Abstract
A furniture item comprises various components for assembly thereof. The furniture items include a substantially flat seat portion, a substantially flat back portion, connectors for securing the flat seat portion to the flat back portion, and a plurality of legs for attachment to the seat portion. Cushions are provided and may be configured to form barriers for use adjacent the seat portion and the back portion when packed in a container. Additionally, compressed and sealed cushions may also be provided to form barriers for use adjacent the seat portion and back portion when packed in a container.
Claims
1. A furniture item having components for assembly thereof, the furniture item components comprising: a substantially flat seat portion having a first shape and thickness and a bottom surface; a substantially flat back portion having a second shape and thickness different from the first shape and thickness; connectors for securing the flat seat portion to the flat back portion; a plurality of legs for attachment to the bottom surface of the seat portion; cushions configured to form barriers for use adjacent the seat portion and the back portion when packed in a container, the cushions comprising a part of the furniture item when assembled; and compressed and sealed cushions to form barriers for use adjacent the seat portion and back portion when packed in a container, the compressed and sealed cushions comprising a part of the furniture item once assembled and after being unsealed, decompressed.
2. A furniture item as claimed in claim 1 further comprising a container for sequentially and compactly receiving the seat portion, back portion, connectors, legs, cushions and compressed cushions, the cushions and compressed cushions being received within the container in positions for protecting adjacent components from damage.
3. A furniture item as claimed in claim 2 wherein the cushions and compressed cushions are arranged within the container so that all contents of the container are relatively tightly packed together to reduce or eliminate movement between them.
4. A furniture item as claimed in claim 2 wherein at least one of the cushions and compressed cushions are placed in the container against a side wall, a base or a top of the container.
5. A furniture item as claimed in claim 2 further comprising connecting hardware utilized for assembling components.
6. A furniture item as claimed in claim 5 wherein the connecting hardware is stored within a hardware box, the hardware box being packed within the container.
7. A furniture item as claimed in claim 1 comprising a first seat portion, a second seat portion, a first back portion and a second back portion, wherein the first seat portion and the second seat portion are connected to each other at corresponding side edges on the first seat portion and second seat portion, the first back portion is connected to the first seat portion, and the second back portion is connected to the second seat portion.
8. A furniture item as claimed in claim 7 wherein the first seat portion and first back portion are connected to each other to form a lounger and the second seat portion and the second back portion are connected to each other to form a loveseat.
9. A furniture item as claimed in claim 7 further comprising at least one side arm.
10. A furniture item as claimed in claim 9 wherein the at least one side arm comprises a first side arm connected to the lounger and a second side arm connected to the loveseat.
11. A furniture item as claimed in claim 1 wherein at least one of the legs comprises a leg portion and a flat connector portion, the flat connector portion being connectable to one of the components.
12. A furniture item as claimed in claim 1 further comprising guide markings on the components to facilitate assembly and construction of the components.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) In the drawings:
(2) FIG. 1 shows a lounger back and wooden legs, including a detail, of an item of furniture in accordance with the present invention;
(3) FIG. 2 shows wooden legs and a lounger back, including a detail, of an item of furniture in accordance with the present invention;
(4) FIG. 3 shows a bottom perspective view showing wooden legs and lounger with markings, including a detail;
(5) FIG. 4 shows an arm rest and attachment mechanism, including a detail, of the item of furniture in accordance with the present invention;
(6) FIG. 5 shows a back rest of a lounger and loveseat, including a detail assembled view, in accordance with the present invention;
(7) FIG. 6 illustrates armrest and loveseat attachment, including use of screws;
(8) FIG. 7 illustrates an item of furniture with components as previously illustrated in their connected positions, according to the invention;
