is a close up partial cross section showing
connection of a screw attaching into a t-nut set into a
sidepiece.
[0033] FIG. 7 is a perspective view of the support frame with a
swivel swing gate in a vertical position relative to the frame.
[0034] FIG. 8 is a perspective view of the support frame with a
swivel swing gate moved along directional arrow from a vertical
position relative to the frame.
[0035] FIG. 9 is a side view of an assembled sofa.
[0036] FIG. 10 is a perspective view showing a sofa frame with end
portions in an elevated horizontal plane relative to the
longitudinal portions connecting each end portion.
[0037] FIG. 10A is an expanded view from FIG. 10 showing the
movement of the swivel swing gate in the frame.
[0038] FIG. 11 is a partial expended view of arm side piece
connectors.
[0039] FIG. 11A is a partial expanded view of a corner of the frame
with arm side piece connectors.
[0040] FIG. 12 is a partial expanded view of arm and back portions
to be assembled on the frame.
[0041] FIG. 12A shows an embodiment of male-female connectors.
[0042] FIG. 12B is an expanded view showing male-female connectors
attaching back portion to frame.
[0043] FIG. 13A shows connectors used in attaching side arm
portions.
[0044] FIG. 13B is an expanded view showing arm portion attaching
to frame and secured with connectors from FIG. 13A.
[0045] FIG. 14 shows a disassembled sofa and directional arrows for
component placement.
[0046] FIG. 15 is an expanded view of arm extension.
[0047] FIG. 15A is an expanded view of arm extension in the
embodiment of FIG. 42.
[0048] FIG. 16 is an expanded view of arm extension.
[0049] FIG. 16A is an expanded view of arm extension in the
embodiment of FIG. 42.
[0050] FIG. 17 is an expanded view of a corner of the frame.
[0051] FIG. 17A is an expanded view of a corner of the frame in the
embodiment of FIG. 42.
[0052] FIG. 18 is an expanded view of back portion placement.
[0053] FIG. 18A is an expanded view of back portion placement in
the embodiment of FIG. 42.
[0054] FIGS. 19-21 show expanded view of male-female connectors for
back portion connecting to the sofa frame.
[0055] FIG. 22 is a partial perspective view showing the horizontal
offset utility in accommodating storage in the cavity when a
support spring is present.
[0056] FIG. 23A is an expanded view showing connection of side arm
portion to frame.
[0057] FIG. 23B is an expanded view showing connection of side arm
portion to frame.
[0058] FIG. 24 is a perspective view showing arms and cushions
nested within a frame.
[0059] FIG. 25 shows the frame with central support member.
[0060] FIG. 26 is a partial perspective view of the sofa of the
present invention wherein the cushion is configured to wrap around
the front of the arm piece.
[0061] FIG. 27 is a separated partial perspective view showing arm
portion 20A separated from frame 40.
[0062] FIG. 28 is a partial connected view of a sofa of the present
invention.
[0063] FIG. 29 is a partial separated view showing arm 20B
separated from frame 40.
[0064] FIG. 30 is a view of arm portion 20B of the present
invention showing a portion of upholstery that is folded upward, as
indicated by directional arrow, for an unassembled configuration,
and is extended downward when the arm is used in an assembled
configuration.
[0065] FIG. 31 is a partial perspective view showing placement of
cushions within the frame of the present invention and showing that
support springs are movable along the horizontal axis on the
underside of the frame.
[0066] FIG. 32 is one embodiment showing swivel swing gate of the
present invention with an orifice in the frame for receiving a
swivel swing gate swivel pin.
[0067] FIG. 33 is a partial view showing swivel swing gate in an
upright position so as to not interfere with storage within the
storage cavity.
[0068] FIG. 34 is expanded view of the swivel swing gate of the
present invention.
[0069] FIG. 35 is an expanded view showing the swivel swing gate
rotation of the present invention rotating on a swivel from
perpendicular downward, to parallel with the horizontal frame, to
perpendicular upward relative to the frame.
[0070] FIG. 36 is a perspective view of the frame of the present
invention.
[0071] FIG. 37 is a partial view of the present invention in the
embodiment of two frame portions.
[0072] FIG. 38 is a separated view of the arm piece and frame of
the present invention.
[0073] FIG. 39 is a view of a single assembled sofa of the present
invention when the invention is formed of two or more frame
portions.
[0074] FIG. 40A is a view of a single assembled sofa of the present
invention when the invention is formed of two or more frame
portions showing removal of the arm portion.
