Modular sofa construction and methods for assembly
11779123 · 2023-10-10
Assignee
Inventors
- Stephen Kuhl (New York, NY, US)
- Kabeer Chopra (New York, NY, US)
- Leah K. S. Amick (Portland, OR, US)
- Paul Koh (New York, NY, US)
- Alex Kubo (Philadelphia, PA, US)
Cpc classification
A47C17/86
HUMAN NECESSITIES
A47C17/04
HUMAN NECESSITIES
International classification
A47C17/04
HUMAN NECESSITIES
Abstract
A modular sofa assembly described herein includes a plurality of seating modules each having a seat section, a backrest section, and side edge surfaces. The backrest section includes first and second portions coupled for movement between a folded configuration and an extended configuration. An armrest module has an armrest side edge surface configured for mating engagement with a side edge surface of a seating module. The modular sofa is assembled by aligning connectors of the seating modules and armrest module, with each respective connectors slidingly engaged along an axis. After bringing the modules together, these connections are secured with the side edge surfaces in abutting engagement. The modular sofa further may include a power cradle mounted at the sofa's bottom surface. The power cradle includes a cubic power outlet near the front of the sofa, and power cable extending beyond the back of the sofa.
Claims
1. A method comprising: causing an end user to: assemble a first portion of a corner sectional sofa, wherein the first portion includes a first seating section, a second seating section, and a first leg assembly, wherein the first seating section includes a first underside including a first underside connector, wherein the second seating section includes a second underside including a second underside connector, wherein the first underside connector is connected to the second underside connector, wherein the first leg assembly spans between the first underside and the second underside; assemble a second portion of the corner sectional sofa, wherein the second portion includes a third seating section, a fourth seating section, and a second leg assembly, wherein the third seating section includes a third underside including a third underside connector, wherein the fourth seating section includes a fourth underside including a fourth underside connector, wherein the third underside connector is connected to the fourth underside connector, wherein the second leg assembly spans between the third underside and the fourth underside; and position the first portion and the second portion such that the first portion and the second portion form the corner sectional sofa.
2. A method comprising: sending an armrest section, a first seating section, a first backrest section, a second seating section, a second backrest section, a third seating section, a third backrest section, a first cushion, a second cushion, a third cushion, a first leg assembly, a second leg assembly, and a leg to a premises of an end user; and causing the end user to assemble a corner sectional modular sofa on the premises by: arranging (i) the first seating section and the first backrest section such that a first seat is formed, (ii) the second seating section and the second backrest section such that a second seat is formed, and (iii) the third seating section and the third backrest section such that a third seat is formed; connecting the first seat to the armrest section and the second seat such that (i) the first seat is positioned between the armrest section and the second seat and (ii) the first seat and the armrest section forms a corner seating module; fastening (i) the first leg assembly to the armrest section and the first seating section such that the first leg assembly spans between the armrest section and the first seating section while the first seat rests on the first backrest section and (ii) the second leg assembly to the first seating section and the second seating section such that the second leg assembly spans between the first seating section and the second seating section while the second seat rests on the second backrest section; flipping the armrest section, the first seat, and the second seat together to be upright such that (i) the first leg assembly supports the armrest section and the first seat and (ii) the second leg assembly supports the first seat and the second seat; fastening the leg to the third seating section while the third seat rests on the third backrest section; flipping the third seat to be upright such that the leg supports the third seat; connecting the corner seating module to the third seat such that (i) the leg is proximal to the corner seating module, (ii) the corner seating module and the second seat form a first section of the corner section modular sofa and the third seat forms a second section of the corner section modular sofa; and positioning the first cushion on the first seating section, the second cushion on the second seating section, and the third cushion on the third seating section such that the end user can sit on the first cushion, the second cushion, or the third cushion.
