READY TO ASSEMBLE MODULAR FURNITURE

Abstract

A ready to assemble modular article of furniture includes a plurality of panels adapted to be assembled without the use of tools. A plurality of fittings are adapted for securing the plurality of panels in assembled relationship, each of the fittings including a first component and a second component. At least a first one of the panels having a surface supporting at least one of the first components. At least a second one of the panels having a surface supporting at least one of the second components. The first and second panels are arrangeable in transverse relationship with the first and second components in alignment with each other, whereby manipulation of the first component without the use of tools causes the first component to engage the second component thereby securing the first and second panels together in transverse relationship.

Description

BACKGROUND OF THE INVENTION

Ready to assemble furniture has been known in the furniture industry for many years. This type of furniture construction provides a number of advantages to the manufacturer, to the retailer, and to the consumer. For example, as to the manufacturer, there are significant cost savings in manufacturing unassembled furniture over conventional fully assembled furniture. These cost savings promote the design of high quality products, which can be passed on to the retailer and ultimately to the consumer.

Ready to assemble furniture also requires less inventory storage space for both the manufacturer and the retailer. The retailer can thus increase his inventory of ready to assemble furniture without significantly increasing the amount of storage space available for the retailer's products. The consumer ultimately benefits from high quality furniture which is often more available as in stock products at the retailer. One will appreciate that there are many advantages to ready to assemble furniture.

Unlike conventional fully assembled furniture, ready to assemble furniture, as the name implies, requires assembly by the consumer. This furniture often requires the use of tools by the consumer to enable the manipulation of specialized fittings which lock the various components of the furniture together in assembled relationship. Not all consumers have the required tools or the necessary mechanical skill level to manipulate the locking elements into their proper locked position. The failure to do so often results in the furniture being unstable, and potentially collapsing during use. It would therefore be desirable to provide ready to assemble furniture which can be assembled without the need for tools in a simple and efficient manner, while ensuring the integrity of the resulting assembled furniture.

There is known from U.S. Pat. No. 7,390,069 and U.S. Patent Application Publication Nos. 2008/0084143 and 2009/0015122 ready to assemble furniture using fittings that do not require tools. The disclosed fittings have a number of drawbacks both at the manufacturing stage and at the consumer stage. For example, these fittings require that the furniture panels be bored with various sized aligned holes to accommodate the fittings. The fittings are typically supplied to the consumer who must properly insert the fittings into their respective bores. In addition, these fittings require precision manipulation of the furniture components for inserting the fitting components into each other during the assembly process.

Despite the existence of the aforementioned prior art, there exists the need for further improvements in ready to assemble furniture which can be assembled by the consumer without the need for tools with a limited skill level.

BRIEF SUMMARY OF TEE INVENTION

In accordance with present invention, there is described a ready to assemble modular article of furniture comprising a plurality of panels adapted to be assembled; a plurality of fittings adapted for securing the plurality of panels in assembled relationship, each of the fittings comprising a first component and a second component; at least a first one of the panels having a surface supporting at least one of the first components; at least a second one of the panels having a surface supporting at least one of the second components; wherein the first and second panels are arrangeable in transverse relationship with the first and second components in alignment with each other, whereby manipulation of the first component without the use of tools causes the first component to engage the second component thereby securing the first and second panels together in transverse relationship.

In accordance with the present invention, there is further described a ready to assemble modular article of furniture comprising a plurality of planar panels adapted to be assembled; a plurality of fittings adapted for securing the plurality of panels in assembled relationship, each of the fittings comprising a first component including a rotatable catch having a handle and a second component; at least a first one of the panels having a planar surface fixedly supporting at least one of the first components; at least a second one of the panels having a planar surface fixedly supporting at least one of the second components; wherein the first and second panels are arrangeable in transverse relationship with the first and second components in alignment with each other, whereby manipulation of the first component without the use of tools causes the first component to engage the second component thereby securing the first and second panels together in transverse relationship, wherein the first component includes a hook shaped end and the second component includes a hook shaped end, whereby rotation of the catch of the first component by the handle causes the hook shaped ends of the first and second components to engage each other thereby securing the first and second panels together, and a plurality of dowels interconnecting at least a pair of the plurality of panels together without the use of the fittings.

