FIELD OF THE DISCLOSURE
This disclosure relates generally to furniture, and, more particularly, to a pivoting hinge for use with a convertible sofa that does not require tools for assembly.
BACKGROUND
There has been a growing trend for large furniture items, such as sofas (or couches), to be shipped to an end-user in a disassembled state to minimize shipping volume. Often, tools (such as screwdrivers, Allen wrenches, or mallets) are required to assemble the components of the sofa. However, the requirement to use tools typically inconveniences the end-user. For example, the end-user may not have the necessary tools, or the fastening members (such as screws) may be small and difficult to insert or tighten. In the past, manufacturers have provided tools with the fastening members, but such provided tools (such as an Allen wrench or a stamped, open-ended wrench) increase costs, may be difficult to handle, and may be lost in transit or by the end-user among the packaging materials. In addition, the tools (or one or more of the fastening members) may be accidentally omitted from the product packaging, thereby frustrating the end-user and requiring customer service support to coordinate the shipment of replacement parts to the end user. Consequently, it would be desirable to provide no-tool assembly sofas that, as the name suggests, allows the end-user to assemble the sofa without the use of tools. In the past, however, sofas assembled without tools lack the ability to convert from a sitting position to a sleeping position. Accordingly, there is a need for a hinge component for a convertible sofa that can be assembled by an end-user without the use of tools, while allowing for the conversion of the sofa from a sleeping position to one or more seating positions.
BRIEF SUMMARY OF THE DISCLOSURE
A hinge assembly includes a linkage base that is adapted to be secured to a portion of a furniture sidewall. The hinge assembly also includes an elongate first linkage arm and an elongate second linkage arm. The hinge assembly may also include an insert member assembly that includes an elongate first insert member, an elongate second insert member, and a pivot assembly disposed adjacent to a second end of the first insert member and a second end of the second insert member such that the pivot assembly pivotably couples the first insert member to the second insert member. The insert member assembly may also include an insert linkage arm that is coupled to the first insert member. A first end of the first linkage arm is pivotably coupled to a first portion of the linkage base and a second end of the first linkage arm is pivotably coupled to a first portion of the insert linkage arm. In addition, a first end of the second linkage arm is pivotably coupled to a second portion of the linkage base and a second end of the second linkage arm is pivotably coupled to a second portion of the insert linkage arm. The first insert member of the hinge assembly may be releasably coupled to a first rear receiving member secured to a first furniture portion and the second insert member of the hinge assembly may be releasably coupled to a first front receiving member secured to a second furniture portion. A second hinge assembly, that may be a minor image of (but otherwise identical to) the hinge assembly, may be secured to a second furniture sidewall such that a first insert member of the second hinge assembly may be releasably coupled to a second rear receiving member secured to the first furniture portion and a second insert member of the second hinge assembly may be releasably coupled to a second front receiving member secured to the second furniture portion.
So assembled, the first furniture portion may be secured to the first hinge assembly and the second hinge assembly and the second furniture portion may be secured to the first hinge assembly and the second hinge assembly such that the first furniture portion is pivotable relative to the second furniture portion about a pivot axis of the pivot assembly. Configured as described, the first and second hinge assemblies may provide for a convertible sofa that is assembled without tools, the first and second convertible hinge assemblies having a first position in which the first furniture portion and the second furniture portion are substantially aligned in the same plane to form a sleeping position and a second position in which the first furniture portion and the second furniture portion are disposed at a right (or an obtuse) angle to form a seating position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a front plan view of an embodiment of an insert member assembly coupled to a linkage base of a hinge assembly, with the linkage base mounted to a furniture sidewall;
FIG. 1B is a top view of the embodiment of the hinge assembly illustrated in FIG. 1A;
FIG. 2 is a front plan view of a linkage base of the embodiment of the hinge assembly illustrated in FIG. 1A;
FIG. 3 is a front plan view of a coil spring of the embodiment of the hinge assembly illustrated in FIG. 1A;
FIG. 4A is a front plan view of a first linkage arm of the embodiment of the hinge assembly illustrated in FIG. 1A;
FIG. 4B is a side view of the first linkage arm illustrated in FIG. 4A;
FIG. 5 is a front plan view of an insert member assembly of the embodiment of the hinge assembly illustrated in FIG. 1A;
FIG. 6 is a rear plan view of the first insert member of the insert member assembly illustrated in FIG. 5;
FIG. 7 is a front plan view of the second insert member of the insert member assembly illustrated in FIG. 5;
FIG. 8A is a front plan view of a second linkage arm of the embodiment of the hinge assembly illustrated in FIG. 1A;
FIG. 8B is a side view of the second linkage arm illustrated in FIG. 4A;
FIG. 9 is a front plan view of a first rear receiver member;
FIG. 10A is an isometric view of the first rear receiver member illustrated in FIG. 9;
FIG. 10B is a partial cross-sectional side view taken along the longitudinal axis of the first rear receiver member illustrated in FIG. 9;
FIG. 11A is a partial cross-sectional side view of the first insert member partially inserted into the first rear receiver member illustrated in FIG. 9;
FIG. 11B is a partial cross-sectional side view of the first insert member completely inserted into the first rear receiver member illustrated in FIG. 9;
FIG. 12 is a front plan view of the embodiment of the hinge assembly illustrated in FIG. 1A in a second position;
FIG. 13 is a front plan view of a furniture sidewall and the embodiment of the hinge assembly illustrated in FIG. 1A with a first furniture portion and a second furniture portion aligned with the first insert member and the second insert member, respectively;
FIG. 14 is an isometric view of the first furniture portion and the second furniture portion aligned with the first insert member and the second insert member, respectively, with the second furniture sidewall omitted for clarity;
FIG. 15 is a partial isometric view of a second furniture sidewall and a second hinge assembly with the first furniture portion and the second furniture portion aligned with the first insert member and the second insert member, respectively;
FIG. 16 is an isometric view of a convertible sofa in a sleeping position;
FIG. 17 is an isometric view of the convertible sofa of FIG. 16 in a seating position; and
FIG. 18 is a partial rear plan view of the first insert member of the insert member assembly illustrated in FIG. 5 that is coupled to the first linkage arm and the second linkage arm.
