FURNITURE ASSEMBLY AND METHOD

Abstract

A furniture assembly includes a top portion and a support frame including a mid-section and a base. The mid-section is configured to be connected between the top portion and the base. The support frame includes at least one cross-member that is configured to be rotated about a swivel joint between a collapsed configuration and an expanded configuration. A foot includes a tip end that is connected to a foot end by a threaded rod, and the tip end is configured to be threaded onto a leg of the mid-section. In addition, the base is configured to be disposed between the mid-section and the foot end of the foot.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63/328,494, filed on Apr. 7, 2022, and U.S. Provisional Patent Application No. 63/309,834, filed on Feb. 14, 2022, each of which are incorporated by reference herein in their entirety.

REFERENCE REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable

SEQUENCE LISTING

Not applicable

BACKGROUND

Field of the Disclosure

The present disclosure relates to furniture assemblies. More specifically, an adjustable furniture assembly that is configured to be provided as a kit with a compact shipping configuration and a simplified assembly process is disclosed.

Description of the Background of the Disclosure

In the field of furniture, tables are common articles that have various uses and styles for various areas. For example, side tables or accent tables may be provided near seating furniture, such as a couch, and used to hold or support a lamp, reading materials, remote controllers, or other small items. Further, tables are often provided in particular styles that are selected for both functional and aesthetic properties. For example, side tables may serve as a design element or accent within a cohesive overall design of a setting by adding color, shape, texture, or size to the overall design, whether interior or exterior of a residential or commercial space. Tables are typically constructed of metal, plastic, and/or wood, or combinations thereof, depending on the use and style.

Furniture is often sold in a disassembled configuration for various benefits, e.g., to reduce shipping costs. Furniture assemblies can be difficult for consumers to assemble due to the number of components, the number of steps, and the complexity of each step. Further, consumer preferences can change over time, which may lead a consumer to discard or replace furniture that is no longer suitable, e.g., too short, uneven flooring or ground surfaces, or shifts in style trends.

Therefore, what is needed is a table assembly that addresses one or more of the drawbacks of existing furniture assemblies.

SUMMARY

In some aspects, a furniture assembly includes a top portion and a support frame including a mid-section and a base. The mid-section is configured to be connected between the top portion and the base. The support frame includes at least one cross-member that is configured to be rotated about a swivel joint between a collapsed configuration and an expanded configuration. A foot includes a tip end that is connected to a foot end by a threaded rod, and the tip end is configured to be threaded onto a leg of the mid-section. In addition, the base is configured to be disposed between the mid-section and the foot end of the foot.

In some embodiments, the foot end is configured to be adjustable relative to the base. In some embodiments, the threaded rod is configured to receive an adjustment nut that is configured to set a position of the foot end relative to the base. In some embodiments, the threaded rod is at least partially concealed within a hollow post of the base. In some embodiments, the leg of the mid-section has a crimped section that is configured to be received within the base, and the tip end of the threaded rod is configured to be received within the leg. In some embodiments, the foot comprises a plurality of feet that are each adjustable relative to the base independently of one another. In some embodiments, the leg of the mid-section includes at least one extended leg and at least one shortened leg, and wherein at least one of the plurality of feet is configured to be received by the at least one extended leg, and at least of the plurality of feet is configured to be received by the at least one shortened leg.

In some aspects, a support frame for a furniture assembly comprises a mid-section that includes a first set of legs and a second set of legs, and a base that is configured to be attached to the mid-section. Further, the base includes a first set of posts and a second set of posts. A foot includes a tip end that is connected to a foot end by a threaded rod. The tip end is configured to be threaded onto at least one leg of the first set of legs or the second set of legs of the mid-section, and the foot end is adjustable relative to the base. The first set of legs is configured to be received by the first set of posts and the second set of legs is configured to be received by the second set of posts. The support frame has a support height and the mid-section comprises a height that is greater than 50% of the support height.

In some embodiments, the support height of the support frame comprises greater than 80% of a furniture height of the furniture assembly. In some embodiments, the first set of legs and the second set of legs of the mid-section are configured to be disposed diagonally when the furniture assembly is inserted into a packaging container in a shipping configuration. In some embodiments, the mid-section includes a first cross-frame that has a first swivel joint to allow for rotation thereabout and a locking feature that is configured to secure the first cross-frame in an expanded configuration. In some embodiments, the locking feature includes an upper collar, a lower collar, and a pin that is configured to be received within at least one of the upper collar and the lower collar when the first cross-frame is in a collapsed configuration. In some embodiments, the pin is configured to be received within the upper collar and the lower collar when the first cross-frame is in the expanded configuration.

In some embodiments, the base includes a second cross-frame that includes a top cross-member and a bottom cross-member that are rotatably coupled to one another by a second swivel joint, and wherein the first set of posts are configured to be rotated about the second swivel joint by connection with the top cross-member and the second set of posts are configured to be rotated about the second swivel joint by connection with the bottom cross-member. In some embodiments, the first cross-frame includes a first set of spacers that are attached to an upper cross-member and a second set of spacers that are attached to a lower cross-member the first set of spacers having a magnetic pad attached thereto.

In some aspects, a method of shipping and assembling a kit comprises providing a package that has a profile that has a first packaging dimension, a second packaging dimension, and a third packaging dimension. Further, the method comprises inserting into the package the kit comprising a furniture assembly that includes a support frame, wherein the support frame comprises a plurality of legs and a base. The plurality of legs of the support frame defines a height. The furniture assembly, when in a shipping configuration, defines a first shipping dimension, a second shipping dimension, and a third shipping dimension. The height of the plurality of legs is greater than each of the of the first shipping dimension, the second shipping dimension, and the third shipping dimension. In addition, the height of the plurality of legs is greater than each of the first packaging dimension, the second packaging dimension, and the third packaging dimension.

In some embodiments, the kit further comprises a top portion, a plurality of feet, a plurality of tools, and a plurality of fasteners. In some embodiments, the support frame comprises at least one cross-member that is configured to be rotated about a swivel joint between a collapsed configuration and an expanded configuration. In some embodiments, the at least one cross-member has a locking feature that is configured to secure at least one cross-frame in the expanded configuration. In some embodiments, the top portion is configured to be removably attached to the support frame.