[0075] FIG. 40B is a view of a single assembled sofa of the present
invention when the invention is formed of two or more frame
portions showing the side portion configured for connection to a
corresponding frame.
[0076] FIG. 41 is a partial cut away view of a single assembled
sofa of the present invention when the invention is formed of two
or more frame portions showing the side portion configured for
connection to a corresponding frame.
[0077] FIG. 42 is a separated view of a sofa in which 2 frames are
configured to be ultimately be assembled and attached one to
another.
[0078] FIG. 43 is a detail from FIG. 45 showing assembled
configuration of two back portions into a single article of
furniture.
[0079] FIG. 44 is a separated view of connectors used to connect
either arms to the frame or to connect 2 frames one to another.
[0080] FIG. 45 is view of the components of the sofa of the present
invention in which 2 frame portions are packaged in an unassembled
configuration with arm portions there between.
[0081] FIG. 46 shows a single frame configuration with arm portions
nested within frame cavity.
[0082] FIG. 47 shows an embodiment having the back portion provide
as two pieces that are connected in the assembled
configuration.
[0083] FIG. 48 shows the stacking of 2 frame portions whereby the
are storage cavities are on the outside of the stacked unassembled
configuration and the arm portions are stored between the stacked
frames.
[0084] FIG. 49 shows a configuration with arm portions nested
within a frame cavity and cushions positioned on top of the
unassembled configuration.
[0085] FIG. 50 shows a single unassembled frame with arm portions
stored in the storage cavity.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0086] Referring now to FIG. 1A, is one embodiment of the fully
assembled RTA frame 5 and is shown including the base assembly
frame 40 and the left and right arm frames 20 connected to each
side portion 30 with a screw 60, and the back frame 10 joined to
rear portion of frame 50 by male connector 70 and female connector
80 in an assembled configuration. This RTA frame is typically
obscured by padding and upholstery when the RTA furniture is
manufactured. FIG. 1B shows a perspective view with each of the
aforementioned elements separated from their attached
configuration.
[0087] Referring now to FIG. 2A shows a perspective view of the
unassembled system. The front of the frame 40 side portion of frame
30, and, in the shown embodiment, cushions 90 are shown placed on
top of frame 40 for storage to substantially form a rectangular
configuration. Said rectangular configuration is defined as a
horizontal planes corresponding to each side of said horizontal
seat support frame. That is to say, component pieces do not extend
outward past the sidepieces of the horizontal seat support frame.
The component pieces also do not extend outward past each of the
front and back potions of the horizontal seat support frame.
Previous attempts at RTA furniture for storage were deficient in
that the arm portions extended outward from the frame when stored.
The extensions of the arm portions from the rectangular
configuration in which the configuration is defined by the shape of
the base alone has made shipping such systems less efficient than
those systems manufactured according to the current invention. Also
shown is FIG. 2B, a side view whereby arm portions 20 are placed in
a nesting arrangement in a cavity inside frame 40. Back portion 10
is placed on top of frame 40 and cushions 90 are on top of back
portion 10.
[0088] Referring now to FIG. 3A a detail of the embodiment, as is
shown in male connector 70, which was shown in FIG. 1 attached to
the rear portion of the frame interacts with female connector 80,
which was shown in FIG. 1 connected to back frame portion 10. The
interaction of the male-female 70 and 80 connection allows the back
portion to be secured to the frame. In a preferred embodiment, no
tools are required to effectuate the interaction and connection.
FIG. 3B shows a view of the male connector 70 and female connector
80 attaching along transverse portion of support frame 50 in their
interconnected state and FIG. 3C shows male connector 70 and female
connector 80 attaching along transverse portion of support frame 50
in their disconnected positions. Although this connection gives one
embodiment of the male-female connector relationship, the invention
is not limited to this particular configuration. As seen in FIGS.
19-21, Female connector 217 is connected to rear portion of frame
50 and connects to the back portion through complimentary male
connector 216.
[0089] Referring now to FIG. 4A, is a cut away view of the upper
drawing shows side 20 that will receive mounting screw 60 through
an incorporated orifice. The lower drawing shows a close up view of
the attachment of side 20. In a preferred embodiment, a T-nut
(shown in FIG. 6 close-up) is permanently attached to sidepiece 20
and the inner portion of T-nut creates a complementary threaded
orifice to receive the threads from screw 60. In this embodiment,
screws 60 have heads suitable for tightening by hand. Also shown in
FIG. 4A is support brace 35 which is on the interior of frame 40
and helps to support and stabilize the full assembled system. FIG.