In accordance with the present invention, there is further described a ready to assemble modular article of furniture comprising a plurality of panels adapted to be assembled; at least one first fitting adapted for securing the plurality of panels in assembled relationship, the first fitting comprising a first component including a rotatable catch and a second component, the first component fixedly secured to an exposed surface of a first one of the panels and the second component fixedly secured to an exposed surface of a second one of the panels; wherein the first and second panels are arrangeable in transverse relationship with the first and second components in adjacent relationship, whereby rotation of the catch of the first component without the use of tools causes the catch to engage the second component thereby securing the first and second panels together in transverse relationship.

In accordance with the present invention, there is further described a ready to assemble modular article of furniture comprising a plurality of panels adapted to be assembled, the plurality of panels including at least a first panel arrangeable transverse to a second panel; at least one fitting having a first component secured to a surface of the first panel and a second component secured to a surface of the second panel; the first component adapted to be manipulated without the use of a tool for engaging the second component for securing the first and second panels together in transverse arrangement.

BRIEF DESCRIPTION OF TEE DRAWINGS

The subject matter regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and method of operation, together with features, objects, and advantages thereof may best be understood by reference to the following detailed description when read with the accompanying drawings in which:

FIG. 1 is a perspective view of a fully assembled article of furniture in accordance with one embodiment of the present invention;

FIGS. 2A and 2B are a diagrammatic illustration of the parts and hardware list and assembly instructions typically included with the ready to assemble furniture of the present invention;

FIG. 3 is a perspective view showing a fitting arranged in accordance with one embodiment of the present invention between a locked and unlocked position;

FIG. 4 is perspective view showing a fitting arranged in accordance with another embodiment of the present invention between a locked and unlocked position; and

FIGS. 5A-C, 6A-C, 7, 8, 9A-B, and 10-13 are perspective views of the assembly of an article of furniture in accordance with one embodiment of the present invention.

DETAILED DESCRIPTION

In describing the preferred embodiments of the invention illustrated in the drawings, specific terminology will be used for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents that operate in a similar manner to accomplish a similar purpose

Referring now to the drawings, wherein like reference numerals represent like elements, there is shown in FIG. 1 an article of furniture generally designated by reference numeral 100 which is constructed as a ready to assemble modular article of furniture. The article illustrated is in the nature of an entertainment unit adapted for supporting a monitor such as flat screen television while having storage space for electronic-related equipment. However, it is to be understood that the present invention is applicable to other types of furniture, for example, cabinets, book cases, computer desks, storage units, dressers, end tables, and other furniture types that are suitable for ready to assemble construction.

By way of illustration only, the article as shown is constructed from a plurality of panels which are assembled to each other by the consumer without the need of tools. In the illustrative example, the article includes a top panel 102, a pair of side panels 104, 106, a bottom panel 108, a back panel 110, a lower vertical panel 112, an upper vertical panel 114 (see FIG. 8), a fixed middle shelf 118 (see FIG. 7), a speaker grill 120, one or more adjustable shelves 122 (see FIG. 11), and a plurality of foot supports 124.

As is typical of ready to assemble furniture, as shown in FIGS. 2A and 2B, included are a parts and hardware list 126, and diagrammatic instructions 128 for assembly of the article of furniture. The instructions 128 enable the consumer to assemble the panels without the need of tools by following the illustrated pictures.

The assembly of the article of furniture will now be described with reference to FIGS. 5-13. Initially, the article of furniture is contained in a shipping carton which is first opened to remove its contents as shown in the parts and hardware list 126. The consumer would first confirm that all of the parts are contained within the carton, and then would identify each of the parts to enable proper assembly.