3. A kit comprising: a first package containing a first seating section and a first backrest section, wherein the first seating section includes a first seating sidewall hosting a first seating sidewall connector, wherein the first backrest section includes a first backrest sidewall hosting a first backrest sidewall connector, wherein the first seating section includes a first seating underside hosting a first underside seating connector, a second package containing a second seating section and a second backrest section, wherein the second seating section includes a second seating sidewall hosting a second seating sidewall connector, wherein the second backrest section includes a second backrest sidewall hosting a second backrest sidewall connector, wherein the second seating section includes a second seating underside hosting a second underside seating connector, a third package containing an armrest section, a fourth package containing a cushion, wherein the first package, the second package, the third package, or the fourth package contains a first leg assembly or a second leg assembly, wherein the first package, the second package, the third package, and the fourth package are shippable to a premises of an end user such that the end user assembles a modular sofa on the premises by: opening the first package, the second package, the third package, and the fourth package to take out the first seating section, the first backrest section, the second seating section, the second backrest section, the armrest section, the first leg assembly, the second leg assembly, and the cushion; arranging (i) the first seating section and the first backrest section such that a first seat is formed and (ii) the second seating section and the second backrest section such that a second seat is formed; connecting (i) the first seating sidewall connector to the second seating sidewall connector, (ii) the first backrest sidewall connector to the second backrest sidewall connector, and (iii) the armrest section to the first seat such that the first seat is positioned between the armrest section and the second seat; resting the first seat on the first backrest section and the second seat on the second backrest section while the armrest section is connected to the first seat; fastening (i) the first leg assembly to the first seating underside and the armrest section while the first seat rests on the first backrest section as the armrest section is connected to the first seat such that the first leg assembly spans between the first seating underside and the armrest section and (ii) the second leg assembly to the first seating underside and the second seating underside while the second seat rests on the second backrest section as the armrest section is connected to the first seat such that the second leg assembly spans between the first seating underside and the second seating underside; connecting the first underside seating connector to the second underside seating connector while the first seat rests on the first backrest section and the second seat rests on the second backrest section while the armrest section is connected to the first seat; positioning the first seat, the second seat, and the armrest section together upright as (i) the first leg assembly is fastened to the first seating underside and the armrest section, (ii) the second leg assembly is fastened to the first seating underside and the second seating underside, and (iii) the first underside seating connector is connected to the second underside seating connector such that (iv) the first leg assembly supports the first seat and the armrest section and (v) the second leg assembly supports the first seat and the second seat; and positioning the cushion on the first seating section or the second seating section as the first seat, the second seat, and the armrest section are positioned upright.
4. A corner sectional modular sofa including an armrest module, a first seating module, a second seating module, and a third seating module, wherein the first seating module is connected to the armrest module and the second seating module such that (i) the first seating module is positioned between the armrest module and the second seating module and (ii) the armrest module, the first seating module, and the second seating module form a first section of the corner sectional modular sofa where the first seating module and the armrest module form a corner seating module, wherein the third seating module forms a second section of the corner sectional modular sofa, wherein the third seating module is connected to the corner seating module such that the first section and the second section form the corner sectional modular sofa, wherein the first seating module includes a first side hosting a first connector, wherein the second seating module includes a second side hosting a second connector, wherein the first connector is connected to the second connector such that (i) the first seating module is connected to the second seating module, (ii) the first connector is coplanar with the second connector, (iii) the first side extends along a horizontal plane as the first seating module is positioned upright for seating, and (iv) the second side extends along the horizontal plane as the second seating module is positioned upright for seating.
5. A method comprising: shipping a corner sectional modular sofa distributed across a set of sections configured to be assembled into a set of modules to a premises of an end user such that the end user performs an assembly of the corner sectional modular sofa from the set of sections on the premises, wherein the set of modules includes an armrest module, a first seating module, a second seating module, and a third seating module, wherein the first seating module includes a first seating section having a first side hosting a first connector, wherein the second seating module includes a second seating section having a second side hosting a second connector, wherein the corner sectional modular sofa is assembled on the premises by the end user: connecting the first seating module to the armrest module and the second seating module such that (i) the first seating module is positioned between the armrest module and the second seating module, (ii) the first connector is connected to the second connector such that (a) the first seating section is connected to the second seating section, (b) the first connector is coplanar with the second connector, (c) the first side extends along a horizontal plane while the first seating section is positioned upright for seating, and (d) the second side extends along the horizontal plane while the second seating section is positioned upright for seating, and (iii) the armrest module, the first seating module, and the second seating module form a first section of the corner sectional modular sofa where the first seating module and the armrest module form a corner seating module, forming a second section of the corner sectional modular sofa to include the third seating module, and connecting the third seating module to the corner seating module such that the first section and the second section form the corner sectional modular sofa.
6. A method comprising: sending a kit to a premises of an end user, wherein the kit includes a first seating section, a second seating section, a first backrest section, a second backrest section, and an armrest section, wherein the armrest section includes an armrest wall hosting an armrest connector, wherein the second backrest section includes a backrest wall hosting a backrest connector, wherein the first seating section, the second seating section, the first backrest section, the second backrest section, and the armrest section are configured for assembly into a modular furniture piece on the premises by the end user: (a) arranging the first seating section and the first backrest section without use of any tool to form a first seating module; (b) arranging the second seating section, the second backrest section, and the armrest section without use of any tool to form a second seating module such that the armrest connector connects with the backrest connector and the armrest wall faces the backrest wall; and (c) positioning the first seating module adjacent to the second seating module.
7. A method comprising: sending a kit to a premises of an end user, wherein the kit includes a first seating section, a second seating section, a first backrest section, and a second backrest section, wherein the first seating section includes a first side hosting a first connector, wherein the second seating section includes a second side hosting a second connector, wherein the first seating section, the second seating section, the first backrest section, and the second backrest section are configured for assembly into a modular furniture sofa on the premises by the end user: arranging the first seating section and the first backrest section without use of any tool to form a first seating module; arranging the second seating section and the second backrest section without use of any tool to form a second seating module; and connecting the first connector to the second connector without use of any tool such that (i) the first seating section is connected to the second seating section, (ii) the first connector is coplanar with the second connector, (iii) the first side extends along a horizontal plane while the first seating section is positioned upright for seating, and (iv) the second side extends along the horizontal plane while the second seating section is positioned upright for seating.