Accordingly, it is desirable to reduce the size of the shipping container for the furniture assembly. It is also desirable to minimize the number of components included with the furniture assembly, as well as to reduce the number of steps for assembling the furniture assembly. Further, it is desirable to provide furniture assemblies that have an adjustable dimension, such as an adjustable height.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front, isometric, exploded view of a furniture assembly, according to an embodiment of the present disclosure;

FIG. 2 is a front, isometric view of the furniture assembly of FIG. 1 in an assembled configuration;

FIG. 3 is a front, isometric, detail view of the furniture assembly of FIG. 1 highlighting an upper cross-frame;

FIG. 4 is a front, isometric, detail view of the furniture assembly of FIG. 1 highlighting an upper connection of a support frame assembly prior to assembly;

FIG. 5 is a front, isometric, detail view of the furniture assembly of FIG. 1 highlighting a locking feature of the upper cross-frame of FIG. 3 shown prior to assembly;

FIG. 6 is a front, isometric view of the furniture assembly of FIG. 1 highlighting the locking feature of the upper cross-frame of FIG. 4 shown after assembly;

FIG. 7 is a front, isometric, exploded view of the furniture assembly of FIG. 1 highlighting a lower connection of the support frame assembly before assembly;

FIG. 8 is a front, isometric, exploded view of the furniture assembly of FIG. 1 highlighting a lower connection of the support frame assembly before assembly;

FIG. 9 is a front, isometric, detail view of the furniture assembly of FIG. 1 with a post hidden from view to highlight a threaded rod received within a leg of the support frame;

FIG. 10 is a front, isometric, detail view of the furniture assembly of FIG. 1 highlighting an adjustment feature shown prior to installation;

FIG. 11 is a front, elevational, detail view of the furniture assembly of FIG. 1 highlighting the adjustment feature of FIG. 10 shown after installation;

FIG. 12 is a front, elevational, detail view of the furniture assembly of FIG. 1 highlighting a swivel joint of a lower cross-frame;

FIG. 13 is a front, isometric view of the furniture assembly of FIG. 1 in a disassembled configuration;

FIG. 14 is a front, isometric view of a plurality of tools provided with the furniture assembly of FIG. 13 as a kit;

FIG. 15 is a side elevational view of the furniture assembly of FIG. 13 inside of a packaging container; and

FIG. 16 is a bottom plan view of the furniture assembly of FIG. 15 inside of the packaging container.

DETAILED DESCRIPTION

The following discussion and accompanying figures disclose various embodiments or configurations of a knock down table and kit for assembly thereof that has an adjustable height and a compact shipping profile. The term “knock down,” as used herein, generally refers to an article of manufacture, e.g., furniture, provided with separable components that are capable of being packed or contained in a disassembled state within shipping packaging and may be assembled upon removal from the shipping packaging, often by a consumer. Although embodiments of a knock down table are disclosed that are specific to a side table or accent table, concepts associated with embodiments of the table assembly may be implemented with a wide variety of table assemblies, including coffee tables, dining tables, high-top tables, folding tables, writing tables or desks, nightstands, outdoor tables, e.g., patio tables, or any other type of table that can be provided as an assembly. More generally, concepts associated with embodiments of the table assembly may be implemented with a wide variety of furniture, including seating furniture, e.g., chairs or stools, consoles, carts, shelving and/or storage structures, cabinets, lighting fixtures, and any other furniture that can be provided as an assembly. Accordingly, concepts described herein may be utilized in a variety of products and in a variety of applications.

The term “about,” as used herein, refers to variations in the numerical quantity that may occur, for example, through typical measuring and manufacturing procedures used for knock down furniture assembly manufacturing, or other articles of manufacture that may include embodiments of the disclosure herein, through inadvertent error in these procedures, through differences in the manufacture, source, or purity of the ingredients used to make the compositions or mixtures or carry out the methods, and the like. Throughout the disclosure, the terms “about” and “approximately” refer to a range of values ±5% of the numeric value that the term precedes.

Additionally, where reference is made to a magnetic element or structure throughout the disclosure, it may be assumed that the element or structure includes one or more magnets (e.g., permanent magnets), or one or more metals or alloys (e.g., ferromagnetic materials, among others), which may be attracted to magnets. Further, a magnetic pad, as described herein, may include a continuous magnetic element, a series of two or more discrete magnetic elements, or a two- or three-dimensional array of magnetic elements. Additionally, these magnetic elements may be constructed from any magnetic metal or alloy, and may be combined with one or more non-magnetic materials, such as polymers, ceramics, or non-magnetic metals or alloys. It is also contemplated that the various embodiments described in this document may be combined in any manner, such that various permutations of combined elements may be possible.

Referring to FIGS. 1 and 2, an embodiment of a furniture assembly 100 in the form of a table assembly is shown in an exploded, disassembled configuration and an assembled configuration, respectively. The table assembly 100 comprises a top portion, such as a tabletop 104 that is supported by a support frame 108. The support frame 108 includes an upper cross-frame 112 that is attached to a first set of extended legs 116 and a second set of shortened legs 120 to form a mid-section 124 of the table assembly 100. Additionally, the support frame 108 includes a bottom or base 128 having a lower cross-frame 132 that is attached to a first set of extended posts 136 and a second set of shortened posts 140. Accordingly, the support frame 108 is provided as a knock down assembly that is bifurcated into at least the base 128 and the mid-section 124. Further, a plurality of feet 144 are provided with the support frame 108 for engagement with a flooring surface of ground surface. Each of the plurality of feet 144 include a threaded rod 148 that extends between a tip end 152 and a foot end 156 that includes a foot pad, e.g., a rubber, plastic, or fabric component.

For purposes of clarity, only one of the feet 144 of FIG. 1 is labeled, but it will be appreciated that each of the feet 144 depicted include the tip end 152, threaded rod 148, and foot end 156. In the illustrated embodiment, the support frame 108 includes a quantity of one (1) upper cross-frame 112, two (2) extended legs 116, two (2) shortened legs 120, one (1) lower cross-frame 132, two (2) extended posts 136, two (2) shortened posts 140, and four (4) feet 144 each including a threaded rod 148. However, support frames 108 with greater or fewer quantities of each of these components is within the scope of this disclosure. For example, the plurality of legs 116, 120 may be further separated into subsections of the mid-section 124 and the plurality of posts 136, 140 may be further separated into subsection of the base 128. In some embodiments, the plurality of legs 116, 120 may be provided with further height adjustment features, such, as, e.g., concentric shaft sections for telescoping vertically, hinges for folding and unfolding, a turnbuckle that allows for vertical displacement upon rotation, or a lattice or truss arrangement capable of expanding vertically upon rotation. In some embodiments, the plurality of legs 116, 120 of the mid-section 124 may each be provided of equal sizes, e.g., equal lengths. In some embodiments, the plurality of posts 136, 140 of the base 128 may be provided of equal sizes, e.g., equal lengths. In any of these embodiments, or in another embodiment, the plurality of legs 116, 120 and the plurality of posts 136, 140 may be sized and configured so that the top portion of the table assembly 100 is disposed horizontally when the table assembly 100 is located on a level, horizontal surface.