DETAILED DESCRIPTION
As illustrated in FIG. 1A, a hinge assembly 10a is adapted to be coupled to a furniture sidewall 12a, and the hinge assembly 10a includes a linkage base 14 adapted to be secured to a portion of the furniture sidewall 12a. The hinge assembly 10a also includes an elongate first linkage arm 16 having a first end 18 and a second end 20 opposite the first end 18 and an elongate second linkage arm 22 having a first end 24 and a second end 26 opposite the first end 24. The hinge assembly 10a additionally includes an insert member assembly 27 including an elongate first insert member 28 having a first end 30 and a second end 32 opposite the first end 30 and an elongate second insert member 34 having a first end 36 and a second end 38 opposite the first end 36. The insert member assembly 27 also includes a pivot assembly 40 disposed adjacent to the second end 32 of the first insert member 28 and the second end 38 of the second insert member 34 such that the pivot assembly 40 pivotably couples the first insert member 28 to the second insert member 34. As illustrated in FIGS. 1B, 6, and 18, the insert member assembly 27 further includes an insert linkage arm 41 having a first end 43 and a second end 45 opposite the first end 43, and the insert linkage arm 41 is coupled to the first insert member 28. Referring to FIGS. 1A and 1B, the first end 18 of the first linkage arm 16 is pivotably coupled to a first portion of the linkage base 14 and the second end 20 of the first linkage arm 16 is pivotably coupled to a first portion of the insert linkage arm 41. In addition, the first end 24 of the second linkage arm 22 is pivotably coupled to a second portion of the linkage base 14 and the second end 26 of the second linkage arm 22 is pivotably coupled to a second portion of the insert linkage arm 41.
Referring to FIG. 14, the first insert member 28 of the hinge assembly 10a may be releasably coupled to a first rear receiving member 42a secured to a first furniture portion 44 and the second insert member 34 of the hinge assembly 10a may be releasably coupled to a first front receiving member 46a secured to a second furniture portion 48. As illustrated in FIG. 15, a second hinge assembly 10b, that is a mirror image of (but otherwise identical to) the first hinge assembly 10a, may be secured to a second furniture sidewall 12b such that a first insert member 28 of the second hinge assembly 10b may be releasably coupled to a second rear receiving member 42b secured to the first furniture portion 44 and a second insert member 34 of the second hinge assembly 10b may be releasably coupled to a second front receiving member 46b secured to the second furniture portion 48.
So assembled, the first furniture portion 44 (which may be a seat back portion of a convertible sofa) may be secured to the first hinge assembly 10a (which may be non-releasably secured to the furniture sidewall 12a, such as a lateral arm of a convertible sofa) and the second hinge assembly 10b (which may be non-releasably secured to the second furniture sidewall 12b, such as a second lateral arm of a convertible sofa) and the second furniture portion 48 (which may be a seat bottom portion of a convertible sofa) may be secured to the first hinge assembly 10a and the second hinge assembly 10b such that the first furniture portion 44 is pivotable relative to the second furniture portion 48 about a pivot axis of the pivot assembly 40, as illustrated in FIG. 17. Configured as described, the first and second hinge assemblies 10a, 10b may provide for a convertible sofa that is assembled without tools, the first and second convertible hinge assemblies 10a, 10b having a first position 50 (illustrated in FIGS. 1A and 16) in which the first furniture portion 44 and the second furniture portion 48 are substantially aligned in the same plane to form a sleeping position and a second position 52 (illustrated in FIGS. 11 and 17) in which the first furniture portion 44 and the second furniture portion 48 are disposed at a right (or an obtuse) angle to form a seating position. Such a convertible sofa has a minimal amount of parts to be assembled. In addition, the convertible sofa requires no fastening members (such as screws) that could make assembly difficult for the end-user or that could inconvenience the end-user by being lost or misplaced.