8. A method comprising: sending a kit to a premises of an end user, wherein the kit includes a first seating section, a second seating section, a first backrest section, and a second backrest section, wherein the first seating section includes a first side hosting a first connector, wherein the second seating section includes a second side hosting a second connector, wherein the first backrest section includes a third side hosting a third connector, wherein the second backrest section includes a fourth side hosting a fourth connector, wherein the first seating section, the second seating section, the first backrest section, and the second backrest section are configured for assembly into a modular furniture sofa on the premises by the end user: arranging the first seating section and the first backrest section without use of any tool to form a first seating module; arranging the second seating section and the second backrest section without use of any tool to form a second seating module; and connecting (a) the first connector to the second connector without use of any tool such that (i) the first seating section is connected to the second seating section, (ii) the first connector is coplanar with the second connector, (iii) the first side extends along a horizontal plane while the first seating section is positioned upright for seating, and (iv) the second side extends along the horizontal plane while the second seating section is positioned upright for seating and (b) third connector to the fourth connector without use of any tool such that (i) the first backrest section is connected to the second backrest section, (ii) the third side extends along a vertical plane while the first seating section is positioned upright for seating, (iii) the fourth side extends along the vertical plane while the second seating section is positioned upright for seating, and (iv) the third side opposes the fourth side.
9. The method of claim 1, wherein the first underside connector includes a clip, wherein the second underside connector including a catch, wherein the first underside connector is connected to the second underside connector by the catch engaging the clip.
10. The method of claim 9, wherein the clip is a first clip, wherein the catch is a first catch, wherein the third underside connector includes a second clip, wherein the fourth underside connector including a second catch, wherein the third underside connector is connected to the fourth underside connector by the second catch engaging the second clip.
11. The method of claim 1, wherein the first portion includes a first backrest section including a first wall hosting a first wall connector and a second backrest section including a second wall hosting a second wall connector, wherein the first portion is assembled by the first backrest section extending from the first seating section such that a first individual seat is formed and the second backrest section extending from the second seating section such that a second individual seat is formed while the first wall connector is connected to the second wall connector and the first wall opposes the second wall.
12. The method of claim 11, wherein the second portion includes a third backrest section including a third wall hosting a third wall connector and a fourth backrest section including a fourth wall hosting a fourth wall connector, wherein the second portion is assembled by the third backrest section extending from the third seating section such that a third individual seat is formed and the fourth backrest section extending from the fourth seating section such that a fourth individual seat is formed while the third wall connector is connected to the fourth wall connector and the third wall opposes the fourth wall.
13. The method of claim 1, wherein the first portion is assembled without use of any tool.
14. The method of claim 13, wherein the second portion is assembled without use of any tool.
15. The method of claim 1, wherein the first portion is secured to the second portion on a wall-to-wall basis.
16. The method of claim 1, wherein the first portion is secured to the second portion on an underside-to-underside basis.
17. The method of claim 2, wherein the first seat is connected to the armrest section at the first backrest section or the second seat at the first backrest section.
18. The method of claim 17, wherein the first seat is connected to the armrest section at the first backrest section and the second seat at the first backrest section.
19. The method of claim 2, wherein the first seating section includes a first side hosting a first connector, wherein the second seating section includes a second side hosting a second connector, wherein connecting the first seat to the second seat includes the first connector connecting to the second connector such that (i) the first seating section is connected to the second seating section, (ii) the first connector is coplanar with the second connector, (iii) the first side extends along a horizontal plane as the first seating section is positioned upright for seating, and (iv) the second side extends along the horizontal plane as the second seating section is positioned upright for seating.
20. The method of claim 19, wherein the first connector includes a clip, wherein the second connector includes a catch, wherein the first connector is connected to the second connector by the catch engaging the clip.
21. The kit of claim 3, wherein the first package contains the first leg assembly or the second leg assembly.
22. The kit of claim 3, wherein the second package contains the first leg assembly or the second leg assembly.
23. The kit of claim 3, wherein the third package contains the first leg assembly or the second leg assembly.
24. The kit of claim 3, wherein the fourth package contains the first leg assembly or the second leg assembly.
25. The kit of claim 3, wherein arranging (i) the first seating section and the first backrest section such that the first seat is formed and (ii) the second seating section and the second backrest section such that the second seat is formed is without use of any tool.
26. The kit of claim 3, wherein connecting (i) the first seating sidewall connector to the second seating sidewall connector, (ii) the first backrest sidewall connector to the second backrest sidewall connector, and (iii) the armrest section to the first seat such that the first seat is positioned between the armrest section and the second seat is without use of any tool.