4B further show receiver 65 whereby the shaft of screw 60 is
inserted into a central orifice in receiver 65 and the shaft
interconnects with T-nuts located within channel 75 incorporated
into sidepiece 20.
[0090] In an alternative embodiment of this invention shown in FIG.
5, the entire article of RTA furniture is in a stacked
configuration, with the interlocked arms 20 and cushions 90 stored
in the storage cavity. Cushions 90 may be placed in a vacuum sealed
bag to reduce the volume required and make them smaller to ship
because typically, cushions are foam or feather and contain a
significant volume of space occupied by air. Removing the air
reduces the volume required to store and ship cushions 90. In this
alternate embodiment, the back assembly, the back and seat cushions
and the arm assemblies may be vacuum packaged separately or in
combination.
[0091] Referring to FIG. 6, a T-nut 64 is mounted onto sidepiece 20
in channel 75 (previously shown). The t-nut 64 has inner
circumferential threaded portion 66 that forms a circular channel
68. The inner circumferential threaded portion 66 interacts with
the screw threaded shaft 62 of screw 60 and serves to secure
sidepiece 20 onto the aforementioned frame. Referring to FIGS. 7-8,
support brace 35 is a swivel swing gate that supports frame 50 in a
vertical orientation and pivots to a horizontal orientation
resulting in an unobstructed cavity within the sofa frame. FIGS.
7-8 show progressive steps of swivel swing gate moving from
vertical to horizontal orientations.
[0092] In assembling a preferred embodiment, the article of the
present invention, the components are separated and the frame is
placed in an upright position, e.g. positioned upright so as to
receive the component parts and be usable upon assembly. Back
portion 10 is connected to the back frame 50 using the male-female
connectors described. Then each sidepiece is connected to the frame
through use of hand screws interacting with T-nuts permanently
mounted into incorporated orifices into each of said side pieces.
An appropriate support may then be attached to the frame to hold
desired seat portions and/or cushions. The assembled system may now
receive any appropriate upholstery covering for the side and back
portions. As previously mentioned, the assembly of the present
invention may be assembled without the use of tools. Many RTA
products require numerous component parts, tools, and take a
significant amount of time and effort to assemble. The RTA system
of the present invention provides not only a cost savings in
shipping, but also a savings in labor for assembling. One the
article is unpacked from shipping configuration; it comprises 4
major components and assembles quickly. Attach the back with the
aforementioned male-female connectors, attach each of the
sidepieces and secure with hand screws, and the RTA assembly is
completed. Additionally, the manufacturing costs are reduced
because the majority of the system is assembled from 4 major
components.
[0093] Assembly of the system of the present invention on a
commercial scale is also economized because any assembly line
processes can be done quickly and without the use of tools.
[0094] In one embodiment, as shown in FIG. 9, the assembled sofa
has a back 10 with an angular deflection "D" relative to a
perpendicular line from the top of back 10 to the floor below. In
conventional sofas, the back portion is substantially vertical. The
present invention provides, angular deflection that allows a back
portion to extend beyond the periphery of the frame. In one
embodiment, the angular deflection is from about 10.degree. and
35.degree. relative to a perpendicular line to the horizontal frame
and towards the front on the sofa, as indicated by dimension "D" in
FIG. 9.
[0095] Part of the tilt is in the frame 10 and the remainder of the
angle is provided by construction of the back portion. A typical
sofa has a frame of depth "C". In providing a sofa in the present
configuration, instead of requiring shipping of a frame with depth
"C", distance "A" is not required in the depth of the frame such
that the frame only has a depth "B" and provides a shorter depth
which is advantageous in packaging the sofa for shipping.
[0096] The present invention includes an offset frame configuration
as shown in FIGS. 10A&B. Frame ends pieces 50b are offset above
the horizontal plane along the top of long frame member 50a by a
distance represented by dimension "R". In one embodiment, the
distance of dimension "R" is between about 0.5-2 inches. The offset
has been shown to accommodate the unassembled configuration desired
in the present invention when support spring 220 as shown in FIG.
22, is present. This allows for the storage of arms and cushions in
the cavity without need to remove support spring 220.
[0097] As shown in FIGS. 10A&B, one embodiment provides a
swivel pin 210 on swivel swing gate 35a that inserts into pin
receiving socket 210a. Receiving socket is any acceptable
complimentary structure for receiving swivel pin and includes an
orifice incorporated in frame 50 and structures attached to frame
50 or to long frame member 50a for facilitating connection.
Furthermore, the male-female relationship may be reversed and the
swing gate may have a female swing structure, such as an orifice
and the like and the frame a male connector, such as a swivel pin.