Turning the hinge assembly 10a in more detail, the hinge assembly 10a may include the linkage base 14 that may be fixedly secured to the first furniture sidewall 12a, as illustrated in FIGS. 1A and 2. The linkage base 14 may have any suitable shape or combinations of shapes. For example, the linkage base 14 may have an elongated, slightly arcuate shape having a first end 54, a second end 56 opposite the first end 54, and an intermediate portion 58 disposed between the first end 54 and the second end 56. The linkage base 14 may be planar or substantially planar, and the linkage base 14 may have a first surface 60 adapted to be adjacent to or in contact with an inner surface of the first furniture sidewall 12a. A second surface 62 may be opposite the first surface 60. The linkage base 14 may also have an attachment feature 70 adapted to secure a first end 72 of a coil spring 74 (illustrated in FIGS. 1A and 3). For example, the attachment feature 70 may be a planar flange portion 76 disposed at or adjacent to a top portion of the first end 54 of the linkage base 14, and the flange portion 76 may have an aperture adapted to receive a portion of the first end 72 of the coil spring 74.
While the example linkage base 14 is illustrated as being a single, unitary part, the linkage base 14 may instead be an assembly of two or more component parts, and any or all of the two or more component parts may be secured to the first furniture sidewall 12a such that the component parts are not in mutual contact. That is, a first component part of the linkage base 14 may include the second portion of the linkage base 14 (e.g., the second end 56), and this first component part may be spaced from a second component part of the linkage base 14 that may include the first portion of the linkage base 14 (e.g., intermediate portion 58).
As illustrated in FIG. 2, one or more apertures 66 or slots may be formed in the linkage base 14 to receive screws or rivets that secure the linkage base 14 to the first furniture sidewall 12a in a manner that is known in the art. Instead of using screws of rivets, the linkage base 14 may be secured to the first furniture sidewall 12a in any manner known in the art. The linkage base 14 may be secured to the first furniture sidewall 12a at the manufacturing facility or at any time prior to shipping the unassembled product to a retail outlet or to an end-user.
Referring to FIGS. 1A, 1B, 4A, and 4B, the hinge assembly 10a may include the first linkage arm 16. The first linkage arm 16 may be elongated and may extend along a longitudinal axis 78 such that the first linkage arm 16 includes the first end 18 and a second end 20 longitudinally opposite the first end 18. The first end 18 of the first linkage arm 16 may be pivotably coupled to a first portion of the linkage base 14. For example, the first end 18 may be pivotably coupled to the intermediate portion 58 of the linkage base 14. The first end 18 may be pivotably coupled to the first portion of the linkage base 14 in any manner known in the art. For example, a pin 80 may be disposed through corresponding apertures formed at or adjacent to the first end 18 of the first linkage arm 16 and at or adjacent to the intermediate portion 58 of the linkage base 14. The first end 18 may be pivotably coupled to the first portion of the linkage base 14 at the manufacturing facility or at any time prior to shipping the unassembled product to a retail outlet or to an end-user. The second end 20 of the first linkage arm 16 may be pivotably coupled to the first portion of the insert linkage arm 41 of the insert member assembly 27 in a manner that will be described in more detail below.
The first linkage arm 16 may be planar or substantially planar or may have one or more portions that are mutually non-planar. For example, an oblique, planar transition portion 82 may be disposed between the first end 18 and the second end 20, and a portion of the first linkage arm 16 between the transition portion 82 and the first end 18 may be planar and a portion of the first linkage arm 16 between the transition portion 82 and the second end 20 may be planar, as illustrated in FIG. 4B. An engagement feature 84 may be disposed on the first linkage arm 16 at any suitable location, and the engagement feature 84 may be adapted to secure a second end 86 of a coil spring 74 (illustrated in FIG. 3). For example, the engagement feature 84 may be an aperture 87 disposed on a protrusion 88 formed on the first linkage arm 16 between the first end 18 and the transition portion 82, and the aperture 87 may be adapted to receive a portion of the second end 86 of the coil spring 74. A longitudinally-extending groove 90 may be formed in the first linkage arm 16 to provide resistance against bending or other structural deformation.
Referring to FIGS. 1A, 1B, 8A, and 8B, the hinge assembly 10a may include the second linkage arm 22. The second linkage arm 22 may be elongated and may include a first portion 92 and a second portion 94 that are disposed at an oblique angle when viewed along a vertical axis (i.e., an axis parallel to the Z-axis of the reference coordinate system provided in FIGS. 1A and 1B). The second linkage arm 22 may include the first end 24 and the second end 26 longitudinally opposite the first end 24. The first end 24 of the second linkage arm 22 may be pivotably coupled to the second portion of the linkage base 14 (e.g., the second end 56 of the linkage base 14). The first end 24 may be pivotably coupled to the second portion of the linkage base 14 in the same manner in which the first end 18 is pivotably coupled to the first portion of the linkage base 14. The first end 24 may be pivotably coupled to the second portion of the linkage base 14 at the manufacturing facility or at any time prior to shipping the unassembled product to a retail outlet or to an end-user. The second end 26 of the second linkage arm 22 may be pivotably coupled to the second portion of the insert linkage arm 41 of the insert member assembly 27 in a manner that will be described in more detail below. As illustrated in FIGS. 8A and 8B, the second linkage arm 22 may be planar or substantially planar or may have one or more portions that are mutually non-planar. For example, an oblique, planar transition portion 96 may be disposed between the first end 24 and the second end 26. A portion of the second linkage arm 22 between the transition portion 96 and the first end 24 may be planar and a portion of the second linkage arm 22 between the transition portion 96 and the second end 26 may be planar. A longitudinally-extending groove 98 may be formed in the second linkage arm 22 to provide resistance against bending or other structural deformation.