As shown in FIGS. 5A-5C, the back panel 110 is preassembled to the side panels 104, 106 by means of a plurality of conventional hinges 129 factory installed interiorly to their adjacent inner surfaces. When stored in its shipping carton, the side panels 104, 106 are arranged folded overlying the back panel 110 as shown in FIG. 5B. The assembly process is started by rotating the side panels 104, 106 as shown by the arrows in FIG. 5A until they are arranged transverse to the back panel 110. This allows the side panels 104, 106 and back panel 110 to be oriented in a self-standing upright position. However, it is to be understood that the back panel 110 may be positioned on the floor as shown in FIG. 5B. The factory installation of the hinges facilitates assembly by the user, as well as avoiding the need for tools during the assembly process.

The remaining panels of the article 100 are assembled using fittings which can be manipulated by the consumer without the need for tools for securely locking the panels together in stable configuration. The fittings are pre-installed to the various panels at the factory thereby avoiding the need for the consumer to attach the fittings to the components as typically required in prior ready to assemble furniture. The fittings are designed to enable connecting panels together in either coplanar or transverse relationship to one another. The fittings are positioned at the appropriate locations within the article as dictated by its construction and function.

With reference to FIGS. 3 and 4, the fittings generally identified by reference numeral 130 are composed of two releasably interlocking components, a rotatable latch 132, and a clasp 134. As shown in FIG. 3, the latch 132 and clasp 134 are arranged for joining panels which have contiguous coplanar surfaces. On the other hand, as shown in FIG. 4, the latch 132 and clasp 134 are arranged for connecting panels having contiguous transversely arranged surfaces. The latch 132 and clasp 134 are surface mounted at the factory at predetermined locations dictated by the design of the article of furniture 100 using suitable fasteners such as screws and the like. By virtue of being surface mounted, this avoids the necessity of having to drill appropriate holes or provide other recessed areas for mounting of the fittings 130. Furthermore, the factory mounting of the fittings 130 facilitates assembly by the consumer, again, without the need for tools.

The latch 132 is constructed from a housing 136 having a pair of side tabs 138 each provided with a through hole to enable mounting to the surface of a furniture panel. The housing 136 includes a central bore which rotatably receives a catch 140. The catch 140 includes a longitudinally projecting extension 142 which terminates at a hook shaped end 144. The hook shaped end 144 defines a generally elongated u-shaped opening underlying the extension 142 and facing rearwardly towards the housing 136. The catch 140 includes a handle 146 which facilitates its rotation within the bore by the consumer during assembly of the article 100.

The clasp 134 includes a flat plate 148 having a pair of side tabs 150 each provided with a through hole for enabling attachment of the clasp to the surface of the panel for assembly using any suitable means, such as screws and the like. The plate 148 terminates at a hook shaped end 152 having an elongated u-shaped opening arranged above the plate and facing rearwardly relative to the plate. The hook shaped end 144 of the latch 132 is of complimentary construction to the hook shaped end 152 of the clasp 134. This arrangement enables the latch 132 to releasably engage the clasp 134 for securing adjacent panels together.

As shown again in FIG. 3, the coplanar surfaces of two furniture panels to be assembled are arranged contiguous to each other. The latch 132 is arranged adjacent the edge of one panel, while the clasp 134 is arranged adjacent the other panel with its hook shaped end 152 extending towards the catch. With the two panels abutted against each other with their surfaces in coplanar relationship, the catch 140 is rotated by the consumer until its hook shaped end 144 engages the hook shaped end 152 of the clasp 134. This engagement securely joins the panels together. The catch 140 can be rotated by the consumer using the handle 146, thereby eliminating the need for tools during the assembly process.