27. The kit of claim 3, wherein fastening (i) the first leg assembly to the first seating underside and the armrest section while the first seat rests on the first backrest section as the armrest section is connected to the first seat such that the first leg assembly spans between the first seating underside and the armrest section and (ii) the second leg assembly to the first seating underside and the second seating underside while the second seat rests on the second backrest section as the armrest section is connected to the first seat such that the second leg assembly spans between the first seating underside and the second seating underside is without use of any tool.
28. The kit of claim 3, wherein connecting the first underside seating connector to the second underside seating connector while the first seat rests on the first backrest section and the second seat rests on the second backrest section while the armrest section is connected to the first seat is without use of any tool.
29. The corner sectional modular sofa of claim 4, wherein the first seating module includes a backrest section having a first wall hosting a first wall connector, wherein the armrest module has a second wall hosting a second wall connector, wherein the first seating module is connected to the armrest module via the first wall connector connecting to the second wall connector as the first wall opposes the second wall when the first seating module and the armrest module are positioned upright for seating.
30. The corner sectional modular sofa of claim 4, wherein the first seating module includes a first backrest section having a first wall hosting a first wall connector, wherein the second seating module includes a second backrest section having a second wall hosting a second wall connector, wherein the first seating module is connected to the second seating module via the first wall connector connecting to the second wall connector as the first wall opposes the second wall when the first seating module and the second seating module are positioned upright for seating.
31. The corner sectional modular sofa of claim 4, wherein the first seating module includes a first backrest section having a first wall hosting a first wall connector and a second wall hosting a second wall connector, wherein the armrest module includes a third wall hosting a third wall connector, wherein the second seating module includes a second backrest section having a fourth wall hosting a fourth wall connector, wherein the first seating module is connected to the armrest module and the second seating module via the first wall connector connecting to the third wall connector as the first wall opposes the third wall and the second wall connector connecting to the fourth wall connector as the second wall opposes the fourth wall when the first seating module, the armrest module, and the second seating module are positioned upright for seating.
32. The corner sectional modular sofa of claim 4, wherein the first seating module is connected to the armrest module and the second seating module without use of any tool to do so.
33. The corner sectional modular sofa of claim 4, wherein the third seating module is connected to the corner seating module without use of any tool to do so.
34. The corner sectional modular sofa of claim 4, wherein the third seating module includes a backrest section, wherein the third seating module is connected to the corner seating module at the backrest section.
35. The corner sectional modular sofa of claim 4, wherein the third seating module includes a seating section, wherein the third seating module is connected to the corner seating module at the seating section.
36. The corner sectional modular sofa of claim 35, wherein the third seating module is connected to the corner seating module at the seating section along a horizontal plane extending along the third seating module and the corner seating module.
37. The corner sectional modular sofa of claim 4, wherein the first connector includes a clip, wherein the second connector includes a catch, wherein the first connector is connected to the second connector such that the catch engages the clip.
38. The method of claim 5, wherein the first seating module includes a backrest section having a first wall hosting a first wall connector, wherein the armrest module has a second wall hosting a second wall connector, wherein the first seating module is connected to the armrest module via the first wall connector connecting to the second wall connector as the first wall opposes the second wall when the first seating module and the armrest module are positioned upright for seating.
39. The method of claim 5, wherein the first seating module includes a first backrest section having a first wall hosting a first wall connector, wherein the second seating module includes a second backrest section having a second wall hosting a second wall connector, wherein the first seating module is connected to the second seating module via the first wall connector connecting to the second wall connector as the first wall opposes the second wall when the first seating module and the second seating module are positioned upright for seating.
40. The method of claim 5, wherein the first seating module includes a first backrest section having a first wall hosting a first wall connector and a second wall hosting a second wall connector, wherein the armrest module includes a third wall hosting a third wall connector, wherein the second seating module includes a second backrest section having a fourth wall hosting a fourth wall connector, wherein the first seating module is connected to the armrest module and the second seating module via the first wall connector connecting to the third wall connector as the first wall opposes the third wall and the second wall connector connecting to the fourth wall connector as the second wall opposes the fourth wall when the first seating module, the armrest module, and the second seating module are positioned upright for seating.
41. The method of claim 5, wherein the first seating module is connected to the armrest module and the second seating module without use of any tool to do so.
42. The method of claim 5, wherein the third seating module is connected to the corner seating module without use of any tool to do so.
43. The method of claim 5, wherein the third seating module includes a backrest section, wherein the third seating module is connected to the corner seating module at the backrest section.
44. The method of claim 5, wherein the third seating module includes a seating section, wherein the third seating module is connected to the corner seating module at the seating section.
45. The method of claim 44, wherein the third seating module is connected to the corner seating module at the seating section along a horizontal plane extending along the third seating module and the corner seating module.
46. The method of claim 5, wherein the first connector includes a clip, wherein the second connector includes a catch, wherein the first connector is connected to the second connector such that the catch engages the clip.
