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1. (WO2019045851) READY-TO-ASSEMBLE FURNITURE
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READY-TO-ASSEMBLE FURNITURE

Cross-Reference to Related Application

[0001] This claims priority to U.S. Provisional Application Serial No. 62/551,432, titled

"Ready-to-Assemble Furniture" and filed August 29, 2017, the entirety of which is incorporated herein by reference.

Technical Field

[0002] This disclosure relates to furniture. More specifically, but not by way of limitation, this disclosure relates to furniture that can be easily assembled.

Background

[0003] Assembling furniture often involves the use of tools to couple different components of an article of furniture together. The tools may include specialized tools that are specifically designed for assembling the specific piece of furniture. Furniture designed to be assembled using tools may be difficult to ship - for example, the furniture may need to be partially assembled in some manner to avoid a customer or recipient from being required to assemble certain sub-components of the article of furniture together.

Summary

[0004] In one example, an article of furniture includes a first component, a second component, and a foundation component. The first component has a first connector coupled thereto. The second component has a second connector coupled thereto. The second connector is configured to be meshed with the first component. The foundation component is positionable with respect to the first connector and the second connector. The foundation component, the first connector, and the second connector are configured to receive a device for coupling the foundation component, the first component, and the second component together.

[0005] In another example, a method includes meshing connectors together to form a meshed connector. The connectors are coupled to different furniture components of an article of furniture. The meshed connector defines a primary channel for receiving a device therein. The method also includes positioning a foundation component with respect to the meshed connectors. The method also includes inserting the device through the foundation

component and the primary channel to limit movement of the furniture components and the foundation component with respect to each other.

[0006] In another example, an assembly for coupling components of an article of furniture includes a first connector and a second connector. The first connector is configured to couple to a first component of the article of furniture. The second connector is configured to couple to a second component of the article of furniture. The first connector and the second connector are configured to be meshed together to define a primary channel and a secondary channel therethrough. The primary channel is sized to receive a pin to couple the first connector, the second connector, and a foundation component of the article of furniture together. The secondary channel is sized to receive an extended portion of the pin.

Brief Description of the Drawings

[0007] FIG. 1 is a perspective view of an article of furniture that is assembled together using connectors according to one example of the present disclosure.

[0008] FIG. 2 is an exploded view of the article of furniture of FIG. 1, prior to assembly, according to one example of the present disclosure.

[0009] FIG. 3 is a perspective view of part of the article of furniture of FIG. 2 is a partially assembled state according to one example of the present disclosure.

[0010] FIG. 4 is a perspective view of the part of the article of furniture of FIG. 3 with additional components to be assembled according to one example of the present disclosure.

[0011] FIG. 5 is a top view of a spring foundation for the article of furniture of FIG. 1 according to one example of the present disclosure.

[0012] FIG. 6 is a perspective view of the article of furniture of FIG. 1 with the spring foundation coupled to other components according to one example of the present disclosure.

[0013] FIG. 7 is perspective view of the portion of the article of furniture of FIG. 6 with a back component to be coupled to the portion according to one example of the present disclosure.

[0014] FIG. 8A is a side view of connectors and a pin according to one example of the present disclosure.

[0015] FIG. 8B is a front view of connectors with the pin according to one example of the present disclosure.

[0016] FIG. 8C is a perspective view of connectors with the pin according to one example of the present disclosure.

[0017] FIG. 9A is a perspective of the connectors of FIGS. 8A-8C coupled together, and of the pin, according to one example of the present disclosure.

[0018] FIG. 9B is a side view of the connectors of FIG. 9A, and the pin, according to one example of the present disclosure.

[0019] FIG. 10A is a side view of the connectors of FIGS. 9A-9B with the pin received therein according to one example of the present disclosure.

[0020] FIG. 10B is a perspective view of the connectors with the pin received therein as shown in FIG. 10A according to one example of the present disclosure.

[0021] FIG. 11 is a perspective view of an unassembled article of furniture according to one example of the present disclosure.

[0022] FIG. 12 is a perspective view of a front rail of the article of furniture of FIG. 11 with a connector according to one example of the present disclosure.