In the illustrated embodiment, the tabletop 104 serves as a top portion of the table assembly 100 and includes a peripheral wall 160 extending from a planar member 164 to define a receptacle 168 of the tabletop 104. The tabletop 104 may be integrally, monolithically formed, such that the planar member 164 and the peripheral wall 160 are provided as a unitary piece by any number of traditional manufacturing methods, such as, e.g., casting or injection molding, or by unconventional manufacturing methods, such as, e.g., additive manufacturing. Alternatively, the peripheral wall 160 may be attached to the planar member 164 to form the tabletop 104 by any suitable method, such as, e.g., fastening, welding, fusing, or the like. In some embodiments, the tabletop 104 is composed of a natural material, such as, e.g., wood or stone, or the tabletop 104 can be composed of a synthetic material, such as, e.g., metal or plastic. In some embodiments, the tabletop 104 does not include the peripheral wall 160 and the receptacle 168. It is contemplated that the tabletop 104 may be provided with surface treatments of various kinds for aesthetic purposes, such as, e.g., adhesive coatings that are design to resemble granite or marble.

With reference to FIGS. 1 and 3, the tabletop 104 is generally circular in shape, but tabletops of various shapes and sizes are included within the scope of this disclosure. For example, the tabletop 104 may be generally oblong, rectangular, squared, triangular, polygonal, or irregularly shaped. The tabletop 104 defines an underside 172 (see FIG. 16) that is configured to be attached to the support frame 108. In the illustrated embodiment, the tabletop 104 is removably attached to the support frame 108 by magnetic pads 176. To that end, at least a portion of the tabletop 104 includes a material that is configured to magnetically interact with the magnetic pads 176 to removably secure the tabletop 104 to the support frame 108. For example, the underside 172 of the tabletop 104 can be provided with a metal or metal alloy that is magnetically attracted to the magnetic pads 176, such that portions of the underside 172 comprise such material, or such material is embedded within the tabletop 104, e.g., within the planar member 164. Alternatively, the entire underside 172 of the tabletop 104 includes magnetically interactive material, e.g., a metal or metal alloy. In the illustrated embodiment, the magnetic pads 176 are attached to the upper cross-frame 112 of the support frame 108. In some embodiments, the magnetic pads 176 may be integrally provided as part of the tabletop 104 or another part of the support frame 108. In some embodiments, the magnetic pads 176 may be removably attached to the tabletop 104 or to another portion of the support frame 108.

Referring to FIGS. 1 and 3, the upper cross-frame 112, which is also referenced herein as the first cross-frame, includes a lower cross-member 180 joined by a swivel joint to an upper cross-member 188. The swivel joint 184 is configured to secure the upper cross-member 188 to the lower cross-member 180. Further, the swivel joint 184 is configured to allow the upper cross-member 188 and the lower cross-member 180 to rotate relative to one another between a collapsed configuration (see FIG. 15) and an expanded configuration (see FIGS. 1 and 3). Referring to FIG. 3, an angle A measured between the upper cross-member 188 and the lower cross-member 180 of the upper cross-frame 112 may be between about 80 degrees and about 100 degrees, or between about 85 degrees and about 95 degrees, or about 90 degrees, as illustrated in FIG. 3. Further, when the upper cross-frame 112 is positioned in the collapsed configuration, the angle A may be between about 2 degrees and about 15 degrees, or between about 3 degrees and about 10 degrees, or between about 4 degrees and about 8 degrees (see FIG. 15). In this way, the upper cross-frame 112 is configured to fan out or expand by rotation about the swivel joint 184 prior to engagement with the tabletop 104. It is contemplated that the upper cross-frame 112 may be differently sized and shaped than shown. For example, the upper cross-frame 112 may be configured with three cross-members connected at their ends to form a triangular shape when in an expanded state, and the upper-cross frame 112 may include multiple swivel joints spaced apart from one another to allow for folding or collapsing into a collapsed position. Alternatively, the upper cross-frame 112 may be configured with two cross-members pivotably connected at one end of each cross-member so as to form a “V” shape when in an expanded state. In some examples, the lower cross-member 180 and the upper cross-member 188 may be differently sized relative to one another to accommodate different sizes and shapes of the tabletop 104, or to afford for different configurations of the support frame 108, or for aesthetic purposes.

With reference to FIGS. 1 and 3, each of the upper cross-member 188 and lower cross-member 180 includes opposing distal ends 196 (see FIG. 3) to which a set of spacers 192 is attached. In the illustrated embodiment, the spacers 192 are attached below the upper cross-member 188 to an underside thereof at both distal ends 196, and the spacers 192 are attached above the lower cross-member 180 to a topside thereof at both distal ends 196. It will be appreciated that the spacers 192 may be formed of the same stock material as the upper cross-member 188 and the lower cross-member 180, such that each has an identical cross-sectional area and/or dimension. Further, a mounting hole 200 (see FIG. 4) may be provided in substantially the same location on each spacer 192, making manufacturing of the spacers 192 easily repeatable with little change to machine setup. For example, it will be appreciated that the spacers 192 on the lower cross-member 180 may be rotated 180 degrees relative to the spacers 192 on the upper cross-member 188, such that the mounting hole 200 is positioned farther from the swivel joint 184 when attached, e.g., welded, to the lower cross-member 180 as part of the upper cross-frame 112. As mentioned above, magnetic pads 176 are provided on the upper cross-frame 112 and, in particular, the magnetic pads 176 are attached to the distal ends 196 of the upper cross-member 188 and to the spacers 192 at the distal ends 196 of the lower cross-member 180, as illustrated in FIG. 3. Further, the magnetic pads 176 may be attached to the spacers 192 by way of the mounting holes 200. The upper cross-frame 112 includes a locking feature 204 to prevent rotation of the upper cross-member 188 and the lower cross-member 180 about the swivel joint 184, which will be discussed further below.