Referring to FIG. 4, the fittings 130 are adapted for securing panels together in transverse relationship. In a similar manner as previously described, the latch 132 and clasp 134 are arranged adjacent the edges of the panels to be assembled. In this arrangement, however, the surfaces of the panels are not coplanar. In general, the inner surface one of the panels is positioned into contiguous relationship with the end of another panel. In this arrangement, the clasp 134 is displaced rearwardly of the edge of the panel to allow for positioning of the other panel in transverse relationship. The two panels are secured to each other by rotation of the catch 140 as previously described. In this regard, rotation of the catch 140 causes its hook shaped end 144 to engage the hook shaped end 152 of the clasp 134. The hook shaped ends 144, 152 may have a cam profile which will result in drawing of the ends together while rotating the catch 140, thereby enhancing the mechanical connection between adjacent panels. It will be appreciated that the fittings 130 are adaptable for operation by the consumer, without the need for tools, so as to securely fasten panels of the article of furniture together during the assembly process.

Referring to FIGS. 5A-5C, a latch 132 is secured at the factory to the inner surface of each of the side panels 104, 106 centrally positioned along their top edge 154. A pair of clasps 134 is secured at the factory along the bottom edge 156 of the side panels 104, 106 at spaced apart locations. The clasps 134 are shown more clearly in secured relationship to the bottom edge 156 of the side panels 104, 106 in FIGS. 5B and 5C.

Referring to FIG. 6A, the bottom panel 108 is provided with one or more dowels 158 projecting outwardly from opposite side edges 160. Any number of dowels may be incorporated for the purpose of aligning the bottom panel 108 into proper position between the side panels 104, 106. In this regard, the inner surface of the side panels 104, 106 adjacent their bottom edge will include bores (not shown) to receive the dowels 158 projecting from the bottom panel 108.

As more clearly shown in FIGS. 6B and 6C, a pair of spaced apart latches 132 is secured to the bottom surface of the bottom panel 108 adjacent its opposite side edges 160 in alignment with the clasps 134 attached to the side panels 104, 106 as shown in FIG. 6A. The bottom panel 108 is securely fastened in position by rotating the catch 140 until its hook shaped end 144 fully engages the hook shaped end 152 of the clasp 134 in the manner as previously described.

Referring to FIG. 7, there will now be described the assembly of the middle shelf 118 and the lower vertical panel 112 within the interior of the article 100. The vertical panel 112 is provided with spaced apart dowels 158 projecting outwardly from its upper and lower edges 162, 164. The vertical panel 112 is secured to the bottom panel 108 by inserting the dowels 158 into aligned bores within the bottom panel. The vertical panels 112 are secured to the middle shelf 118 by inserting the dowels 158 into aligned bores within the bottom surface of the middle shelf. The middle shelf 118 itself is provided with pairs of projecting dowels 158 from its opposite side edges 166, 168. These dowels 158 are received within bores formed in the inner surface of the side panels 104, 106. The dowels 108 are typically provided to the consumer who merely inserts the dowels into pre-drilled bores, no tools being required. Optionally, the dowels can be pre-installed into the bores at the factory. The assembled middle shelf 118 and the vertical panel 112 is shown in FIG. 8.

Turning to FIG. 8, the upper vertical panel 114 is secured to the upper surface of the middle shelf 118 using suitable dowels 158 projecting downwardly from its lower edge 170. The dowels 158 may be inserted into pre-drilled bores within the upper surface of the middle shelf 118 in a manner a previously described with respect to the assembly of the lower vertical panel 112.

Referring now to FIGS. 9A and 9B, there will be described the assembly of the top panel 102. A plurality of dowels 158 are inserted into bores within the upper edge 172 of the vertical panel 114 and the upper edges 174, 176 of the side panels 104, 106. The dowels 158 are adapted to be received within aligned bores within the lower surface of the top panel 102. The top panel is positioned overlying the side panels 104, 106, back panel 110 and vertical panel 114 whereby the dowels 158 are received within their corresponding bores.