[0023] FIG. 13 is a perspective view of connectors of the article of furniture meshed together according to one example of the present disclosure.

[0024] FIG. 14 is a perspective view of a pin being received in areas of connectors that are meshed together according to one example of the present disclosure.

[0025] FIG. 15 is a close-up view of a spring foundation and the meshed connectors receiving a pin to couple the components together according to one example of the present disclosure.

[0026] FIG. 16 is a close-up view of the pin received in areas defined by the spring foundation and the meshed connectors according to one example of the present disclosure.

[0027] FIG. 17 is an exploded view of an unassembled article of furniture that is a bench according to one example of the present disclosure.

[0028] FIG. 18 is a perspective view of components of the article of furniture of FIG.

17, some of which are assembled and other components are to be assembled according to one example of the present disclosure.

[0029] FIG. 19 is a perspective view of the assembled article of furniture of FIG. 17 according to one example of the present disclosure.

[0030] FIG. 20 is an exploded view of an unassembled article of furniture that is an ottoman according to one example of the present disclosure.

[0031] FIG. 21 is a perspective view of components of the article of furniture of FIG.

20, some of which are assembled and other components are to be assembled according to one example of the present disclosure.

[0032] FIG. 22 is a perspective view of the assembled article of furniture of FIG. 20 according to one example of the present disclosure.

[0033] FIG. 23 is a perspective view of connectors coupled by a pin according to another example of the present disclosure.

[0034] FIG. 24 is a perspective view of a pin usable with the connectors of FIG. 23 according to one example of the present disclosure.

[0035] FIG. 25 is a perspective view of the connectors of FIG. 23 unmeshed together according to one example of the present disclosure.

[0036] FIG. 26 is a perspective view of the connectors of FIG. 23 meshed together to receive the pin according to one example of the present disclosure.

[0037] FIG. 27 is a perspective top view of the connectors with the pin received therein and that is rotatable according to one example of the present disclosure.

[0038] FIG. 28 is a perspective bottom view of the connectors with the pin received therein according to one example of the present disclosure.

[0039] FIG. 29 is a perspective view of part of a pin that is usable with the connectors of FIG. 23 according to one example of the present disclosure.

[0040] FIG. 30 is a perspective view of the top of a pin that is usable with the connectors of FIG. 23 according to one example of the present disclosure.

[0041] FIGS. 31A and 31B are side and top views of the top of a pin that is usable with the connectors of FIG. 23 according to one example of the present disclosure.

[0042] FIG. 32 is a perspective view of part of the pin shown in FIGS. 31A and 31B rotatable using a tool according to one example of the present disclosure.

[0043] FIG. 33 is a side view of a pin that is usable with the connectors of FIG. 23 according to another example of the present disclosure.

[0044] FIG. 34 is a side view of a pin that is usable with the connectors of FIG. 23 according to a further example of the present disclosure.

Detailed Description

[0045] Certain aspects and features relate to an article of furniture that is easily assembled, potentially without requiring tools to assemble. The article of furniture can include two or more components that each has a connector with one or more layers. The connectors can be meshed together and can define an area for receiving a pin (or another coupling component) to couple the components together. A connector can include a base and two or more portions extending from the base that define receiving areas for receiving the portions from the other connector so that the connectors are meshed together. The portions extending from the base can also define an area for receiving a pin. Another component, such as a foundation component, can be positioned proximate to the connectors and define an area for receiving the pin to couple the foundation component with the components that have the connectors.

[0046] An article of furniture according to some aspects can be easily shipped to an assembling plant, or to a consumer, from a manufacturing plant. For example, the components can be shipped in more standard shipping boxes and in a flatter manner than components of furniture that involve other types of coupling mechanisms, such as male/female fasteners. Fewer pieces may be required for the furniture to be assembled. And assembly can be accomplished quickly, and easily, without requiring tools to bolt or otherwise fasten components to each other. Examples of types of articles of furniture that can use connectors with one or more layers to couple components together include sofas, chairs, sectionals that can include a combination of one-arm sofas/chairs/chaises/armless units, ottomans, and any other type of upholstered furniture.