Referring to FIGS. 1 and 4, the upper cross-frame 112 is configured to be attached to the extended legs 116 and the shortened legs 120 of the mid-section 124 to form an upper connection 208. In particular, an upper end 212 of each of the extended legs 116 and the shortened legs 120 includes a channel member 216 that protrudes outwardly therefrom, and the channel member 216 includes a channel hole 220 thereon. In the illustrated embodiment, each of the channel members 216 is generally U-shaped, such that an upper wall of the hollow tube is removed to form each of the channel members 216. For purposes of clarity, only one of the extended legs 116 of FIG. 1 is labeled with the upper end 212 and channel member 216, but it will be appreciated that each of the set of extended legs 116 and the shortened legs 120 include the upper end 212 and the channel member 216.

Turning to FIG. 4, the channel member 216 of each of the shortened legs 120 is configured to be received within the spacers 192 of the upper cross-member 188 of the upper cross-frame 112, such that the channel hole 220 is aligned with the mounting hole 200 provided on the spacer 192 and configured to at least partially receive one of a plurality of fasteners 224, such as a threaded hex-screw. Additionally, the fastener 224, which is understood to refer to one of the plurality of fasteners 224, is configured to be inserted and threaded into the mounting hole 200 and the channel hole 220 to secure the shortened leg 120 to the upper cross-frame 112 by way of tightening the channel member 216 to the spacer 192 on the upper cross-member 188. Similarly, the channel member 216 of each of the extended legs 116 is configured to be received within the distal ends 196 of the lower cross-member 180, such that the channel hole 220 of each channel member 216 is aligned with each of the mounting holes 200 of the lower cross-member 180. Additionally, the fastener 224 is configured to be inserted and threaded into the mounting hole 200 and the channel hole 220 to secure the extended leg 116 to the upper cross-frame 112 by way of tightening the channel member 216 to the lower cross-member 180.

Referring to FIGS. 5 and 6, the locking feature 204 of the upper cross-frame 112 includes an upper collar 228 mounted to the upper cross-member 188, a lower collar 232 mounted to the lower cross-member 180, and a pin 236 that is configured to be received within the upper and lower collars 228, 232. To that end, the upper and lower collars, 228, 232 are movable relative to one another, such that when the upper cross-frame 112 is in the expanded configuration, e.g., when the angle A is about 90 degrees, as illustrated in FIGS. 5 and 6, the upper and lower collars 228, 232 are substantially vertically aligned with one another. As such, the pin 236 is configured to be inserted vertically through the upper collar 228 and pressed downward into the lower collar 232, which prevents upper cross-member 188 and the lower cross-member 180 from moving relative to one another, thereby locking or securing the upper cross-frame 112 in the expanded configuration. In the collapsed configuration of FIG. 15, for example, the upper and lower collars 228, 232 are misaligned or spaced apart, e.g., radially offset, from one another. As a result, the pin 236 is inserted within one of the upper collar 228 or the lower collar 232, which allows the pin 236 to be retained by at least one of the 228 or the lower collar 232 during shipping and prior to assembly.

Turning to FIGS. 7 and 8, the mid-section 124 and the base 128 are coupled together to form a lower connection 276 of the support frame 108. In particular, the extended leg 116 of the mid-section 124 is received within the shortened post 140 of the base 128 and, more specifically, a lower end 240 of a crimped section 244 of the extended leg 116 is received within a top end 248 of the shortened post 140 of the base 128. The crimped section 244 of the extended leg 116 is narrower and has reduced dimensions, e.g., taken through cross-section, as compared to the rest of the extended leg 116. Further, the lower end 240 of the extended leg 116 includes a threaded mounting hole 250 in which the threaded rod 148 of the foot 144 is configured to be received. As illustrated with respect to the extended leg 116 of the FIG. 1, it will be appreciated that each of the extended legs 116 and the shortened legs 120 include the lower end 240 having the crimped section 244 and the mounting hole 250. In some embodiments, each of the plurality of legs 116, 120 is hollow continuously between the upper end 212 and the lower end 240. In some embodiments, the plurality of legs 116, 120 are only partially hollow or are at least partially filled with a filler material, e.g., a non-metal material.

In the illustrated embodiment of FIGS. 7 and 8, the threaded rod 148 is configured to be inserted through the shortened post 140 of the base 128 to engage with the extended leg 116. In particular, the tip end 152 of the threaded rod 148 is inserted through an aperture 252 at a bottom end 256 of the shortened post 140 and into the hollow interior thereof until the tip end 152 protrudes from the top end 248 of the shortened post 140. In some embodiments, the aperture 252 is threaded and engages with the threaded rod 148 of the foot 144. In some embodiments, the aperture 252 is unthreaded and allows the threaded rod 148 to pass therethrough with minimal contact or friction therebetween. Further, during assembly the tip end 152 of the threaded rod 148 is rotatably and threadably engaged with the mounting hole 250 of the extended leg 116, as illustrated in FIG. 9, to translate the foot end 156 of the threaded rod 148 toward the bottom end 256 of the shortened post 140 of the base 128. As illustrated with respect to the shortened post 140 of FIGS. 7 and 8, it will be appreciated that each of the extended posts 136 and the shortened posts 140 include the top end 248, the aperture 252, and the bottom end 256. In some embodiments, each of the plurality of posts 136, 140 is continuously hollow between the top end 248 and the bottom end 256. In some embodiments, the plurality of posts 136, 140 are only partially hollow or are at least partially filled with an insert or filler material, e.g., a non-metal material.

Similarly, and with reference to FIGS. 1 and 9, the shortened leg 120 of the mid-section 124 is received within the extended post 136 of the base 128. A lower end 240 of a crimped section 244 of the shortened leg 120 is received within the top end 248 of the extended post 136 of the base 128. The crimped section 244 of the shortened leg 120 is narrower and has reduced dimensions, e.g., thickness, as compared to the rest of the shortened leg 120. Further, the lower end 240 of the shortened leg 120 includes a threaded mounting hole 250 into which the threaded rod 148 of the foot 144 is configured to be received. In the illustrated embodiment, the threaded rod 148 is configured to be inserted through the extended post 136 of the base 128 to engage with the shortened leg 120. In particular, the tip end 152 of the threaded rod 148 is inserted through the aperture 252 at the bottom end 256 of the extended post 136 and into the hollow interior thereof until the tip end 152 protrudes from the top end 248 of the extended post 136. Further, the tip end 152 of the threaded rod 148 is then rotatably and threadably engaged with the mounting hole 250 of the extended leg 116 to translate the foot end 156 of the threaded rod 148 toward the bottom end 256 of the extended post 136 of the base 128.