47. The method of claim 6, wherein the armrest connector connects with the backrest connector by releasably mating.
48. The method of claim 6, wherein the first seating section includes a first side hosting a first side connector, wherein the second seating section includes a second side hosting a second side connector, wherein the first seating section is connected to the second seating section such that (i) the first side connector is connected to the second side connector, (ii) the first side connector is coplanar with the second side connector, (iii) the first side extends along a horizontal plane while the first seating section is positioned upright for seating, and (iv) the second side extends along the horizontal plane while the second seating section is positioned upright for seating.
49. The method of claim 48, wherein the first side connector includes a clip, wherein the second side connector includes a catch, wherein the first side connector is connected to the second side connector such that the catch engages the clip.
50. The method of claim 6, wherein the backrest wall is a first backrest wall, wherein the backrest connector is a first backrest connector, wherein the second backrest section includes a second backrest wall hosting a second backrest connector, wherein the first backrest section includes a third backrest wall hosting a third backrest connector, wherein the second backrest connector connects with the third backrest connector as the second backrest wall faces the third backrest wall.
51. The method of claim 50, wherein the second backrest connector connects with the third backrest connector by releasably mating.
52. The method of claim 6, wherein the modular furniture piece is a corner sectional sofa.
53. The method of claim 6, wherein the modular furniture piece is not a corner sectional sofa.
54. The method of claim 6, wherein the modular furniture piece is not a sofa.
55. The method of claim 7, wherein the first connector includes a clip, wherein the second connector includes a catch, wherein the first connector is connected to the second connector such that the catch engages the clip.
56. The method of claim 7, wherein the first backrest section includes a first wall hosting a first wall connector, wherein the second backrest section includes a second wall hosting a second wall connector, wherein the modular furniture sofa is assembled on the premises by the end user connecting the first wall connector to the second wall connector without use of any tool such that the first wall opposes the second wall.
57. The method of claim 56, wherein the modular furniture sofa is assembled on the premises by the end user connecting the first wall connector to the second wall connector without use of any tool by releasably mating.
58. The method of claim 7, wherein the kit includes an armrest section, wherein the first backrest section includes a first wall hosting a first wall connector, wherein the armrest section includes a second wall hosting a second wall connector, wherein the modular furniture sofa is assembled on the premises by the end user connecting the first wall connector to the second wall connector without use of any tool such that the first wall opposes the second wall.
59. The method of claim 58, wherein the modular furniture sofa is assembled on the premises by the end user connecting the first wall connector to the second wall connector without use of any tool by releasably mating.
60. The method of claim 58, wherein the modular furniture sofa is a corner sectional sofa.
61. The method of claim 58, wherein the modular furniture sofa is not a corner sectional sofa.
62. The method of claim 8, wherein the first connector includes a clip, wherein the second connector includes a catch, wherein the first connector is connected to the second connector such that the catch engages the clip.
63. The method of claim 8, wherein the third connector is connected to the fourth connector without use of any tool by releasably mating.
64. The method of claim 8, wherein the kit includes an armrest section including a fifth side hosting a fifth connector, wherein the second backrest section includes a sixth side hosting a sixth connector, wherein the modular furniture sofa is assembled on the premises by the end user connecting the fifth connector to the sixth connector without use of any tool such that the fifth side opposes the sixth side.
65. The method of claim 64, wherein the fifth connector is connected to the sixth connector without use of any tool by releasably mating.
66. The method of claim 8, wherein the modular furniture sofa is a corner sectional sofa.
67. The method of claim 8, wherein the modular furniture sofa is not a corner sectional sofa.
68. A method comprising: sending a kit to a premises of an end user, wherein the kit includes a first seating section, a second seating section, a backrest section, an armrest section, and a leg assembly, wherein the armrest section includes an armrest wall hosting an armrest connector, wherein the backrest section includes a backrest wall hosting a backrest connector, wherein the first seating section, the second seating section, the backrest section, the armrest section, and the leg assembly are configured for assembly into a modular furniture piece on the premises by the end user: arranging (a) the first seating section, the backrest section, and the armrest section without use of any tool to form a seating portion such that the armrest connector connects with the backrest connector and the armrest wall faces the backrest wall, (b) the leg assembly such that the leg assembly extends underneath the armrest section and the first seating section, and (c) the second seating section to be positioned adjacent to the first seating section.
69. The method of claim 68, wherein the kit includes a package containing the first seating section, the backrest section, and the leg assembly.
70. The method of claim 68, wherein the modular furniture piece is a corner sectional sofa.
71. The method of claim 70, wherein the kit includes a corner seating section, a first corner backrest section, and a second corner backrest section, wherein the first corner backrest section includes a first corner backrest side hosting a first corner backrest connector, wherein the second corner backrest section includes a second corner backrest side hosting a second corner backrest connector, wherein the corner seating section, the first corner backrest section, and the second corner backrest section are configured for assembly into the modular furniture piece on the premises by the end user: connecting the first corner backrest connector with a first adjacent backrest connector and the second corner backrest connector with a second adjacent backrest connector such that the first corner backrest section and the second corner backrest section extend from the corner seating section forming a corner module, wherein the armrest section opposes the first corner backrest section, wherein the first corner backrest section extends along a first plane and the second corner backrest section extends along a second plane orthogonal to the first plane, wherein the first adjacent backrest connector and the second adjacent backrest connector avoid facing each other, wherein the modular furniture piece includes the corner module.