Referring to FIGS. 1A, 1B, and 5, the hinge assembly 10a may include the insert member assembly 27, and the insert member assembly 27 may include the first insert member 28, the second insert member 34, the pivot assembly 40, and the insert linkage arm 41. As illustrated in FIGS. 5 and 6, the first insert member 28 may be elongate and may extend along a longitudinal axis 100 such that the first insert member 28 includes the first end 30 and the second end 32 longitudinally opposite the first end 30. The first insert member 28 may be planar and may be defined by a first lateral edge 102 and a second lateral edge 104 that each extend from the first end 30 to the second end 32, and the first lateral edge 102 and the second lateral edge 104 may each converge towards the longitudinal axis 100 as the first lateral edge 102 and the second lateral edge 104 each extends from the second end 32 towards the first end 30 of the first insert member 28. The first lateral edge 102 and the second lateral edge 104 may be linear or substantially linear, or the first lateral edge 102 and the second lateral edge 104 may be curved relative to the longitudinal axis 100. The first lateral edge 102 and the second lateral edge 104 may be symmetrical or substantially symmetrical about the longitudinal axis 100. However, the first lateral edge 102 and the second lateral edge 104 (or portions of one or both of the first lateral edge 102 and the second lateral edge 104) may be asymmetrical about the longitudinal axis 100.
Referring to FIG. 5, the first insert member 28 may also include a nose portion 106 disposed at or adjacent to the first end 30 of the first insert member 28. The nose portion 106 may be at least partially defined by a nose edge 108 that extends between the first lateral edge 102 and the second lateral edge 104, and the nose edge 108 may be rounded or contoured. The first insert member 28 may be further defined by a transverse edge 110 that upwardly extends from the second lateral edge 104 at or adjacent to the second end 32 towards the pivot assembly 40 secured to the second end 32 of first insert member 28. As explained above, the first insert member 28 may be planar and may have a first surface 112 (illustrated in FIG. 5) facing away from the first furniture sidewall 12a and a second surface 114 (illustrated in FIG. 6) facing towards the first furniture sidewall 12a. The first insert member 28 may include a locking aperture 116, and the locking aperture 116 may have any suitable shape or location to receive a portion of corresponding locking tab 118 of the first rear receiving member 42a (illustrated in FIG. 9) to removably secure the first insert member 28 within the first rear receiving member 42a in a manner that will be described in more detail below. For example, the locking aperture 116 may be disposed between the first end 30 and the second end 32 of the first insert member 28, and the locking aperture 116 may have a square (or rectangular) shape that is symmetrically formed about the longitudinal axis 100.
Referring to FIGS. 1A, 1B, 5, and 7, the insert member assembly 27 of the hinge assembly 10a may include the second insert member 34, and the second insert member 34 may be substantially similar or identical to the first insert member 34. However, the second insert member 34 may have one or more dimensions that are smaller than the first insert member 34. The second insert member 34 may be elongate and may extend along a longitudinal axis 120 such that the second insert member 34 includes the first end 36 and the second end 38 longitudinally opposite the first end 36. The second insert member 34 may be planar and may be defined by a first lateral edge 122 and a second lateral edge 124 that extend from the first end 36 to the second end 38, and the first lateral edge 122 and the second lateral edge 124 may each converge towards the longitudinal axis 120 as the first lateral edge 122 and the second lateral edge 124 each extends from the second end 38 towards the first end 36 of the second insert member 34. The first lateral edge 122 and the second lateral edge 124 may be linear or substantially linear, or the first lateral edge 122 and the second lateral edge 124 may be curved relative to the longitudinal axis 120. The first lateral edge 122 and the second lateral edge 124 may be symmetrical or substantially symmetrical about the longitudinal axis 120. However, the first lateral edge 122 and the second lateral edge 124 (or portions of one or both of the first lateral edge 122 and the second lateral edge 124) may be asymmetrical about the longitudinal axis 120.
The second insert member 34 may also include a nose portion 126 disposed at or adjacent to the first end 36 of the second insert member 34. The nose portion 126 may be at least partially defined by a nose edge 128 that extends between the first lateral edge 122 and the second lateral edge 124, and the nose edge 128 may be rounded or contoured. The second insert member 34 may be further defined by a transverse edge 130 that upwardly extends from the second lateral edge 124 at or adjacent to the second end 38 towards the hinge portion 40 secured to the second end 38 of second insert member 34. As explained above, the second insert member 34 may be planar and may have a first surface 132 facing away from the first furniture sidewall 12a and a second surface 134 facing towards the first furniture sidewall 12a. The second insert member 34 may include a locking aperture 136 that may be identical in function to the locking aperture 116 previously described. The locking aperture 136 may be disposed between the first end 36 and the second end 38 of the second insert member 34, and the locking aperture 136 may have a square (or rectangular) shape that is symmetrically formed about the longitudinal axis 120.