With reference to FIGS. 1, 10, and 11, the foot 144 is configured to be adjustable relative to the base 128 by an adjustment feature 268 of the support frame 108, which allows for selective adjustment of the overall height of the table assembly 100. In particular, the adjustment feature 268 includes an adjustment nut 272 that is threaded onto the threaded rod 148 prior to the tip end 152 of the threaded rod 148 being inserted through the base 128, as described in connection with FIGS. 7 and 8. The adjustment nut 272 can be displaced vertically along the threaded rod 148 relative to the foot end 156 by rotation and, similarly, the threaded rod 148 can be displaced vertically relative to the base 128 and the mid-section 124, especially relative to the mounting hole 250, by rotation. For example, rotating the threaded rod 148 counterclockwise will cause the foot end 156 of the threaded rod 148 to move toward the mounting hole 250 of the mid-section 124, thereby decreasing an adjustment distance, i.e., the distance between the lower end 240 of the respective leg 116, 120 of the mid-section 124 (see FIG. 1) and the adjustment nut 272 (see FIGS. 10 and 11). By contrast, rotating the threaded rod 148 clockwise will cause the foot end 156 of the threaded rod 148 to move away from the mounting hole 250 of the mid-section 124, thereby increasing the adjustment distance between the mounting hole 250 of the mid-section 124 and the foot end 156. The adjustment nut 272 can be translated by rotation along the threaded rod 148 to increase or decrease the adjustment distance, which allows the height of the table assembly 100 to be adjusted and set, e.g., for accommodation of uneven flooring or surfaces, or for achieving a particular aesthetic or functional purpose.

Referring to FIGS. 1 and 9-11, the base 128, specifically the extended post 136 or shortened post 140, is positioned between the mid-section 124 and the foot end 156 while the threaded rod 148 is disposed therein without being threadably engaged to the base 128. Further, the base 128 is attached and retained to the mid-section 124 by engagement with the crimped section 244 of the extended legs 116 and shortened legs 120, and the base 128 is also supported by contact with the adjustment nut 272 on the threaded rod 148. Accordingly, when the threaded rod 148 is rotated clockwise to increase the adjustment distance, i.e., to displace the foot end 156 away from the mid-section 124, the adjustment nut 272 is rotated counterclockwise to be displaced toward the tip end 152 of the threaded rod 148 in the mounting hole 250 of the mid-section 124 and, thus, to reduce the adjustment distance until the adjustment nut 272 is brought into contact with and exerts pressure on the bottom end 256 of the extended posts 136 and shortened posts 140 of the base 128.

It will be appreciated that each threaded rod 148 is independently adjustable relative to the mid-section 124, and that each adjustment nut 272 is independently adjustable relative to the base 128 and the foot end 156 along the threaded rod. As such, each foot 144, which includes the foot end 156 and the threaded rod 148, is independently adjustable, such that one foot 144 can be set at a different height relative to another foot 144. In this way, the adjustment feature 268 of the support frame 108 provides the table assembly 100 with the ability to remain stable and firmly in contact with various types of flooring or ground surfaces. For example, one or more of the feet 144 may be adjusted relative to the mid-section 124 to partially, selectively adjust the height of the table assembly 100, as described above, so the table assembly 100 can be positioned on uneven flooring, e.g., an edge of a rug, on a paved or stone patio, on a textured or patterned rug, or so the table assembly 100 can fit a particular function or aesthetic purpose, e.g., aligning with a height of nearby furniture, allowing for more space underneath the base 128 to accommodate baskets or other items, or the like.

With reference to FIGS. 1 and 12, the lower cross-frame 132 of the base 128 includes a swivel joint 280 that permanently couples a top cross-member 284 to a bottom cross-member 288. The swivel joint 184 includes a top flange 292 that is mounted to the top cross-member 284 and a bottom flange 296 that is mounted to the bottom cross-member 288, thereby preventing separation of the top cross-member 284 from the bottom cross-member 288. However, the swivel joint 184 allows for rotation of the top cross-member 284 relative to the bottom cross-member 288 from an expanded configuration (see FIG. 1) to a collapsed configuration (see FIG. 15), in a similar fashion to the upper cross-frame 112. In the expanded configuration, an angle B (see FIG. 2) measured between the top cross-member 284 and the bottom cross-member 288 of the lower cross-frame 132 may be between about 80 degrees and about 100 degrees, or about 85 degrees and about 95 degrees, or about 90 degrees.

Further, when the lower cross-frame 132 is positioned in the collapsed configuration, the angle B may be between about 2 degrees and about 15 degrees, or between about 3 degrees and about 10 degrees, or between about 4 degrees and about 8 degrees (see FIG. 15). It is contemplated that the lower cross-frame 132 may be differently sized and shaped than shown. For example, the lower cross-frame 132 may be configured with three cross-members connected at their ends to form a triangular shape when in an expanded state, and the lower-cross frame 132 may include multiple swivel joints spaced apart from one another to allow for folding or collapsing into a collapsed position. Alternatively, the lower cross-frame 132 may be configured with two cross-members pivotably connected at one end of each cross-member so as to form a “V” shape when in an expanded state. In some examples, the bottom cross-member 288 and the top cross-member 284 may be differently sized relative to one another to accommodate different sizes and shapes of the tabletop 104, or to afford for different configurations of the support frame 108, or for aesthetic purposes.

With reference to FIG. 13, the table assembly 100 is configured to be knocked down or broken down for transport, e.g., shipping, purposes. In the illustrated embodiment, the table assembly 100 is provided in a shipping configuration in which the feet 144 are collected and stored within the receptacle 168 of the tabletop 104. Also, the shipping configuration includes the shortened legs 120 being arranged to laterally bookend the extended legs 116 as each is laid side-by-side to be parallel with one another, such that the channel members 216 extend in the same direction and adjacent one another and such that the crimped sections 244 are adjacent one another. For purposes of clarity, one of the channel members 216 is labeled in FIG. 13, but it will be appreciated that each of the legs 116, 120 includes the channel member 216 arranged side-by-side relative to one another. Further, the shipping configuration includes the lower cross-frame 132 of the base 128 being provided in the collapsed configuration, such that one of the extended posts 136 rests on top of one of the shortened posts 140, and the other of the shortened posts 140 rests on top of the other of the extended posts 136.