72. The method of claim 68, wherein (a) occurs before (b).
73. The method of claim 68, wherein (b) occurs before (a).
74. The method of claim 6, wherein (a) occurs before (b).
75. The method of claim 6, wherein (b) occurs before (a).
76. The method of claim 75, wherein (c) occurs contemporaneously with (a).
Description
BRIEF DESCRIPTION OF DRAWINGS
(1) Non-limiting embodiments of the present disclosure are described by way of example with reference to the accompanying figures which are schematic and are not intended to be drawn to scale. Unless indicated as representing the background art, the figures represent aspects of the disclosure.
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DETAILED DESCRIPTION
(44) The present disclosure is here described in detail with reference to embodiments illustrated in the drawings, which form a part here. Other embodiments may be used and/or other changes may be made without departing from the spirit or scope of the present disclosure. The illustrative embodiments described in the detailed description are not meant to be limiting of the subject matter presented here. Furthermore, the various components and embodiments described herein may be combined to form additional embodiments not expressly described, without departing from the spirit or scope of the invention.
(45) Reference will now be made to the exemplary embodiments illustrated in the drawings, and specific language will be used here to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Alterations and further modifications of the inventive features illustrated here, and additional applications of the principles of the inventions as illustrated here, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention.
(46) A sofa includes a seat, a back, and arms. In the modular sofa described herein, components or subassemblies of a sofa are collectively sometimes called “modules.” A “seating module” refers to a component that includes a seat (also herein called a seat section) and a back or backrest (also herein called a backrest section). An “armrest module” (also herein called armrest) refers to a component that includes an arm of a sofa. One or more armrest modules can be assembled with one or more seating modules as the subassemblies of a modular sofa.
(47) In various embodiments, the modular sofa includes a plurality of seating modules, such as two or three seating modules. In other embodiments, the modular sofa includes a single seating module. In various embodiments, the modular sofa also includes two armrest modules, referred to herein as a left armrest and a right armrest. In other embodiments, the modular sofa includes a single armrest module. In the embodiment of
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(50) In the first assembly state shown in
(51) The upper and lower backrest portions 132, 134 are coupled to each other for relative pivotal movement at hinge 138. The seating modules include a plurality of seating connectors 140 used in assembling the seating modules to each other and to armrest modules (not shown in
(52) As used herein, “connectors,” such as seating connectors 140 and back connectors 160, are mechanisms configured to hold together adjacent modules of modular sofa 100 in a side-by-side relationship. Individual connectors may be referred to as “clips,” and two joined connectors may be referred to as a clip. “Side edge surfaces” of seating modules and armrest modules may refer to surfaces that face to the left or to the right when the modules are in their normal use configurations in modular sofa 100. In an embodiment, side edge surfaces are substantially planar surfaces configured for side-by-side abutting engagement when adjacent modules are assembled and secured to each other.
(53) Ordinal numbers, such as first and second, are sometimes used to distinguish between left connectors and right connectors of a seating module, or between connectors of different modules. Given ordinal numbers (e.g., first seating connectors) may refer to left or right connectors, or connectors of different modules, depending on context. Similarly, a given ordinal number in referring to an axis along which particular connectors extend (e.g., first axis) may refer to axes of different connectors or different modules, depending on context. Ordinal numbers, such as first and second, are sometimes used to distinguish between left side edge surfaces and right side edge surfaces of a seating module, or between side edge surfaces of different modules. Given ordinal numbers (e.g., first side edge surface) may refer to left or right side edge surfaces, or side edge surfaces of different modules, depending on context.
(54) Various directional terms, such as right, left, upper, lower, top, bottom, and middle, are based on a perspective of a modular sofa standing in its normal orientation during use as viewed from the front. These directional terms are retained when viewing the sofa, or parts or subassemblies of the sofa, from other perspectives. For example, in
(55) At the second assembly stage seen in
(56) Module 110 includes seating connectors 144, 146 at the left edge surface 122 and seating connectors 154, 156 at the right edge surface 124. More generally, each of the seating modules includes two left seating connectors 142 at the left edge surface of the seating section 120. In an embodiment, one connector is located toward the front of the seating section and one is located toward the back of the seating section 120. Each of the seating modules includes two right seating connectors 152 at the right edge surface of that seating section 120. In an embodiment, one connector is located toward the front of the front of the seating section 120 and one is located toward the back of the back of the seating section 120. Additionally, each of the seating modules includes one back connector 160 at the left edge surface 122 in the backrest section 130, and one back connector 160 at the right edge surface 124 in the backrest section 130 (not visible in
(57) At the third assembly stage shown in
(58) At the fourth assembly stage shown in
(59) At the fifth assembly stage shown in
(60) At the sixth assembly stage shown in
(61) At the seventh assembly stage shown in
(62) At the eighth assembly stage shown in
(63)
(64)
(65) In an embodiment, the connectors 144, 146 and connectors 154, 156 incorporate a dowel pin mechanism for coupling adjacent modules. Mounting pins 145 (also called dowel pins) extend along a first axis, e.g., at a substantially 90° angle from the side edge surface 122. Mounting slots 155, 157 extend along a second axis, e.g., at a substantially 90° angle from the side edge surface 124. As used in the present disclosure, a “slot” may refer to an opening that extends along an axis, or may refer to an aperture at the surface of a module, depending on context. In aligning and joining connectors 144, 146 to connectors 154, 156, the user aligns the pins and slots and thereby aligns the first axis with the second axis. The user may then easily move the seating modules including these respective connectors together, via sliding relative movement of the connectors.