[0047] FIG. 1 is a perspective view of an article of furniture that is assembled together using connectors according to one example of the present disclosure. The article of furniture in this example is a sofa with a spring foundation 102, arms 104, 106, a front rail 108, a back rail (not viewable in FIG. 1), and a back component 110. The arms 104, 106 and the front rail 108 include connectors that can receive pins for coupling the components together.

[0048] FIG. 2 shows part of the sofa of FIG. 1 in an unassembled state according to one example of the present disclosure. Shown in FIG. 2 is a front rail 108 and arms 104, 106. Each of arms 104, 106 and front rail 108 includes multilayer connectors 202a-f. The front rail 108 can be positioned with respect to the arms 104, 106 such that connectors 202a-b of the front rail 108 mesh with connectors 202c-d of the arms 104, 106, which results in the unassembled sofa in the state shown in FIG. 3. In FIG. 3, the front rail 108 is positioned relative to the arms 104, 106 such that connectors of each component mesh. The connectors can be made from any suitable material. Examples of suitable material include plastic, rubber, metal, and carbon fiber.

[0049] In FIG. 4, the spring foundation 102 and the back rail 302 are shown. The spring foundation 102 can be positioned proximate to the connectors 202a-f and those components can define an area, chamber, or port, to receive a coupling mechanism, such as pins 304a-d. The back rail 302 can be coupled to the arms 104, 106 via a bed-frame-type connector, such as a hook and lock, or another type of coupling. Although not included in this example, the back rail 302 may be coupled to the arms 104, 106 via multilayer connectors in other examples. FIG. 5 shows a top view of the spring foundation 102 according to one example. At each corner of the spring foundation 102 there is a connector portion 410a-d. The connector portions 410a-d may be single-layer connectors, multilayer connectors, rings, or another type of structure. The connector portions 410a-d define openings for receiving pins or other couplers to couple the spring foundation 102 to other components of the article of furniture. The spring foundation 102 can be coupled to other components via 90° angle, multilayer connectors, in some examples.

[0050] FIG. 6 depicts an example of the result of these components being coupled together. A close-up view is shown of the back rail 302 coupled to the arm 106 via the bed-frame-type connector. A close-up view of a connector 202f coupled to the spring foundation 102 via a pin 304d. A close-up view is shown of connectors 202b, 202d coupled to the spring foundation 102 via a pin 304b. For example, the pins can couple the components together via gravity, or via an interference fit. In some examples, a multilayer connector can include a feature that allows the pin to be partially rotated to lock the pin in place. Additionally or alternatively, a connector can include anti-slip material in a wall defining the area for receiving the pin to prevent the pin from slipping.

[0051] The connectors positioned at different places of a component can be different sizes. For example, connector 202f in FIG. 4 may be smaller than the connector 202d because

the connector 202f does not need to mesh with a connector from another component - e.g., the foundation 102.

[0052] After the back component 110 is coupled to the arms 104, 106 in FIG. 7, the assembled sofa of FIG. 1 can be formed. The back component 110 can be coupled to the other components via any type of coupling mechanism, such as a male/female clip mechanism.

[0053] FIGS. 8A-10B depict views of connectors 602, 604 according to one example.

As shown in the side view of FIG. 8A, each of the connectors 602, 604 includes a body 606, 608 and portions that extend from the respective body 606, 608. The portions define areas for receiving portions from the other connector. Each body 606, 608 includes a coupling portion 612, 614 that can couple to a respective component of an article of furniture. For example, screws or other fasteners can be used through the coupling portions 612, 614 to couple the connectors 602, 604 to components of the article of furniture. In other examples, adhesive or another coupling mechanism is used. In those examples, the bodies 606, 608 may not include the coupling portions 612, 614.

[0054] The portions can also define openings for receiving a pin 605 or another device for preventing the connectors 602, 604 from moving independent of each other, or at least preventing the connectors 602, 604 from moving more than a threshold amount of distance independent of each other.