Further, due to the dimensions of the lower cross-frame 132 when in the collapsed configuration, the tabletop 104 at least partially fits between the extended posts 136 and the shortened posts 140. In addition, the tabletop 104 rests on the extended legs 116 and the shortened legs 120 between the channel members 216 and the crimped sections 244. Further, in the shipping configuration, the upper cross-frame 112 is placed in the collapsed configuration, such that one of the spacers 192 of the lower cross-member 180 rests on top of one of the distal ends 196 of the upper cross-member 188, and the other of the distal ends 196 of the upper cross-member 188 rests on top of the other of the spacers 192 of the lower cross-member 180. Relatedly, at least one of the spacers 192 of the upper cross-member 188 rests on top of one of the distal ends 196 of the lower cross-member 180, and the other of the distal ends 196 of the lower cross-member 180 rests on top of the other of the spacers 192 of the upper cross-member 188.

With reference to FIGS. 13 and 14, the table assembly 100 is configured to be provided as a kit that includes a plurality of tools 304, including an open-end wrench 308 and a hex key 312, e.g., an Allen® wrench. In some embodiments, the plurality of tools 304 may be removably attached to the tabletop 104 or received within the receptacle 168. In some embodiments, the plurality of tools 304 can be individually packaged within a bag or container (not shown) along with or separately from the plurality of fasteners 224.

It surprisingly was found that new packaging container 316 (see FIGS. 15 and 16) afforded by the configuration of the table assembly 100 significantly improves issues associated with transit, including space constraints and shipping costs, as well as issues surrounding the use of valuable shelf space at the retail level. The traditional or old packaging container (not shown) for the table assembly 100 includes a surrounding buffer or space of about 2 inches for packing material, e.g., styrofoam blocks and wedges, and has dimensions that are approximately 30 inches×18 inches×18 inches to accommodate the table assembly 100 in the assembled configuration, i.e., 9,720 in³. The new packaging container 316 of the concept disclosed herein has dimensions of approximately 19 inches×16 inches×4 inches, i.e., 1,216 in³. Thus, for every 1 table packed in old packaging container (not shown), approximately 8 disassembled tables may be packed in a new packaging container 316 and take up approximately the same volume, i.e., the volume of the new packaging 316 is one-eighth of the volume of the old packaging container, which is advantageous as a volumetric reduction for efficient space usage in a shipping container, a vehicle, on a store shelf, etc. Additionally, it was found that shipping costs for both the old packaging container (not shown) and new packaging container 316 may be based on a formula involving a volumetric calculation component, whereby the reduced volume of the new packaging 316 may reduce that volumetric calculation component by approximately an order of magnitude, significantly reducing per unit shipping costs. In some embodiments, the volumetric calculation component may be represented as a percentage, such that the reduced volume of the new packaging 316 is between about 5% and about 30% of the volume of the old packaging (not shown), or between about 8% and about 8% and about 25%, or between about 10% and about 20%, or between about 12% and about 15%.

Still referring to FIGS. 15 and 16, the new packaging container 316 defines a profile having a width of the packaging WB (see FIG. 16), a length of the packaging LB, and a depth of the packaging TB (see FIG. 14). The table 100, when in the disassembled assembled for shipping, defines a width of the table WS (see FIG. 16), a length of the table LS, and a depth of the table TS (see FIG. 15). In the illustrated embodiment, the mid-section 124 includes the plurality of legs 116, 120 that are configured to be disposed diagonally when the table assembly 100 is inserted into the packaging container 316 in the shipping configuration.

The width of the packaging WB may be a first packaging dimension, the length of the packaging LB may be a second packaging dimension, and the depth of the packaging TB may be a third packaging dimension. In the shipping configuration when the table is in a disassembled configuration, the width of the table WS may be a first table dimension, the length of the table LS may be a second table dimension, and the depth of the first table TS may be a third panel dimension. In the assembled configuration, the diameter of the table D may be a first table dimension, a length of the base LB may be a second table dimension, the height of the table H1 may be a third table dimension, the first lateral distance L1 may be a fourth table dimension, the second lateral distance L2 may be a fifth table dimension, the mid-section height H2 may be a sixth table dimension, and the support frame height H3 may be a seventh table dimension. In some embodiments, the first packaging dimension is less than the respective third table dimension, as shown in the Figures. The first, second, and third dimensions of the packaging, disassembled table, and assembled table may be rearranged, and need not be limited to the specific structure recited above.

Turning again to FIG. 2, which depicts the table assembly 100 in an assembled configuration and having various dimensions, a furniture or table height H1 is defined between the feet 144 and the uppermost point of the tabletop 104. Further, a support height H2 of the support frame 108 is defined between the upper ends 212 of the mid-section 124 and the bottom ends 256 of the base 128. Additionally, a mid-section height H3 is defined between the upper ends 212 and the lower ends 240 of the mid-section 124. In the illustrated embodiment, the mid-section height H3 may be equal to a length dimension measured along the plurality of extended legs 116, 120. Further, a first lateral distance L1 is defined between one of the shortened posts 140 and one of the extended posts 136 of the base 128. Also, a second lateral distance L2 is defined between another of the extended posts 136 and another of the shortened posts 140. In some embodiments, when the angle B is equal to 90 degrees, the first lateral distance L1 is equal to the second lateral distance L2. Relatedly, when the angle B is less than or greater than 90 degrees, the first lateral distance L1 will be different from the second lateral distance L2. In addition, when angle B is equal to angle A, as depicted in the embodiment of FIG. 2, the first lateral distance L1 and the second lateral distance L2 may be equally defined along the support frame 108, including along the mid-section 124. It is contemplated that when the tabletop 104 is differently shaped, such as an oblong or rectangular or irregular shape, the relationship among the angle B, angle A, the first lateral distance L1 and the second lateral distance L2 will change accordingly. For example, when the tabletop 104 is oblong, the first lateral distance L1 and the second lateral distance L2 may be different from one another, and both angles A and B may be 90 degrees.