(9) FIG. 8 illustrates cushion covers for use with the furniture of the present invention, including a detail;
(10) FIG. 9 illustrates a perspective view of a lounger with cushion mounted thereon, with components as previously illustrated;
(11) FIG. 10 illustrates wooden legs which are assembled onto a loveseat arm, including a detail, in accordance with the invention;
(12) FIG. 11 illustrates the loveseat armrest mounted on the loveseat frame, including a detailed illustration;
(13) FIG. 12 illustrates mounting points, shown in circles, for connecting furniture components, including different perspectives;
(14) FIG. 13 illustrates, including a detail, the use of five screws for effecting the connection;
(15) FIG. 14 shows mounting guides, including a detail, for placement in mounting positions, of various components of the invention;
(16) FIG. 15 shows installation of a wooden legs on a sofa, including a detail thereof;
(17) FIG. 16 illustrates a love seat constructed and shown in the fully installed and assembled condition;
(18) FIG. 17 shows sequential removal of a compressed air chair cushion, for use with a furniture item in accordance with the invention;
(19) FIG. 18 is a front perspective view of a loveseat, including cushion covers and cushions, in accordance with the invention;
(20) FIG. 19 shows sequential assembly and connection points of the loveseat and lounge, previously assembled, in accordance with the invention;
(21) FIG. 20 illustrates the completed loveseat and lounge assembly of the furniture in accordance with the invention;
(22) FIG. 21 illustrates parts and components of a furniture item for packaging within a container;
(23) FIG. 22 illustrates packing all or some of the legs within the container;
(24) FIGS. 23A and 23B illustrate further packing of remaining or additional legs within the container;
(25) FIG. 24 shows the addition of certain hardware for assembly added to the container;
(26) FIG. 25 shows the addition of the chaise lounge seat placed within the container;
(27) FIG. 26 illustrates the placement of the arm rest into the container;
(28) FIG. 27 illustrates the placement of the packed seat cushion within the container;
(29) FIG. 28 illustrates the placement of the sofa seat within the container;
(30) FIG. 29 illustrates placement of the vacuum packed seat cushions within the container;
(31) FIG. 30 illustrates the placement of a separate leg box which is inserted into the container;
(32) FIG. 31 of the drawings illustrates the placement of the sofa seat back within the container;
(33) FIG. 32 illustrates the placement of cushions for use with the furniture within the container;
(34) FIG. 33 illustrates the container when closed and sealed, the container comprising a standard size regularly used in the shipment of products; and
(35) FIG. 34 illustrates a further view in accordance with an embodiment of the invention illustrating the assembled item of furniture constructed and assembled in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
(36) Reference is now made to the accompanying drawings which show various aspects of the invention. In the drawings, FIGS. 1 to 20 show assembly of a specific item of furniture in accordance with the invention, while FIGS. 21 to 33 illustrate the packing methodology by means of which the individual components are prepared and boxed so as to take advantage of optimal spacing and packing requirements.
(37) Reference is now made to FIGS. 21 to 30 which show one method in accordance with the invention for the compact packaging system. FIG. 21 of the drawings illustrates all of the parts and components 12 of a sectional sofa 14, which have been prepared for packaging within a single container. Where necessary, some pre-packing of components into interior boxes 16 have been made, so that certain parts, such as small hardware, can be packed and easily found later during unpacking. Seat cushions 18 for the sofa 14 are vacuum packed or otherwise wrapped so as to provide some protection for the actual product which will ultimately be used by the consumer. Furthermore, the various legs which will support the remainder of the sofa will preferably be pre-wrapped, such as with PVC wraps, in order to prevent or reduce damage, including scratches, chipping or breakages.
(38) FIGS. 22 to 24 illustrate the packaging of the legs 20. The legs 20 may be wrapped in bubble pack 22, and placed inside a smaller box 24 and wrapped with wrapping material. Certain hardware is placed in the same box 24, as shown in FIG. 24, and the box 24 is closed and appropriately sealed. FIG. 25 illustrates the placement of the chaise lounge seat 26 within the box 28. This is separated from the backrest, and placed in the box face down. The seat cushion 18, which is relatively thick, will also serve as packaging padding for the main base frame.