Referring to FIGS. 1A, 1B, 5, and 6, the insert member assembly 27 of the hinge assembly 10a may also include the pivot assembly 40. The pivot assembly 40 may include any structure or combination of structures that allows the first insert member 28 to pivot relative to the second insert member 34 about a pivot axis 137 that is vertical (i.e., disposed parallel to the Z-axis of the reference coordinate system provided in FIGS. 1A and 1B). For example, the pivot assembly 40 may include a planar first end plate 138 and a planar second end plate 140 vertically offset from the first end plate 138, and a bottom wall 142 may extend between a bottom portion of the first end plate 138 and a bottom portion of the second end plate 140. The portion of the bottom wall 142 adjacent to the first end plate 138 may be secured to a top portion of the second end 32 of the first insert member 28 by any means known in the art, such as welding or mechanical fastening. So secured, a rear portion of each of the first end plate 138 and the second end plate 140 may extend beyond the transverse edge 110 of the first insert member 28.
As illustrated in FIGS. 1B and 7, the pivot assembly 40 may also include a planar third end plate 144 and a planar fourth end plate 146 offset from the third end plate 144, and a bottom wall 148 may extend between a bottom portion of the third end plate 144 and a bottom portion of the fourth end plate 146. The portion of the bottom wall 148 adjacent to the third end plate 138 may be secured to a top portion of the second end 38 of the second insert member 34 by any means known in the art, such as welding or mechanical fastening. So secured, a rear portion of each of the third end plate 144 and the fourth end plate 146 may extend beyond the transverse edge 130 of the second insert member 34. The vertical distance between the outer surfaces of the third end plate 144 and the fourth end plate 146 of the second insert member 34 may be slightly smaller than the vertical distance between the inner surfaces of the first end plate 138 and the second end plate 140 of the first insert member 28 such that the third end plate 144 and the fourth end plate 146 are disposed between the first end plate 138 and the second end plate 140. So disposed, each of the first, second, third, and fourth end plates 138, 140, 144, 146 may have an aperture (not shown) disposed therethrough, and the apertures may be coaxially aligned along the pivot axis 137. A pin 149 (such as a rivet) may be disposed through the apertures such that the first insert member 28 and the second insert member 34 may each rotate about the pivot axis 137 that is coaxially aligned with a longitudinal axis of the pin 149. Accordingly, the first insert member 28 may be pivotably coupled to the second insert member 34. A locking mechanism (shown generally as 147 in FIG. 1B) may be disposed between the third end plate 144 and the fourth end plate 146, and the locking mechanism 147 may allow the first insert member 28 and the second insert member 34 to be selectively locked in one or more desired positions (such as a first position 50 and/or a second position 52 illustrated in FIGS. 1A and 12, respectively) that will be described in more detail below.
Referring to FIGS. 1B, 6, and 18, the insert member assembly 27 of the hinge assembly 10a may also include the insert linkage arm 41 that may be coupled to the first insert member 28. The insert linkage arm 41 may be elongated and may extend parallel to the longitudinal axis 100 of the first insert member 28 such that the insert linkage arm 41 includes the first end 43 and the second end 45 longitudinally opposite the first end 43. The insert linkage arm 41 may be planar and may be vertically offset from the second surface 114 of the first insert member 28. The insert linkage arm 41 may be defined by a bottom lateral edge 150 that may be aligned with the second lateral edge 104 of the first insert member 28 (when viewed along a vertical axis). The insert linkage arm 41 may be further defined by a top lateral edge 151 that may be disposed adjacent to the longitudinal axis 100 when viewed along a vertical axis, and the top lateral edge 151 may be irregularly curved or otherwise contoured. The insert linkage arm 41 may also have a back edge 152 that is substantially aligned with the transverse edge 142 of the first insert member 28 when viewed along a vertical axis. A forward edge 154 may extend between the top lateral edge 151 and the bottom lateral edge 150, and the forward edge 154 may be disposed between (e.g., a midpoint between) the first end 30 and the second end 32 of the first insert member 28 when viewed along a vertical axis. A top portion of the insert linkage arm 41 adjacent to the second end 45 may be secured to the pivot assembly 40 that is itself secured to the first insert member 28 by the pin 149. The top portion of the insert linkage arm 41 adjacent to the second end 45 may be secured to the pivot assembly 40 by any means known in the art. For example, the top portion of the insert linkage arm 41 adjacent to the second end 45 may be welded or mechanically fastened to a bottom portion of the second plate 140 and/or to a portion of the bottom wall 142 of the pivot assembly 40. So secured, a gap may exist between an inner surface 145 (i.e., a surface facing the second surface 114 of the first insert member 28) and the second surface 114 of the first insert member 28, as illustrated in FIG. 1B.
Referring to FIGS. 1B and 18, the second end 20 of the first linkage arm 16 may be pivotably coupled to a first portion of the insert linkage arm 41 and the second end 26 of the second linkage arm 22 may be pivotably coupled to a second portion of the insert linkage arm 41. For example, the second end 20 of the first linkage arm 16 may be pivotably coupled to the insert linkage arm 41 adjacent to the second end 45 of the insert linkage arm 41 and the second end 26 of the second linkage arm 22 may be pivotably coupled to the insert linkage arm 41 adjacent to the first end 43 of the insert linkage arm 41. The second ends 20, 26 of each of the first and second linkage arms 16, 22 may be pivotably coupled to the insert linkage arm 41 in any manner known in the art. For example, a pin 133 may be disposed through corresponding apertures 139a, 139b (illustrated in FIG. 6) formed through the first portion and second portion of the insert linkage arm 41 such that each of the first linkage arm 16 and the second linkage arm 22 is pivotable about a corresponding pin 133. The second ends 20, 26 of each of the first and second linkage arms 16, 22 may be pivotably coupled to the insert linkage arm 41 at the manufacturing facility or at any time prior to shipping the unassembled product to a retail outlet or to an end-user.