In some embodiments, with the table assembly 100 in the shipping configuration, the length of the table LS is between about 15 inches and about 20 inches, or about 17.0 inches. In some embodiments, the depth of the table TS is between about 1 inch and about 4 inches, or about 2.25 inches. In some embodiments, the width of the table WS is between about 10 inches and about 15 inches, or about 13.75 inches. Accordingly, the length of the packaging LB is greater than the length of the table LS, the depth of the packaging TB is greater than the depth of the table TS, and the width of the packaging WB is greater than the width of the table WS. Further, with the table in the assembled configuration (see FIG. 2), the diameter of the table D is between about 10 inches and about 20 inches, or between about 12 inches and about 17 inches, or between about 12 inches and about 15 inches. The table height H1 is between about 20 inches and about 30 inches, or between 22 inches and about 28 inches, or between about 24 inches and about 27 inches. The support height H2 is between about 15 inches and about 30 inches, or between about 18 inches and about 28 inches, or between about 20 inches and about 26 inches. The mid-section height H3 is between about 12 inches and about 24 inches, or between about 14 inches and about 22 inches, or between about 16 inches and about 20 inches. The first lateral distance L1 is between about 5 inches and about 15 inches, or between about 7 inches and about 13 inches, or between about 9 inches and about 11 inches. In some embodiments, the second lateral distance L2 is equal to the first lateral distance L1. In some embodiments, the second lateral distance L2 and the first lateral distance L1 are different from one another. It will be appreciated that the foregoing dimensions are exemplary and the table assembly 100 should not be limited such dimensions.

In the illustrated embodiment, the support height H2 of the support frame 108 is less than the table height H1 of the table assembly 100 and greater than the mid-section height H3. In some embodiments, the support height H2 is greater than about 80% of the table height H1 of the table assembly 100. In this way, the support frame 108 is configured to support the tabletop 104 to achieve functional and aesthetic benefits. In some embodiments, the mid-section height H3 is greater than 50% of the table height H1 of the table assembly 100 and greater than 50% of the support height H2 of the support frame 108. In some embodiments, the mid-section height H3 is between about 50% and about 80% of the support height H2 of the support frame 108. Accordingly, the support frame 108 is configured to be disassembled and placed into the shipping configuration (see FIGS. 13-16) to minimize shipping costs, reduce the volume of the packaging 316, and facilitate assembly. In some embodiments, the diameter D of the tabletop 104 is equal to the first lateral distance L1 or the second lateral distance L2.

In some embodiments, the diameter D is greater than the first lateral distance L1 or the second lateral distance L2, or the summation thereof. In some embodiments, the first lateral distance L1 or the second lateral distance L2 is between about 60% and about 80% of the diameter D. In some embodiments, the diameter D is between about 30% and about 60% of the table height H1 of the table assembly 100 or between about 30% and about 60% of the support height H2 of the support frame 108. In some embodiments, the diameter D is equal to a length L3 measured along the top cross-member 284 or the bottom cross-member 288. Accordingly, the tabletop 104 and the support frame 108 are configured to be disassembled and placed into the shipping configuration (see FIGS. 13-16) to minimize shipping costs, reduce the volume of the packaging 316, and facilitate assembly. Further, it will be appreciated that where the tabletop 104 is differently sized and shaped, such as, e.g., oblong or rectangular or irregular, the relationship among the diameter D of the tabletop 104 and the dimensions of the support frame 108 may differ from those above. For example, when the tabletop 104 is oblong, the diameter D may represent the maximum dimension thereof, and the support height H2 may comprise a substantially lower percentage of the diameter D, and the length L3 may comprise a substantially lower percentage of the diameter D and/or the support height H2.

In some embodiments, the packaging 316 has at least one dimension, i.e., the width WB, the length of the packaging LB, or the depth of the packaging TB, that is less than at least one respective dimension of the table assembly 100 in the disassembled configuration, i.e., the width of the table WS, the length of the table LS, or the depth of the table TS. In some embodiments, the width of the table WS is equal to the diameter D of the tabletop D. In some embodiments, the depth of the packaging TB is between about 5% and about 30% of the width of the table WS, or between about 5% and about 30% of the diameter of the table D, or between about 10% and about 40% of the first lateral L1 or second lateral L2 of the table, or between about 1% and about 20% of the table height H1. While the widths, heights, and depths of the packaging 316 and the table assembly 100 are specifically referred to in the figures, the dimensions may be re-organized, such that the width, height, and/or depth comprise different dimensions than those shown in the Figures. Further, it will be appreciated that where the tabletop 104 is differently sized and shaped, such as, e.g., oblong or rectangular or irregular, the relationship among the diameter D of the tabletop 104 and the dimensions of the support frame 108 may differ from those above. For example, when the tabletop 104 is oblong, the diameter D may represent the maximum dimension thereof, and the first and second lateral distances L1 and L2 may be substantially different from one another, such that the first lateral distance L1 comprises a greater percentage of the diameter D than a percentage comprised by the second lateral distance L1, or vice versa.

In some embodiments, a method of shipping and assembling the kit, including the table assembly 100, includes providing the packaging container 316 that has a profile with the first packaging dimension WB, the second packaging dimension LB, and the third packaging dimension TB. Further, the method includes inserting into the packaging container 316 the kit comprising the support frame 108 of the table assembly 100 in the disassembled configuration (see FIG. 13-16). Accordingly, the mid-section 124 of the support frame 108 includes the plurality of legs 116, 120, which define the length that is substantially equal to the mid-section height H3. With the table assembly 100 in the shipping configuration, the length of the plurality of legs 116, 120 is greater than each of the first shipping dimension WS, the second shipping dimension LS, and the third shipping dimension TS. Further, the length of the plurality of legs 116, 120 is greater than each of the first packaging dimension WB, the second packaging dimension LB, and the third packaging dimension TB. It will be appreciated that the kit further comprises the tabletop 104, the plurality of feet 144, the plurality of tools 304, and the plurality of fasteners 224 packaged inside of the packaging container 316. Accordingly, the plurality of legs 116, 120 of the mid-section 124 are configured to be disposed diagonally when the table assembly 100 is inserted into a packaging container 316 in the shipping configuration. Further, the upper cross-frame 112 and the lower cross-frame 132 are configured to be collapsed such that the angle A and the angle B, respectively, are reduced to between about 3% and about 10% of the angle A and angle B in the expanded configuration (see FIGS. 2 and 3).