(39) FIG. 26 illustrates the placement of the arm rest 30 into the carton box 28. The arm rest 30 may be packed into the housing of the seat cushion 18. The arm rests 30 of both the chaise lounge and the opposing end of the sofa are packed so as to lie flat on top of the chaise lounge seat, that has previously been packed. This is followed by the packaging of the chaise lounge vacuum packed seat cushion 32 on the seat of the chaise lounge, as shown in FIG. 27. These cushions 32 are placed in the box 28 in a manner so as to lie flat on top of the packaging described with respect to FIGS. 25 and 26.
(40) In FIG. 28, the sofa seat 34 is placed into the box 28 on top of the sealed cushion 18, and separated from the sofa back. In FIG. 29, the vacuum packed seat cushions 36 are packed. These pillows 36 may be oval-shaped or have another shape, and are inserted into the box 28 between the sofa seat and one short edge of the box. In FIG. 30, the previously sealed separate leg box 24 is inserted into the larger box 28 between the sofa seat and one long end of the box.
(41) In FIG. 31, the sofa seat back 40, detached from the sofa seat 34, is placed into the box 28 on top of the sofa seat 34 previously packed within the box 28. Thereafter, the square pillows 42 are placed in between the sofa seat back and the long edge of the box 28. These cushions 42 on the side also serve as cushion padding. In FIG. 32, the complete placement of all the cushions is illustrated. A second oval pillow 44 is placed into the box between the sofa seat back and the long edge of the box 28, sitting next to the square pillows 42. At this point, all of the topmost items will be substantially flush with the upper box edges. In FIG. 33, the carton boxed is finally closed and sealed. The size of the box is one known in the industry as a FedEx 165 inch standard, selected for its ready availability, and appropriate for transportation by delivery companies.
(42) Once delivered and ready for unpacking and assembly, the components can be removed from the box in a methodical and orderly way, facilitating such assembly. Some of these steps are illustrated in FIGS. 1 to 20 of the accompanying drawings.
(43) In FIG. 1, wooden legs 102 are fastened to the lounger back 104, and it should be noted that the markings for the mounting positions on the lounger and wooden legs 102 should match in order to assure proper alignment and orientation. The legs 102 are attached using bolts, washers and spring washers, and the tightening of the bolts may be effected by an Allen key or some other tool. In FIG. 2, wooden legs 106 are assembled or fastened to the lounger armrests 108 and, once more, the marking on the respective pieces of hardware should be matched to ensure proper assembly. Once more, bolts, washers and spring washers are used, and may be tightened by an Allen key. For the convenience of the customer or person assembling, the lounger armrests and love seat armrest may be distinguished from each other in that the bottom of the lounger armrest has a painted wooden frame.
(44) In FIG. 3, there is a further illustration to emphasize the fact that the wooden legs 106 and the lounger received both have appropriate markings for orientation and mounting positions, which should be matched.
(45) In FIG. 4, it is illustrated that the armrest 108 is placed in the “open arm housing area” of the loveseat and precisely affixed to the corresponding position. Four screws are utilized to both position and affix the armrest 108 to the loveseat. In FIG. 5, the backrest 107 of the lounger is affixed to the loveseat, and attention should be paid to the “buckle and hook” clasps, which are marked by the circle in this figure. This is a slip and slide clasp. Upon completion of the buckle and hook step, appropriate tightening utilizing the provided bolts is effected to ensure a secure connection.
(46) FIG. 6 illustrates the utilization of all four screws to affix and tighten the armrests 108 to the loveseat apron area. FIG. 7 illustrates the parts which have been connected at this point of the assembly, which to a large extent has fastened the lounger components together to form the lounger 110.