Referring to FIGS. 9, 10A, 13, and 14, the hinge assembly 10a may include a first rear receiving member 42a secured to the first furniture portion 44 (which may be a seat back portion of a convertible sofa), and the first rear receiving member 42a may be adapted to receive a portion of the first insert member 28 to releasably secure the first insert member 28 to the first rear receiving member 42a, as illustrated in FIGS. 13 and 14. The first rear receiving member 42a may be disposed on a first lateral member 156 at or adjacent to a first end 158 of the first lateral member 156. Referring to FIGS. 9 and 10A, the first rear receiving member 42a may be elongated and may extend along a longitudinal axis 160 such that the first rear receiving member 42a includes a first end 162 and a second end 164 longitudinally opposite the first end 162. The longitudinal axis 160 may be aligned with a longitudinal axis of the first lateral member 156 of the first furniture portion 44, and the first end 162 of the first rear receiving member 42a may be at or adjacent to the first end 158 of the first lateral member 156.
Still referring to FIGS. 9 and 10A, the first rear receiving member 42a may include a base 166 that is secured to the first lateral member 156 by any manner known in the art, such as welding or mechanical fastening. The base 166 may be planar and may be defined by a first lateral edge 174 and a second lateral edge 176 that extend from the first end 162 to the second end 164, and the first lateral edge 174 and the second lateral edge 176 may each converge towards the longitudinal axis 160 as the first lateral edge 174 and the second lateral edge 176 each extends from the first end 162 towards the second end 164. The first lateral edge 174 and the second lateral edge 176 may be linear or substantially linear, or the first lateral edge 174 and the second lateral edge 176 may be curved relative to the longitudinal axis 160. The first lateral edge 174 and the second lateral edge 176 may be symmetrical or substantially symmetrical about the longitudinal axis 160. However, the first lateral edge 174 and the second lateral edge 176 (or portions of one or both of the first lateral edge 174 and the second lateral edge 176) may be asymmetrical about the longitudinal axis 160.
A first lip portion 168 may inwardly extend from the first lateral edge 174 to form a first groove 170 between an inner surface of the first lip portion 168 and a top surface 172 of the base 166. A second lip portion 178 may inwardly extend from the second lateral edge 176 to form a second groove 180 between an inner surface of the second lip portion 178 and the top surface 172 of the base 166, and the first lip portion 168 and the second lip portion 178 may be symmetrically formed about the longitudinal axis 160. The first groove 170 may be adapted to receive a longitudinal portion of the first insert member 28 adjacent to (and along) the first lateral edge 102 and the second groove 180 may be adapted to receive a longitudinal portion of the first insert member 28 adjacent to (and along) the second lateral edge 104. With the first insert member 28 inserted into the first rear receiving member 42a (i.e., when the longitudinal axis 100 of the first insert member 28 is aligned with the longitudinal axis 160 of the first rear receiving member 42a and, as illustrated in FIG. 11B, a portion of the first surface 112 of the first insert member 28 is adjacent to or in contact with a portion of the top surface 172 of the base 160 of the first rear receiving member 42a, and when a portion of the locking tab 118 engages the locking aperture 116), an inward edge of the first lip portion 168 may be disposed closer to the longitudinal axis 100 of the first insert member 28 (when viewed along a vertical axis) than the first lateral edge 102 of the first insert member 28 and an inward edge of the second lip portion 178 may be disposed closer to the longitudinal axis 100 of the first insert member 28 (when viewed along a vertical axis) than the second lateral edge 104 of the first insert member 28. So configured, the first and second grooves 170, 180 act as a guide to ensure that a portion of the locking tab 118 properly engages the locking aperture 116 during coupling of the first insert member 28 and the first rear receiving member 42a. One having ordinary skill in the art would recognize that this configuration prevents the first insert member 28 from being vertically separated from the first rear receiving member 42a, but also allows for an end user to access the locking tab 118 to disengage the first insert member 28 form the first rear receiving member 42a in a manner that will be described in greater detail below.
As Illustrated in FIGS. 9, 10A, and 10B, the first rear receiving member 42a may include the locking tab 118. The locking tab 118 may be a one-piece assembly that may be coupled to the base 166 at or adjacent to the second end 164 of the first rear receiving member 42a. Referring to FIG. 10B, the locking tab 118 may include a spring portion 182 and an engagement portion 184 that is adapted to be aligned with the locking aperture 116 of the first insert member 28 when the first insert member 28 is inserted into the first rear receiving member 42a. Specifically, the spring portion 182 may be a cantilevered leaf spring that is offset from the top surface 172 of the base 166, and the engagement portion 184 may be feature at the terminal end of the spring portion 182. The engagement portion 184 may include an oblique transition portion 186 and a bottom portion 188 that may be planar or substantially planar. The bottom portion 188 may be dimensioned to be received into the locking aperture 116 of the first insert member 28. For example, if the locking aperture 116 has a length and a width dimension, the bottom portion 188 may have a length and a width dimension that is each slightly less than the corresponding length and width dimensions of the locking aperture 116. A second oblique transition portion 190 may extend from the bottom portion 188, and a release tab 192 may extend from the terminal end of the second oblique transition portion 190. The cantilevered spring portion 182 may bias the bottom portion 188 of the engagement portion 184 into contact with (or into a position immediately adjacent to) the top surface 172 of the base 166.