[0055] FIG. 8B is a front view of the connectors 602, 604, looking into the areas defined by the portions, along with the pin 605. FIG. 8C is a perspective view of the connectors 602, 604 positioned with respect to each other for being meshed together and receiving the pin 605. In one example, the coupling portions 612, 614 are on opposite ends of the connectors 602, 604 when the connectors 602, 604 are meshed together, as shown via perspective view in FIG. 9A, but not receiving the pin 605. The connectors 602, 604 meshed together define an opening 650 for receiving the pin 605. FIG. 9B is a side view of the connectors 602, 604 meshed together, but not yet receiving the pin 605. FIG. 10A is a side view of the connectors 602, 604 meshed together and receiving the pin 605 for limiting the connectors 602, 604 from moving independent of each other. FIG. 10B is a perspective view of the connectors 602, 604 meshed together and receiving the pin 605.

[0056] FIGS. 11-16 depict an article of furniture, or part of an article of furniture, that includes multilayer connectors for coupling components together. The article of furniture in this example is a sofa.

[0057] FIG. 11 is a perspective view of components 702 of an article of furniture according to one example. The components 702 are shown in FIG. 11 as being unassembled and can be laid flat for easier shipping purposes.

[0058] FIG. 12 is a perspective view of a front rail 704 with a connector 706 for coupling to a side component 708 with a connector 710. The connectors 706, 710 are multilayer and have portions extending from a body and defining areas for receiving portions of the other connector of the other component. Each of the connectors 706, 710 defines an area for receiving a pin or another connector component. FIG. 13 shows the connectors 706, 710 meshed together.

[0059] FIG. 14 shows a pin 712 being received in areas of the connectors 706, 710 that are meshed together, along with an area defined by a spring foundation component 714. FIG. 15 is a close-up view of the spring foundation component 714 and the meshed connectors 706, 710 receiving the pin 712 to couple the components together. FIG. 16 is a close up view of the pin 712 received in areas defined by the spring foundation component 714 and the meshed connectors 706, 710. The pin 712 can couple the components together.

[0060] FIGS. 17 depict an example of an article of furniture in an unassembled state that is a bench 802 that can be easily assembled using connectors. FIG. 17 shows components that include: two short-side panels 804, 806 and two long-side panels 808, 810. The two short-side panels 804, 806 can have a shorter length than the two long-side panels 808, 810. The panels 804-810 each have connectors that are multilayer to facilitate coupling the components of the bench 802 together.

[0061] In FIG. 18 the connectors of each of the short-side panels 804, 806 are meshed with connectors of the long-side panels 810 and a foundation component 812, which in this case is a webbed cover. The foundation component 812 is positioned proximate to the meshed connectors 814a-d for receiving pins 816a-d or other couplers to couple the webbed cover to the panels. A close-up view is shown of meshed connectors 814b. FIG. 19 is a perspective view of the bench 802 in a completed state. A close-up and partially cutaway view of connectors 814c and pin 816c is also shown.

[0062] FIGS. 20-22 depict another example of an article of furniture that is an ottoman

902 that can be easily assembled using connectors. In this example, the panels 904, 906, 908, 910 are substantially the same or similar size and each include connectors 905a-b, 907a-b, 909a-b, 911a-b, as shown in FIG. 20, for coupling the panels 904, 906, 908, 910 together. FIG. 21 depict a foundation component 912 that is a webbed cover being positioned proximate to meshed connectors for receiving pins 914a-d to couple the foundation component 912 and the panels 904, 906, 908, 910 together. Included in FIG. 21 is a close-up view of a meshed connector 913 for panels 904, 906. FIG. 22 is a perspective view of the ottoman 902 in a completed state. A close-up and partially cutaway view of connectors 907b, 909a and pin 914c is also shown.

[0063] Using a connector according to some aspects, the foundation of an article of furniture can be prevented from sliding subsequent to assembly, and the article of furniture can be easier to assemble than using standard coupling mechanism. An article of furniture can be shipped to a consumer easier and be ready to assemble upon arrival, rather than involving a manufacturer for assembly. And the meshed connectors can improve stability of an assembled article of furniture, as compared to bolts that may become disconnected.

