Compactable furniture system
A compactable furniture system having a seat back with front and rear panels that are pivotally connected at the top of the front and rear panels and removably connected at the bottom of the front and rear panels with a pitch mechanism that fixes the seat back at a pitch angle during assembly.
Traditionally, large furniture seating items such as sofas, loveseats, chairs, and sleepers are fully constructed and assembled in a factory and then shipped, in the assembled state, to a desired destination, either a retailer or directly to a consumer. A major manufacturing cost for producing these items is the cost of shipping (i.e., freight costs). In addition, these bulky furniture items require a large amount of space to warehouse and store, which is also costly.
Furniture that can be manufactured and shipped, and then fully assembled by an end user, such as a retailer or consumer, is currently known. An example of such a furniture system can be found in U.S. Pat. No. 5,423,596. Disadvantageously, however, this furniture system has many components and assembly/disassembly of the finished product can be difficult for the end user.
In addition, many consumers live in homes or apartments that have narrow doors or stairways that cannot be navigated by traditional bulky furniture. This can require removing windows or doors, and/or hoisting large furniture items through upper story windows to place large furniture in these homes or apartments. Removing the furniture from the dwelling requires the same arduous process.
Therefore, there is a need for a furniture system that can be compacted into a small space for shipping, storage, and moving. It would also be advantageous if this furniture system can be easily assembled and disassembled by a retailer or consumer.
SUMMARYAccording to the present invention, there is provided a compactable furniture system with a pitch mechanism that removably connects a front and rear panel of a seat back at a pitch angle. The compactable furniture system also has first and second side supports attached to the seat back and a front rail attached to the first and second side supports. A removable seat deck is disposed between the seat back, the front rail, and the first and second side supports.
The furniture system can additionally have a seat deck lock, which has a bracket, and a joining pin with a plate that can provide support for the seat deck. The furniture system can additionally have a center bar interposed between the rear panel and the front rail to provide support for the seat deck. A hinge lock can be used to join the front rail and the first and second side supports. The hinge lock can also have a hinge plate to provide support for the seat deck. Further, the furniture system can additionally have a set of legs that are attached to the first and second side supports.
In one embodiment, the pitch mechanism comprises a slotted bracket having one or more notches. The furniture system of claim 1 wherein the pitch mechanism comprises a bar with two apertures. The furniture system of claim 1 wherein the pitch mechanism comprises a bar with an aperture and a hook. The furniture system of claim 1 wherein the pitch mechanism comprises a locking joint. The furniture system of claim 1 wherein the front panel and the rear panel are pivotally connected with one or more hinges.
In another embodiment according to the present invention, there is provided a method for assembling compactable furniture. In one embodiment, a furniture system according to the present invention is selected. Then, the seat back and the front rail are attached to the first and second side supports. The pitch mechanism is then inserted into the seat back and the seat back is fixed a pitch angle. The seat deck is then inserted between the seat back, the front rail, and the first and second side supports. In a preferred embodiment, the furniture system additionally has a seat deck lock, and the seat deck lock is attached to at least one of the first side support, the second side support, or the front rail. In another preferred embodiment, the furniture system additionally has a hinge lock, at least one of the first and second side supports is attached to the front rail with the hinge lock.
FIGURESThese and other features, aspects and advantages of the present invention will become better understood from the following description, appended claims, and accompanying figures where:
According to the present invention a compactable furniture system is provided. The furniture system is a “knock-down” seating system where the furniture can be manufactured remotely in unassembled pieces that can be shipped, stored, or moved in compact form and later assembled by the end user. The compactable furniture system has a pitch mechanism that allows the seat back to fold flat for shipping, storage, and moving. When the compactable furniture is assembled by the end user, the seat back is positioned for proper seating by inserting the pitch mechanism into place and locking, which adjusts the seat back to a desired pitch angle. The compactable furniture system according to the present invention allows approximately double the number of sofas to be shipped in a conventional shipping container, substantially lowering manufacturing costs. The compactable furniture system has the added advantage of having few detachable components for ease of assembly by the end user.
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In another embodiment, the present invention is a method for assembling compactable furniture. In one embodiment, the method comprises selecting a furniture system according to the present invention. Then, the seat back 12 is attached to the first side support 30 and the second side support 32. Next, the front rail 34 is attached to the first side support 30 and the second side support 32. Next, the pitch mechanism 26 and 28 is inserted into the seat back 12 and the seat back 12 is locked at a pitch angle. Next, the seat deck 36 is inserted between the seat back 12, the front rail 34, and the first and second side supports 30 and 32.
In another embodiment, the method additionally comprises attaching a front seat deck lock 44 to the front rail 34, and attaching a side seat deck lock 46 and 48 to the first and second side supports 30 and 32, respectively. In another embodiment, the method additionally comprises attaching the first side support 30 and the second side support 32 to the front rail 34 with a hinge lock 80 and 90.
Although the present invention has been discussed in considerable detail with reference to certain preferred embodiments, other embodiments are possible. Therefore, the scope of the appended claims should not be limited to the description of preferred embodiments contained herein.
Claims
1. A compactable furniture system comprising:
- a) a seat back having a front panel and a rear panel, wherein the front panel and the rear panel are: i) pivotally connected at a front panel top end and a rear panel top end; and ii) removably connected at a front panel bottom end and a rear panel bottom end;
- b) a pitch mechanism for removably connecting the front panel bottom end and the rear panel bottom end at a pitch angle;
- c) first and second side supports attached to the seat back;
- d) a front rail attached to the first and second side supports; and
- e) a seat deck disposed between the seat back, the front rail, and the first and second side supports.
2. The furniture system of claim 1 additionally comprising a seat deck lock.
3. The furniture system of claim 2 wherein the seat deck lock comprises a bracket and a plate having a joining pin.
4. The furniture system of claim 1 additionally comprising a center bar interposed between the rear panel and the front rail.
5. The furniture system of claim 1 additionally comprising a hinge lock.
6. The furniture system of claim 5 wherein the hinge lock comprises first and second hinge plates and a hinge pin.
7. The furniture system of claim 1 additionally comprising first and second legs attached to the first side support and third and fourth legs attached to the second side support.
8. The furniture system of claim 1 wherein the pitch mechanism comprises a slotted bracket having one or more notches.
9. The furniture system of claim 1 wherein the pitch mechanism comprises a bar with two apertures.
10. The furniture system of claim 1 wherein the pitch mechanism comprises a bar with an aperture and a hook.
11. The furniture system of claim 1 wherein the pitch mechanism comprises a locking joint.
12. The furniture system of claim 1 wherein the front panel and the rear panel are pivotally connected with one or more hinges.
13. A method for assembling compactable furniture comprising:
- a) selecting a furniture system according to claim 1;
- b) attaching the seat back to the first and second side supports;
- c) attaching the front rail to the first and second side supports;
- d) inserting the pitch mechanism and fixing the seat back at a pitch angle; and
- e) inserting the seat deck between the seat back, the front rail, and the first and second side supports.
14. A method according to claim 13 wherein the furniture system additionally comprises a seat deck lock and the method additionally comprises attaching the seat deck lock to at least one of the first side support, the second side support or the front rail.
15. A method according to claim 13 wherein the furniture system additionally comprises a hinge lock and the method additionally comprises attaching at least one of the first and second side supports to the front rail with a hinge lock.
Type: Application
Filed: May 25, 2004
Publication Date: Oct 13, 2005
Inventor: Shren Ou (Monterey Park, CA)
Application Number: 10/854,096