To insert the first insert member 28 into the first rear receiving member 42a, the longitudinal axis 100 of the first insert member 28 is aligned with the longitudinal axis 160 of the first rear receiving member 42a and a portion of the first surface 112 of the first insert member 28 is adjacent to or in contact with a portion of the top surface 172 of the base 160 of the first rear receiving member 42a. The nose portion 106 of the first insert member 28 is displaced towards the second end 164 of the first rear receiving member 42a until the nose edge 102 contacts the second oblique transition portion 190 adjacent to the bottom portion 188. Further longitudinal displacement of the first insert member 28 causes the engagement portion 184 to displace away from the top surface 172 such that the bottom portion 188 is biased into contact with the first surface 112 of the first insert member 28 upon further longitudinal displacement, as illustrated in FIG. 11A. When the first insert member 28 is displaced a predetermined distance into the first rear receiving member 42a (as illustrated in FIG. 11B), all or a portion of the bottom portion 188 of the engagement portion 184 may be received into the locking aperture 116 of the first insert member 28 due to the force exerted by the cantilevered spring portion 182, thus preventing further longitudinal displacement of the first insert member 28 towards the second end 164 of the first rear receiving member 42a. Accordingly, the first insert member 28 may be secured to the first lateral member 156 of the first furniture portion 44 by inserting the first insert member 28 into the first rear receiving member 42a and displacing the first insert member 28 a predetermined distance towards the second end 164 of the first rear receiving member 42a.
To disengage the first insert member 28 from the first rear receiving member 42a, the release tab 192 may be displaced away from the first insert member 28 such that the bottom portion 188 of the engagement portion 184 is no longer received into the locking aperture 116 of the first insert member 28. At the same time, the first insert member 28 may be longitudinally displaced away from the second end 164 of the first rear receiving member 42a until the first insert member 28 is completely removed from the first rear receiving member 42a.
As illustrated in FIG. 15, a second hinge assembly 10b, that is a minor image of (but otherwise identical to) the first hinge assembly 10a, may be secured to a second furniture sidewall 12b. Referring to FIGS. 14 and 15, the second hinge assembly 10b secured to the second furniture sidewall 12b may include a second rear receiving member 42b secured to a second lateral member 194 of the first furniture portion 44 at or adjacent to a first end 196 of the first lateral member 194. The second rear receiving member 42b may be identical or substantially identical to the first rear receiving member 42a, and the first insert member 28 of the second hinge assembly 10b may be engaged and disengaged from the second rear receiving member 42b in the same manner that the first insert member 28 of the first hinge assembly 10a is engaged and disengaged from the first rear receiving member 42a. Accordingly, the first furniture portion 44 (having a first rear receiving member 42a and a second rear receiving member 42b) may be releasably secured to the first insert member 28 of each of the first and second hinge assemblies 10a, 10b, respectively, to releasably and pivotably secure the first furniture portion 44 to the first furniture sidewall 12a and the second furniture sidewall 12b.
Referring to FIGS. 13 and 14, the first hinge assembly 10a secured to the first furniture sidewall 12a may include a first front receiving member 46a secured to the second furniture portion 48 (which may be a seat bottom portion of a convertible sofa), and the first front receiving member 46a may be adapted to receive a portion of the second insert member 34 to releasably secure the second insert member 34 to the first front receiving member 46a. The first front receiving member 46a may be disposed on a first lateral member 198 at or adjacent to a first end 200 of the first lateral member 198. The first front receiving member 46a may be identical or substantially identical to the first rear receiving member 42a, and the second insert member 34 of the first hinge assembly 10a may be engaged and disengaged from the first front receiving member 46a in the same manner that the first insert member 28 of the first hinge assembly 10a is engaged and disengaged from the first rear receiving member 42a. However, if the second insert member 34 has slight dimensional differences from the first insert member 28, one having ordinary skill in the art would recognize that the first front receiving member 46a may have corresponding dimensional differences to the first rear receiving member 42a to accommodate the second insert member 34.
Referring to FIGS. 14 and 15, the second hinge assembly 10b secured to the second furniture sidewall 12b may include a second front receiving member 46b secured to a second lateral member 202 of the second furniture portion 48 at or adjacent to a first end 204 of the second lateral member 202. The second front receiving member 46b may be identical or substantially identical to the first rear receiving member 42a (or the second front receiving member 46b may have slight dimensional differences from the first rear receiving member 42a, as discussed above), and the second insert member 34 of the second hinge assembly 10b may be engaged and disengaged from the second front receiving member 46b in the same manner that the first insert member 28 of the first hinge assembly 10a is engaged and disengaged from the first rear receiving member 42a. Accordingly, the second furniture portion 48 (having a first front receiving member 46a and a second front receiving member 46b) may be releasably secured to the second insert member 34 of each of the first and second hinge assemblies 10a, 10b, respectively, to releasably and pivotably secure the second furniture portion 48 to the first furniture sidewall 12a and the second furniture sidewall 12b.