(66) This assembly stage, e.g., shown in
(67)
(68) In an embodiment, the first back clip 164 is always located on the right side of seating modules 110, 114, 118, and second back clip 162 is always located on the left side of seating modules 110, 114, 118. In this embodiment, the left armrest module may include a back clip of the same configuration as the first back clip 164 (e.g., as shown at 180 in
(69)
(70)
(71)
(72)
(73)
(74) It should be understood that in modular sofa embodiments incorporating dowel pin (pin and slot) connectors, the modular sofa may utilize other pin and slot configurations than shown in
(75) A further modular sofa embodiment shown in
(76) The left armrest module 372 further includes a front armrest seat connector 370, and rear armrest seat connector 375. These slotted armrest seat connectors both have a dual-slot configuration as contrasted to the single-slot configuration of slotted connectors in the embodiment of
(77)
(78)
(79) In one embodiment, each of the seating modules and armrest modules is formed of a frame made from a suitable structural material such as soft or hard woods, chipboard, medium-density fiberboard, oriented strand board or plywood. The frame is in turn upholstered at required locations in fabric, leather, lining cloth, inter-liner, or other appropriate material, or combinations of materials. References in the present disclosure to structures of the modular sofa such as seating modules and armrest modules, and to portions of these structures such as surfaces, may refer to various materials including, e.g., frame and upholstering. For example, the seating module 310 of
(80)
(81)
(82)
(83)
(84)
(85)
(86) AC power cable 220 extends from cubic power adaptor 210 to and beyond the back edge 229 of the bottom surface 126 of modular sofa 100. AC power cord 220 terminates at a power plug, e.g., a three prong AC plug in accordance with the North American standard, which may be plugged into a power outlet located behind modular sofa 100.
(87)
(88) In the embodiments of
(89) Some or all elements of power cradle 200 may be pre-assembled to the bottom surface 126 of a seating module as that module is shipped, and some or all elements of power cradle 200 may be assembled by user to the bottom surface during the assembly of modular sofa 100. For example, a mounting dock 240 may be pre-assembled to the bottom surface and/or one or more fastening strip 250 may be pre-assembled to the bottom surface, as shown in
(90)
(91) At step 4, the user aligns the pins and mating slots of adjacent modules, then slides the modules together. In an embodiment, middle module 114 is slid into abutting engagement with right module 118, then left module 110 is slid into abutting engagement with middle module 114. At step 5, the user aligns the armrests with the seating modules, and slides the armrests into abutting engagement with the adjacent seating modules. Then, the user secures all eight latches (or other securement device; e.g., threaded fasteners as in
(92) At step 7 (
(93) At step 10, the user secures the power cord to the sofa bottom using two fastening strips that are pre-assembled to the sofa bottom at two locations between the mounting dock and the rear edge of the seating module. In an embodiment, these power strips are Velcro® hook and loop lineal fabric strips. At step 11, the user reorients the modular sofa in its upright, use orientation, and at step 12 the user arranges cushions on the sofa seat and backrest.
(94) In further embodiments, the modular sofa of the present disclosure can be assembled with one or more other types of modules besides sofa seating modules and sofa armrest modules to form a combination sofa that includes other furniture, including a shelf, refrigerator, table, or the like. For example, one edge surface of a seating module can include connectors in accordance with the present disclosure that join with connectors at an abutting edge surface of an end table module. Additionally, the modular components of the present disclosure can incorporate a corner seating module that includes seating connectors at adjacent first and second edge surfaces of the corner seating module. In this embodiment, the corner seating module would be connected to one or more seating module at the first edge surface of the corner seating module, and to one or more seating module at the second edge surface of the corner seating module, thereby forming a corner sectional sofa.