Additionally, although swing gates, as described herein, are shown
as rotating about an axis defined by a swivel pin, it is
contemplated that other rotational and movement devices that
provide the same effect could be used. Movement about a rotational
ball and socket, rotational hinges, snap-fit arrangements and the
like, as long as they provide for the desired movement of moving
the support out of the cavity to provide an unobstructed cavity for
storage in the unassembled configuration and placement within the
cavity for the assembled configuration. It is desirable that swing
gate 35 be positioned between the front and back panels in each of
the assembled and unassembled configurations. In an assembled
configuration, the swing gate provides the desired structural
support of an assembled sofa. In an unassembled configuration, the
position prevents the frame from collapsing due to any forces or
stresses of shipping.
[0098] In some embodiments, as shown in FIGS. 14-17, arm piece 20
is constructed and arranged such that attachment to the frame is on
the topside of frame 50 where the underside of arm side piece 20
attaches along the top of frame 50, and arm side piece 20 has a
side extension portion 211 in which lip 212 secures under frame
edge. The lip 211 provides a region where a covering placed on arm
side piece 20 is attached such that said attachment is not visible
in the assembled configuration. Additionally, back piece 10 is now
similarly constructed with an extension member 213 terminating in
lip 214. Lip 214 provides an area for attachment of covering
material over back portion 10 such that the attachment is not
viewable in the assembled configuration. Covering 215 covers the
frame and panel and has closure underneath the sofa such that the
closure seam is hidden from view. Attachment of a covering over
each of side pieces 20 and back piece 10 are performed in manners
known in the art such has hook and loop fasteners, snaps, zippers,
and the like. The shape and configuration provides the advantage
that in an assembled configuration, the point of attachment is not
easily seen or readily apparent. Similarly a covering material 215,
as seen in FIGS. 14 and 17, covers the frame. Also, as shown in
FIGS. 11 and 12C arm side piece 20 has a forward extension 20P
constructed and arranged to extend along the vertical face of the
assembled frame. On the interior portion (the surface facing the
sofa frame) 20P has incorporated thereon connector 205 that fastens
to complementary connector 200 to provide a fastening of side arm
piece 20 to the assembled sofa and further provides additional
strength and support to the assembled structure. In one embodiment,
the connector 205 attached to 20P and connector 200 attached to the
frame, are complimentary male-female connectors. They may also be
male-female connectors with a snap-fit configuration.
[0099] In one embodiment, side arm portion 20 connects on top of
the base to keep the height of the arm (20) short in height so that
both arms side portions 20 can be packed in an unassembled
configuration side by side within the cavity in the unassembled
configuration. This saves space to allow packing cushion and other
parts within the cavity in the unassembled configuration. Arm
portions 20 can further be provided completely upholstered or semi
upholstered with removable upholstery positioned such that assembly
portions on arm portions 20 are accessible.
[0100] In one embodiment, as shown in FIGS. 24 and 25, rigid
central support 35b is fixed and does not move. While there are
distinct advantages to the swivel gate 35 as described herein, the
present invention has a configuration in which the central support
is rigid central support 35b. The present invention recognizes that
the basic support frame 50a must have transverse support extending
generally perpendicular from the front to the back of frame 50a.
Each arm section 20 is constructed and arranged such that in an
unassembled configuration, they will nest within a portion of the
cavity defined by rigid central support 35a.
[0101] In this embodiment, the overall purpose of having an
unassembled configuration in which components nest within the
cavity is still achieved without the need for the swivel swing
gate. Cushions 90 are similarly configured to nest within a portion
of the cavity defined by rigid central support 35a. Although
described as a "central support" it is not necessary that rigid
central support 35a be precisely centered and may be somewhat off
centered by +/-20% of the length the long side of the frame while
still being substantially perpendicular to each of the front and
back longitudinal sides. In one embodiment, cushion 90a is
configured to extend around the front of arm piece 20a. In another
embodiment, cushion 90b is flush along the length of arm piece
20b.
[0102] In one embodiment, the present invention includes each arm
section 20 configured to attach on top of support frame 50a.
[0103] In another embodiment, as is generally known, RTA furniture
typically is shipped without padding on features such as arms and
backs. The present invention, in one embodiment, has provided not
only RTA furniture, but also done so in a manner such that padding
and covering are shipped in a preassembled and preconfigured
arrangement. In one embodiment, arm 20A affixes on to frame 40, and
arm 20A has an extension portion 306A with a bottom portion 302 and
a corner portion 301 that assists for affixation on to frame 40. In
one embodiment, as shown in FIG. 35, spring portions 220 are
constructed and arranged such that they have sufficient movement in
order to facilitate placement of arm portions 20a within the cavity
of frame 40. As shown in FIGS. 32 and 33 swivel swing gate 307
swivels by virtue of connection into opening 308 of frame 50A.