The linkage base 14, first linkage arm 16, second linkage arm 22, first insert member 28, second insert member 34, pivot assembly 40, first and second rear receiving members 42a, 42b, and first and second front receiving members 46a, 46b may each be made from any suitable materials or combination of materials. For example, these components may be made from steel or a steel alloy that may be stamped and formed as appropriate.
As illustrated in FIGS. 1A, 14 and 15, with the first furniture sidewall 12a and the second furniture sidewall 12a mutually secured by one or more transverse members (not shown) that may be assembled by the end user without the use of tools, the first insert member 28 and the second insert member 34 may be initially positioned in a first position 50 (i.e., a position in which the longitudinal axis 100 the first insert member 28 is parallel to or collinear with the longitudinal axis 120 the second insert member 34). In this first position 50, the first furniture portion 44 (which may be a seat back portion of a convertible sofa) and the second furniture portion 48 (which may be a seat bottom portion of a convertible sofa) may be coupled to the first hinge assembly 10a and the second hinge assembly 10b as previously described. Instead of being parallel or collinear, the longitudinal axis 100 the first insert member 28 may form an angle within the range of 170° to 190° with the longitudinal axis 120 the second insert member 34. Subsequently, cushions 206 may be attached or secured to each of the first furniture portion 44 and the second furniture portion 48. So configured, the first furniture portion 44 and the second furniture portion 48 are in a first position (e.g., a sleeping position) are substantially aligned in the same plane to form a sleeping surface (i.e., a position in which the longitudinal axis 100 the first insert member 28 is parallel to or collinear with the longitudinal axis 120 the first insert member 28), as illustrated in FIG. 16.
The first furniture portion 44 and the second furniture portion 48 may be converted to a second position (e.g., a sitting position) in which the first furniture portion 44 and the second furniture portion 48 are disposed at a right (or an obtuse) angle to form a seating position, as illustrated in FIG. 17. Such a position corresponds to the second position 52 illustrated in FIG. 12, in which the longitudinal axis 100 of the first insert member 28 is obliquely disposed (or disposed at a right angle) relative to the longitudinal axis 120 of the second insert member 34. For example, the longitudinal axis 100 of the first insert member 28 may form an angle between 80° and 130° with the longitudinal axis 120 of the second insert member 34.
The locking mechanism of the pivot assembly 40 may allow for a third position in which the longitudinal axis 100 the first insert member 28 is disposed at an oblique, obtuse, or right angle relative to the longitudinal axis 120 of the second insert member 34 that is different than the angle of the second position 52. In fact, the locking mechanism of the pivot assembly 40 may allow for any number of positions in which the first insert member 28 is disposed at an oblique, obtuse, or right angle relative to the longitudinal axis 120 of the second insert member 34.
To move the first and second hinge assemblies 10a, 10b from the first position 50 to the second position 52, the second furniture portion 48 (illustrated in FIG. 16) may be rotated towards the first furniture portion 44 until the locking mechanism of the pivot assembly 40 is automatically engaged, thereby locking the first insert member 28 relative to the second insert member 34. While locked, the second furniture portion 48 may be downwardly rotated such that the first linkage arm 16 and the second linkage arm 22 of each of the first and second hinge assemblies 10a, 10b are pivoted about the first portion and the second portion, respectively, of the linkage base 14 (which is a counterclockwise rotation in FIG. 1A). The coil spring 74 secured to the linkage base 14 and the first linkage arm 16 opposes this rotation, and thereby provides assistance to the user when the process is reversed to convert the sofa from the second position 52 to the first position 50. The four-bar linkage provided by the insert linkage arm 41, the first linkage arm 16, the second linkage arm 22, and the linkage base 14 maintains the first insert member 28 and the second insert member 34 in a proper orientation when moving from the first position 50 to the second position 52 (and vice versa). Additionally, when in the second position 52, an intermediate portion of the second linkage arm 22 contacts the first linkage arm 16 at or adjacent to the second end 20 to prevent further counterclockwise rotational displacement of the first linkage arm 16 and the second linkage arm 22.
To move the first and second hinge assemblies 10a, 10b from the second position 52 (or the third position, fourth position, etc.) to the first position 50, the second furniture portion 48 may pulled towards the user and pivoted towards the first furniture portion 44 to unlock the locking mechanism and to pivot the first linkage arm 16 and the second linkage arm 22 in a clockwise direction. The second furniture portion 48 may then be rotated away from the first furniture portion 44 and into the sleeping position illustrated in FIG. 16.
Configured as described, one having ordinary skill in the art would recognize that the hinge assembly 10a, 10b may provide for a convertible sofa that is assembled by an end-user without tools, the hinge assemblies 10a, 10b of the convertible sofa having a first position 50 in which the first furniture portion 44 and the second furniture portion 48 are substantially aligned in the same plane to form a sleeping position and a second position 52 in which the first furniture portion 44 and the second furniture portion 48 are disposed at a right (or an obtuse) angle to form a seating position.
While various embodiments have been described above, this disclosure is not intended to be limited thereto. Variations can be made to the disclosed embodiments that are still within the scope of the appended claims. For example, while embodiments of a convertible sofa have been disclosed, one having ordinary skill in the art would recognize that the disclosed hinge assembly 10a, 10b may be used with any suitable type of furniture that may be assembled by an end-user without the use of tools.
Patent Grant
8713726