[0064] Other types of connectors can be used with an article of furniture, such as the examples described previously, to allow components to be easily coupled together while further preventing the components from moving independently from each other. FIG. 23 is a perspective view of meshed connectors 1002 with a pin 1004 received therein according to another example. The pin 1004, which is shown via perspective view in FIG. 24, can have an extended portion 1006 that extends radially from the base of the pin 1004. The pin 1004 can also have a top portion 1007 that is cloverleaf shaped to facilitate a user rotating the pin 1004 when it is received in the meshed connectors 1002. The extended portion 1006 can be used to lock the pin 1004 in place with the meshed connectors 1002. Each connector 1008, 1010 that form the meshed connectors 1002 can have multiple channels, as shown in the perspective view of FIG. 25. The connectors 1008, 1010 are separated in FIG. 25 and each includes a primary channel 1012, 1013 for receiving the pin 1004, and a secondary channel 1014, 1015 for allowing the extended portion 1006 to pass through the connectors 1008, 1010 when the connectors 1008, 1010 form the meshed connectors 1002, as shown in FIG. 26. The pin 1004 received in the meshed connectors 1002 can be rotated (as shown via arrow in FIG.

27) by a user rotating the top portion 1007. The pin 1004 can be rotated to rotate the extended portion 1006 such that it does not align with the secondary channels 1014, 1015, as shown in FIG. 28, and the meshed connectors 1002 can maintain coupling even when the meshed connectors 1002 are turned upside down. For example, the extended portion 1006 can be rotated with respect to the secondary channels 1014, 1015 to prevent the pin 1004 from decoupling from the connectors 1008, 1010 and a foundation component of the article of furniture.

[0065] A pin with an extended portion and that can be used with connectors with multiple channels can have other types of top portions to facilitate a user rotating the pin. FIGS. 29-34 depict examples of other types of top portions for pins.

[0066] FIG. 29 depicts part of a pin 1102 with a top portion 1104 that includes crossing slots. The crossing slots can allow a user to use a flat-head screwdriver to rotate the pin 1102 when it is received in connectors. Or, the crossing slots may be configured to involve the use of a wrench that is specially adapted to be received by one or more of the crossing slots. The crossing slots can allow the user to turn a tool forty-five degrees or less to engage the slots.

[0067] FIG. 30 depicts a top portion 1204 for a pin that extends upward such that the top portion 1204 can be rotated by a user's hands or via a tool, such as pliers. The top portion 1204 extends axially from a body of the pin and includes a smaller diameter than the body of the pin to allow a user to rotate the pin.

[0068] FIG. 31A is a side view of a pin 1302 that includes a top portion 1304 with a rigid portion 1306 extending laterally across the top portion 1304. FIG. 31B depicts a top view of the top portion 1304. On both sides of the rigid portion 1306 are chambers 1308, 1310 define by the pin. The chambers 1308, 1310 can allow a tool, such as pliers 1312 (as shown in FIG. 32) to be used to grasp the rigid portion 1306 and rotate the pin 1302 when it is received in meshed connectors.

[0069] FIG. 33 is a side view of a pin 1402 with a top portion 1404 that includes a key handle 1406 to allow a user to rotate the pin 1402 when it is received in meshed connectors. FIG. 34 is a side view of a pin 1502 when a top portion 1504 that includes a slot 1506 for receiving a flat-head screwdriver to allow a user to rotate the pin 1502 when it is received in meshed connectors.

[0070] Connectors according to other examples can take different forms than the examples depicted. For example, one connector can be an inverted pin, and the other connector can include an inverted cone that can be positioned over the inverted pin on first connector (leaving a small amount protruding from top). A seat foundation can be positioned over the inverted pin and can be secured with a horizontally placed pin or cap. In addition, in other examples, the seat foundation can be secured, additionally or alternatively to coupling to the connectors, to other components via fastening mechanisms, such as a screw.

[0071] The foregoing description of certain embodiments, including illustrated embodiments, has been presented only for the purpose of illustration and description and is not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Numerous modifications, adaptations, combinations, and uses thereof are possible without departing from the scope of the disclosure.