Swivel swing gate has a generally perpendicular position when frame
58 is assembled as a sofa and generally perpendicular orientation
is moved to a parallel orientation as shown in FIG. 35. This
rotation of either parallel to the general horizontal plane of
frame 58 or in the alternative rotation 180 degrees from its
downward perpendicular to an upward perpendicular orientation. This
upward perpendicular orientation further facilitates placement of
arm pieces 20A within frame 40.
[0104] As is generally understood, most RTA furniture products do
not come with articles such as upholstery and padding affixed
thereto. However, the present invention has developed a unique
configuration whereby RTA furniture, specifically RTA sofa and RTA
chairs, are shipped with padding and upholstery affixed thereto.
Affixation of upholstery is in any manner. A preferred embodiment
provides the upholstered arm and back portions in which upholstery
is affixed using hook and loop fasteners as is known in the art. In
general terms, the upholstery has a general configuration
corresponding to the shape of an arm or back portion. One edge,
preferably the lower edge on which the arm or back portion attaches
to the frame, has hook and loop fasteners that both hold the
upholstery in place, and provide access to the male-female
connectors used to fasten the arm or back portion to the frame.
[0105] In an embodiment of the present invention, arm pieces are
affixed to the top of a frame without the need to have any portion
of an arm piece extend downward along side a frame. In this
configuration, an arm piece is still able to be securely attached
to a frame and provide ease of assembly of an RTA piece of
furniture. Additionally, RTA sofa and chairs of the present
invention are shipped with a back portion fully upholstered and
padded such that affixation of the back portion onto the frame
constitutes the complete assembly of the back portion of the RTA
furniture. In one embodiment a decorative panel on the front of the
arm piece extends downward along the height of the frame, as best
seen in FIGS. 28 and 39.
[0106] As seen in FIG. 31, support springs 220 can be constructed
to move along the horizontal portion of frame 50a such that any
desired distance, such as distance represented by dimension "E" and
"F" in FIG. 31 can be varied as desired. A swivel swing gate 307 in
FIG. 31, is swiveled out of the storage cavity to provide maximum
storage volume form arm pieces 20a stored within.
[0107] As is understood and shown in FIGS. 31-33, swivel swing gate
307 is rotatable 360 degrees on a swivel through connection in
swivel cavity 308 in frame 50a. This allows swing gate 307 to
extend downward, perpendicular to the frame in an assembled
configuration and swing out of the storage cavity in an unassembled
configuration. Completely removing swing gates is generally not
desired as the swing gate provides strength and stability and keeps
the horizontal portions of the frame from bowing inward towards
each other.
[0108] In one embodiment, as shown in FIGS. 37-42, more than one
frame is provided and the frames are connected when assembled to
form a larger article of furniture. Frame 601 has a support 606 and
connecting panel 605. There are also legs 608 along and underneath
panel 605. As shown in FIG. 44, connection of 2 or more frames at
panel 605 and support 606 is through any acceptable connection
means. One such RTA connection utilizes male-female connectors such
as connecting screws 607.
[0109] In a disassembled configuration, as shown in FIG. 45, each
frame 604 is stacked in opposition such that arm pieces 20a are
contained there between.
[0110] In another embodiment, the back portion can be split into 2
or pieces. This can be in combination with a single frame
accommodation a two or three piece back portion or any other
configuration that facilitates the assembled and disassembled
storage, shipping, and assembly of the present invention. In one
embodiment, as shown in FIG. 49, a frame with a length denoted by
dimension "F" is used as a single article of furniture and can
serve a dual purpose of a single article, or assembled as an
attached article to one or more additional frames. In some
embodiments, such as FIG. 49, even though a particular frame 601
can be used as a single article without attachment, it still may be
required to have swing gate 307 incorporated therein in order to
provide support such that springs 220 do not urge horizontal
portions of frame 50a towards each other and distort the
rectangular orientation of either 50a 601 or both.
[0111] Further, the present invention contemplates one taking a
complete assembled sofa, and separating the frames 601 of an
assembled sofa into two or more articles of furniture, for example,
separation into either a smaller sofa, single chair portions, or
combinations thereof.
[0112] 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.
* * * * *