(95)
(96) The corner module 400 of
(97) The exploded view of
(98) Corner base 400 includes a lower horizontal surface 420 and a plurality of edge walls extending upwardly from lower horizontal surface 420. In an embodiment, corner base 400 defines a substantially polygonal horizontal shape including four or more side edges, such as a square, rectangle or rhombus. In various embodiments, the plurality of edge walls include first and second edge walls 413, 414 located at a front portion of corner base 400, and third and fourth edge walls 416, 418 located at a rear portion of corner base 400. In an embodiment, first edge wall 413 and second edge wall 415 are low profile members that define outer side edge surfaces 411, 412 adjoining a front corner 419 of the substantially polygonal horizontal shape. In an embodiment, side edge surfaces 411, 412 are oriented perpendicularly to each other, and the substantially polygonal horizontal shape is substantially square. In an embodiment, third edge wall 416 and fourth edge wall 418 are more prominent than first and second edge walls 413, 414, and include guide surfaces for engaging corner backs 430, 450. In an embodiment, third and fourth edge walls 413, 414 guide and engage the corner backs during assembly, and support the corner backs 430, 450 in the assembled corner base 410. In an embodiment, the lower horizontal surface 420 carries base connectors 422, 424, 426, 428. In an embodiment, the base connectors are located at a rear portion of the lower horizontal surface adjacent edge walls 416 and 418, and the base connectors and edge walls act together to securely engage and support the corner backs 430, 450 in the assembled corner module. In an embodiment, base connectors 422, 424, 426, 428 are located at an elevated section 421 of lower horizontal surface 420.
(99) First corner back 430 and second corner back 450 are vertically extending members configured to provide backrest surfaces. The corner backs 430, 450 are also called corner backrest sections in the present disclosure. First corner back 430 includes a backrest surface 438, outer side edge surface 432, and inner side edge surface 434. Similarly, second corner back 450 includes a backrest surface 458, outer side edge surface 452, and inner side edge surface 454. First corner back 430 includes a mounting portion 436 at a lower region of the first corner back, and second corner back 450 includes a mounting portion 456 at a lower region of the second corner back. In an embodiment, mounting portion 436 and mounting portion 456 are indented surfaces of the first and second corner backs. During assembly of the corner module, mounting portions 436, 456 are configured to engage third and fourth edge walls 416, 418 of base 410 during assembly and form an engineering fit with edge walls 416, 418 to firmly secure first corner back 430 and second corner back 450 to corner base 410.
(100) First corner back 430 includes at its bottom edge connectors 436, 438 that are configured respectively to engage connectors 422, 424 when corner back 430 is lowered into mating alignment with corner base 410. Second corner back 450 includes at its bottom edge connectors 456, 458 that are configured respectively to engage connectors 426, 428 when corner back 450 is lowered into mating alignment with corner base 410. In an embodiment, these respective connectors form dowel joints that provide releasable connections of the corner backs to the corner base. In an embodiment, the connectors at corner base include dowel pins, while the connectors at corner backs 430, 450 include slots (not visible in
(101) In an embodiment, first corner back 430 includes a first set of inner back connectors 444, 446 at its inner edge surface 434, and second corner back 450 includes a second set of inner back connectors 464, 466 at its inner edge surface 434. In an embodiment, the back connectors form dowel joints. In an embodiment, each of the inner back connectors 464 and 466 includes a pin extending from the second inner side edge surface 454, while each of the inner back connectors 444, 446 includes a mating slot (not visible in
(102)
(103) In an embodiment, corner seating connectors 522, 524, 526, 528 incorporate a latch mechanism for securing connection of a corner base of an assembled corner module to an adjacent furniture module. In an embodiment, the latch mechanism is a toggle latch mechanism at the bottom of corner base 500, such as the toggle match mechanism shown at
(104) As shown in
(105) An exemplary process for assembling a corner sectional sofa includes three stages. At the first stage, the user assembles benches 630 and 650, e.g., using the modular sofa assembly process shown at
(106) At the second assembly stage, the user assembles the corner module, and joins the corner module to the corner bench 630.
(107) At step 4 (
(108) At the third assembly stage, the user completes assembly of the wing bench and joins the wing bench to the corner bench to complete assembly of the corner sectional. At completion of stage two the corner bench 610 should have two support leg plates 644 protruding from the open side of the corner 640 (
(109) Although the exemplary embodiments recite the use of furniture modules and connectors to form a sofa and a corner sectional, it is intended that the modules and connectors described herein can be used to form other types of furniture besides a sofa and a corner sectional, including seating surfaces, beds, tables, shelving, and the like. Components for furniture can utilize the connectors described herein to construct the furniture using modules that are coupled using these connectors.
(110) While various aspects and embodiments have been disclosed, other aspects and embodiments are contemplated. The various aspects and embodiments disclosed are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
(111) The foregoing method descriptions and the interface configuration are provided merely as illustrative examples and are not intended to require or imply that the steps of the various embodiments must be performed in the order presented. As will be appreciated by one of skill in the art the steps in the foregoing embodiments may be performed in any order. Words such as “then,” “next,” etc. are not intended to limit the order of the steps; these words are simply used to guide the reader through the description of the methods. Although process flow diagrams may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a function, its termination may correspond to a return of the function to the calling function or the main function.