As more clearly shown in FIG. 9B, a clasp 134 is secured to the lower surface of the top panel 104 inwardly of its opposite ends 178, 180. The clasps 134 are aligned with a corresponding latch 132 provided adjacent the top edge of the side panels 104, 106. The top panel 102 is arranged transverse to the side panels 104, 106 with the respective latches 132 and clasps 134 in alignment with each other as shown in FIGS. 4 and 9B. Upon rotation of the catch 140 of the respective latches 132, its hook shaped end 144 will engage the hook shaped end 152 of the opposing clasp 134. As thus far described, the fittings 130 are adapted for rigidly securing together panels in either coplanar or transverse relationship, without the need for tools or a special consumer skill level.

Referring to FIG. 10, foot supports 124 are secured at the corners of the bottom panel 108 by any suitable means. By way of example, the foot supports 114 may be aligned using dowels 158 inserted into respective bores provided in the foot supports 124 and bottom surface of the bottom panel 108. A screw and washer assembly 178 may be used for fixedly attaching the foot supports 124 to the bottom panel 108. A provided allen wrench may be used by the consumer for tightening the screw. Alternatively, the screw may be provided with an enlarged head which may be grasped by the consumers' fingers to affect tightening. Any other means suitable for securing the foot supports 124 to the bottom panel 108 may be employed, for example, gluing and the like. It is to be understood that the use of the screw and washer assembly 178, as well as the previously described dowels 158 for interconnecting the various components in aligned relationship forms no part of the present invention.

Adjustable shelves 122, as shown in FIG. 11, may now be installed. As is conventional, a plurality of shelf support pins 180 are inserted into bores provided in the inner surfaces of the side panels 104, 106 and opposite sides of the lower vertical panel 112. The shelves 122 are tilted so they will fit into the width of the cavity defined within the interior of the article of furniture 100. Once in position, the shelves 122 are oriented into a horizontal position so as to be supported by the shelf supports 180 as more clearly shown in FIG. 12. Although two shelves 122 have been illustrated, any number of shelves may be utilized in the article of furniture 100.

Referring to FIG. 12, a pair of spaced apart longitudinally extending guide tracks 182 are provided forwardly in the top surface of the bottom panel 108 and bottom surface of the middle shelf 118 (see FIG. 10). The guide tracks 118 are in the nature of longitudinally extending grooves which may be cut into the bottom panel 108 and middle shelf 118, or can be formed from a separate pre-constructed assembly secured thereto.

A guide pin assembly 184 is provided inwardly of the four corners of each of the doors 116. Each of the guide pin assemblies 184 is provided with a spring biased guide pin 186. The guide pin 186 is normally biased outwardly of the doors 186 in normal operative position. For installation, the guide pins 186 are retracted into the interior of the guide pin assembly 184 by downward manipulation of a pin retractor 188. Once the guide pins 186 have been retracted, the doors 116 may be positioned into the opening formed between the bottom panel 108 and middle shelf 118. The doors 116 are positioned such that their guide pins 186 are aligned with one of the corresponding guide tracks 182. Upon releasing the pin retractors 188, the guide pins 186 will be biased outwardly so as to engage their respective guide tracks 182. This arrangement allows the doors 116 to slide longitudinally across the face of the article of furniture. It is to be understood that the doors 116 can also be prehung thereby avoiding their installation by the consumer.

Referring to FIG. 13, the article is completed by installing the speaker grill 120 within the opening formed between the side panels 104, 106, top panel 102 and middle shelf 118. The speaker grill is secured into position by any suitable means, for example, clips, friction fit, magnets, dowels, adhesives, and the like.

Although the present invention has been described with respect to the particular construction of fittings 130, it is to be understood that other constructions of fittings which accomplish the same purpose of those described pursuant to this application may be incorporated within the scope of the present invention. Further, although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.

Claims

1. A ready to assemble modular article of furniture comprising: a plurality of panels adapted to be assembled;at least one first fitting adapted for securing said plurality of panels in assembled relationship, said first fitting comprising a first component including a rotatable catch and a second component, said first component fixedly secured to an exposed surface of a first one of said panels and said second component fixedly secured to an exposed surface of a second one of said panels;wherein said first and second panels are arrangeable in transverse relationship with said first and second components in adjacent relationship, whereby rotation of said catch of said first component without the use of tools causes said catch to engage said second component thereby securing said first and second panels together in transverse relationship.