In general, a method of shipping and assembling the kit of the present disclosure includes providing the packaging 316 with a profile that has the first packaging dimension WB, the second packaging dimension LB, and a third packaging dimension TB. Further, the method may comprise inserting into the package 316 the kit comprising the furniture assembly 100 that includes the support frame 108. The support frame can comprise the plurality of legs 116, 120 and the base 128. Further, the plurality of legs 116, 120 of the support frame 108 may define the mid-section height H3. The furniture assembly 100, when in the shipping configuration, has the first shipping dimension WS, the second shipping dimension LS, and a third shipping dimension TS. The mid-section height H3 of the plurality of legs 116, 120 may be greater than each of the of the first shipping dimension WS, the second shipping dimension LS, and the third shipping dimension TS. In addition, the mid-section height H3 of the plurality of legs 116, 120 can be greater than each of the first packaging dimension WB, the second packaging dimension LB, and the third packaging dimension TB.

By designing a kit including the various disassembled components described herein and the new packaging 316 for retaining those components, a table assembly that can be set up on site quickly and with relatively simple assembly, with a reduced shipping and storage profile, and with reduced shipping costs is provided.

It will be appreciated by those skilled in the art that while the invention has been described above in connection with particular embodiments and examples, the invention is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications and departures from the embodiments, examples and uses are intended to be encompassed by the present disclosure and claims. The entire disclosure of each patent and publication cited herein is incorporated by reference, as if each such patent or publication were individually incorporated by reference herein.

Claims

1. A furniture assembly, comprising:

a top portion; and

a support frame including a mid-section and a base,

wherein the support frame comprises at least one cross-member that is configured to be rotated about a swivel joint between a collapsed configuration and an expanded configuration,

wherein the mid-section is configured to be connected between the top portion and the base,

wherein a foot includes a tip end that is connected to a foot end by a threaded rod, the tip end being configured to be threaded onto a leg of the mid-section, and

wherein the base is configured to be disposed between the mid-section and the foot end of the foot.

2. The furniture assembly of claim 1, wherein the foot end is configured to be adjustable relative to the base.

3. The furniture assembly of claim 2, wherein the threaded rod is configured to receive an adjustment nut that is configured to set a position of the foot end relative to the base.

4. The furniture assembly of claim 2, wherein the threaded rod is at least partially concealed within a hollow post of the base.

5. The furniture assembly of claim 1, wherein the leg of the mid-section has a crimped section that is configured to be received within the base, and wherein the tip end of the threaded rod is configured to be received within the leg.

6. The furniture assembly of claim 1, wherein the foot comprises a plurality of feet that are each adjustable relative to the base independently of one another.

7. The furniture assembly of claim 6, wherein the leg of the mid-section includes at least one extended leg and at least one shortened leg, and wherein at least one of the plurality of feet is configured to be received by the at least one extended leg and at least of the plurality of feet is configured to be received by the at least one shortened leg.

8. A support frame for a furniture assembly, comprising:

a mid-section that includes a first set of legs and a second set of legs; and

a base that is configured to be attached to the mid-section,

wherein the base includes a first set of posts and a second set of posts,

wherein a foot includes a tip end that is connected to a foot end by a threaded rod, the tip end being configured to be threaded onto a leg of the mid-section, and the foot end being adjustable relative to the base,

wherein the first set of legs is configured to be received by the first set of posts and the second set of legs is configured to be received by the second set of posts, and

wherein the support frame has a support height and the mid-section comprises greater than 50% of the support height.

9. The support frame of claim 8, wherein the support height of the support frame comprises greater than 80% of a furniture height of the furniture assembly.

10. The support frame of claim 8, wherein the first set of legs and the second set of legs of the mid-section are configured to be disposed diagonally when the furniture assembly is inserted into a packaging container in a shipping configuration.

11. The support frame of claim 8, wherein the mid-section includes a first cross-frame that has a first swivel joint to allow for rotation thereabout and a locking feature that is configured to secure the first cross-frame in an expanded configuration.

12. The support frame of claim 11, wherein the locking feature includes an upper collar, a lower collar, and a pin that is configured to be received within at least one of the upper collar and the lower collar when the first cross-frame is in a collapsed configuration.

13. The support frame of claim 12, wherein the pin is configured to be received within the upper collar and the lower collar when the first cross-frame is in the expanded configuration.

14. The support frame of claim 11, wherein the base includes a second cross-frame that includes a top cross-member and a bottom cross-member that are rotatably coupled to one another by a second swivel joint, and wherein the first set of posts are configured to be rotated about the second swivel joint by connection with the top cross-member and the second set of posts are configured to be rotated about the second swivel joint by connection with the bottom cross-member.

15. The support frame of claim 11, wherein the first cross-frame includes a first set of spacers that are attached to an upper cross-member and a second set of spacers that are attached to a lower cross-member, the first set of spacers having a magnetic pad attached thereto.

16. A method of shipping and assembling a kit, the method comprising:

providing a package that has a profile that has a first packaging dimension, a second packaging dimension, and a third packaging dimension; and

inserting into the package the kit comprising a furniture assembly that includes a support frame, wherein the support frame comprises a plurality of legs and a base,

wherein the plurality of legs of the support frame defines a height,

wherein the furniture assembly, when in a shipping configuration, defines a first shipping dimension, a second shipping dimension, and a third shipping dimension,

wherein the height of the plurality of legs is greater than each of the of the first shipping dimension, the second shipping dimension, and the third shipping dimension, and

wherein the height of the plurality of legs is greater than each of the first packaging dimension, the second packaging dimension, and the third packaging dimension.

17. The method of shipping and assembling the kit of claim 16, wherein the kit further comprises a top portion, a plurality of feet, a plurality of tools, and a plurality of fasteners.

18. The method of shipping and assembling the kit of claim 17, wherein the support frame comprises at least one cross-member that is configured to be rotated about a swivel joint between a collapsed configuration and an expanded configuration.

19. The method of shipping and assembling the kit of claim 18, wherein the at least one cross-member has a locking feature that is configured to secure at least one cross-frame in the expanded configuration.

20. The method of shipping and assembling the kit of claim 17, wherein the top portion is configured to be removably attached to the support frame.