(47) Reference is now made to FIG. 8 of the drawings. The cushion covers 112 are shipped folded and loose. The customer assembling will at this point place the correct cushions with the corresponding correct cover and slip the cushion, which is still sealed, into the cushion cover. Thereafter, the user will move a pair of scissors into the cushion cover and cut open the PVC vacuum pack which contains the cushion. Of course, caution must be exercised at this step to ensure that neither the cushion or the cushion cover is inadvertently cut or damaged. The seat cushion is gently slipped out of the PVC bag, and slowly allowed to fill up with air, since it has been compressed for storage and transportation. The cushion cover 112 may then be closed by means of the provided zipper, and the cushion 114 may be plumped up and smacked a few times to draw air into the filled cushion. This process allows the cushion to expand from it compact state and return to its original shape. It should be noted that, before the cushion may in fact gain its fullest shape, a significant amount of time, such as up to 10 days, may be required.
(48) In FIG. 9, the lounger 110 is shown, and the seat cushions prepared as previously described may be placed on the lounger and loveseat as illustrated or otherwise desired.
(49) In FIG. 10, wooden legs 106 are assembled onto the loveseat arm, as illustrated, and, as described above, appropriate mounting positions on the respective components are provided to ensure correct assembly and orientation. The wooden legs 106 are fastened and tightened as previously described.
(50) In FIG. 11, the loveseat armrest 140 is mounted to the loveseat frame 142. In the circle, and detail illustration, the two wooden legs are inserted in the paint frame, the armrest is turned up, and screws are used in the loveseat frame to secure and fix the armrest. In FIG. 12, with the loveseat armrest 140 mounted to the loveseat frame 142, and as highlighted by the circles, small inserts need to be fixed, in effecting the connection. As shown in FIG. 13, five screws 146 are mounted in the back of the chair to secure a tight connection.
(51) As shown in FIG. 14, when assembling the wooden legs of the loveseat back, the letter on the mounting position should match the letter on the leg. Attachment by means of bolts etc. with an Allen key, as described, is effected. In FIG. 15, there is illustrated the step of installing the last of the wooden legs 150 on the sofa, and appropriate matching as described is provided to assist in proper assembly and orientation. FIG. 16 of the drawings shows the loveseat 152 in the fully installed and assembled condition.
(52) FIG. 17 illustrates once more the removal of the compressed chair cushion, which may be made of sponge, unwrapped from each packing, and set in its appropriate cushion case. It is sealed with the provided zipper, and the vacuum packing removed so that the cushion can rebound and eventually reach its full size. FIG. 18 is a front view of a loveseat 152 installed with the two cushion covers 112, as well as accessorized with cushions 114.
(53) In FIG. 19, with the loveseat 152 and lounger 110 having been separately assembled, attachment of these two components can now be carried out. On the left of the loveseat 152 and on the right of the lounger 110 assembly rods and inserts 160 are provided, and when these two components are connected, the sofa set insulation and finish is complete. The completed assembly 164 is illustrated in FIG. 20 of the drawings. A review of this figure illustrates the significant number of components and size of the assembled product, but the construction of the components and its methodology for packing nevertheless enable it to fit within a single standard size container, having all of the benefits and advantages which result therefrom, as discussed above.
(54) Throughout this description, the embodiments and examples shown should be considered as exemplars, rather than limitations on the apparatus and procedures disclosed or claimed. Although many of the examples presented herein involve specific combinations of method acts or system elements, it should be understood that those acts and those elements may be combined in other ways to accomplish the same objectives. Acts, elements and features discussed only in connection with one embodiment are not intended to be excluded from a similar role in other embodiments.
(55) As used herein, “plurality” means two or more. As used herein, a “set” of items may include one or more of such items. As used herein, whether in the written description or the claims, the terms “comprising”, “including”, “carrying”, “having”, “containing”, “involving”, and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of” and “consisting essentially of”, respectively, are closed or semi-closed transitional phrases with respect to claims. Use of ordinal terms such as “first”, “second”, “third”, etc., in the claims to modify a claim element does not by itself connote any priority, precedence, or order of one claim element over another or the temporal order in which acts of a method are performed, but are used merely as labels to distinguish one claim element having a certain name from another element having a same name (but for use of the ordinal term) to distinguish the claim elements. As used herein, “and/or” means that the listed items are alternatives, but the alternatives also include any combination of the listed items.