2. The article of furniture of claim 1, wherein said catch includes a hook shaped end and said second component includes a hook shaped end, whereby rotation of said catch causes said hook shaped ends of said catch and said second component to engage each other thereby securing said first and second panels together.

3. The article of furniture of claim 2, wherein said hook shaped ends each have a cam profile.

4. The article of furniture of claim 2, wherein said catch includes a handle for manipulation without the use of a tool to cause rotation of said catch.

5. The article of furniture of claim 2, wherein each of said hook shaped ends provide a U-shaped opening.

6. The article of furniture of claim 1, further including a third panel arrangeable adjacent to a fourth panel.

7. The article of furniture of claim 6, further including at least one second fitting adapted for securing said third panel to said fourth panel, said second fitting comprising a third component including a rotatable catch and a fourth component, said third component fixedly secured to an exposed surface of said third panel and said fourth component fixedly secured to an exposed surface of said fourth panel.

8. The article of furniture of claim 7, wherein said third and fourth panels are arrangeable in transverse relationship with said third and fourth components in adjacent relationship, whereby rotation of said catch of said third component without the use of tools causes said catch to engage said fourth component thereby securing said third and fourth panels together in transverse relationship.

9. The article of furniture of claim 8, wherein said catch of said third component includes a hook shaped end and said fourth component includes a hook shaped end, whereby rotation of said catch causes said hook shaped ends of said catch and said fourth component to engage each other thereby securing said third and fourth panels together.

10. The article of furniture of claim 9, wherein said hook shaped ends each have a cam profile.

11. The article of furniture of claim 9, wherein said catch of said third component includes a handle for manipulation without the use of a tool to cause rotation of said catch.

12. The article of furniture of claim 7, further including a plurality of second fittings adapted for securing said third and fourth panels together.

13. The article of claim 1, further including a plurality of first fittings adapted for securing said first and second panels together.

14. A ready to assemble modular article of furniture comprising: a plurality of panels adapted to be assembled, said plurality of panels including at least a first panel arrangeable transverse to a second panel;at least one fitting having a first component secured to a surface of said first panel and a second component secured to a surface of said second panel;said first component adapted to be manipulated without the use of a tool for engaging said second component for securing said first and second panels together in transverse arrangement.

15. The article of furniture of claim 14, wherein said first component includes a rotatable catch.

16. The article of furniture of claim 15, wherein said first and second components each include a hook shaped end engageable with each other upon rotation of said catch for securing said first and second panels together in transverse arrangement.

17. The article of furniture of claim 14, further including a plurality of said fittings adapted for securing said first and second panels together in transverse arrangement.

18. The article of furniture of claim 14, further including a third panel and a fourth panel arrangeable in transverse arrangement, and at least another fitting adapted for securing said third and fourth panels together in transverse arrangement.

19. A ready to assemble modular article of furniture comprising: a plurality of planar panels adapted to be assembled;a plurality of fittings adapted for securing said plurality of panels in assembled relationship, each of said fittings comprising a first component including a rotatable catch having a handle and a second component;at least a first one of said panels having a planar surface fixedly supporting at least one of said first components;at least a second one of said panels having a planar surface fixedly supporting at least one of said second components;wherein said first and second panels are arrangeable in transverse relationship with said first and second components in alignment with each other, whereby manipulation of said first component without the use of tools causes said first component to engage said second component thereby securing said first and second panels together in transverse relationship,wherein said first component includes a hook shaped end and said second component includes a hook shaped end, whereby rotation of said catch of said first component by said handle causes the hook shaped ends of the first and second components to engage each other thereby securing the first and second panels together, anda plurality of dowels interconnecting at least a pair of said plurality of panels together without the use of said fittings.

20. The article of furniture of claim 19, wherein said hook shaped ends have a cam profile.

21. The article of claim 19, wherein said planar surface of said first and second panels are exposed.