PACKAGING FOR FURNITURE CONSOLE

Abstract

A packaging device for a furniture assembly may include a body, a first leg, and a second leg. The body may be configured to at least partially cover a portion of the furniture assembly. The first and second leg may extend from the body. Each of the first and second legs may include a retention feature configured to engage the furniture assembly. The retention features may be movable between a first position in which the retention features allow the first and second legs to be inserted into respective first and second spaces between components of the furniture assembly and a second position in which the retention features restrict removal of the first and second legs from the respective first and second spaces the furniture assembly.

Claims

1. A furniture assembly comprising: a first seat portion; a second seat portion; a third portion positioned between the first seat portion and the second seat portion, wherein a first space is defined between the first seat portion and the third portion and a second space is defined between the second seat portion and the third portion; and a packaging device removably installed onto the furniture assembly, the packaging device comprising: a body at least partially covering the third portion of the furniture assembly; and a first leg and a second leg extending from opposing ends of the body, wherein each of the first and second legs includes a retention feature configured to engage the furniture assembly, wherein the retention features are movable between a first position in which the retention features allow the first and second legs to be inserted into the respective first and second spaces between components of the furniture assembly and a second position in which the retention features restrict removal of the first and second legs from the respective first and second spaces of the furniture assembly.

2. The furniture assembly f claim 1, wherein: a first end of the first leg is attached to the body, a first end of the second leg is attached to the body, and the retention features are disposed at second ends of the first and second legs, respectively.

3. The furniture assembly of claim 2, wherein the first and second legs are spaced apart from each other when the packaging device is installed on the furniture assembly.

4. The furniture assembly of claim 1, wherein the body, the first leg, and the second leg are formed from a sheet of material.

5. The furniture assembly of claim 4, wherein the retention features are formed from the sheet of material.

6. The furniture assembly of claim 5, wherein the body, the first and second legs, and the retention features are integrally formed as a single piece.

7. A furniture assembly comprising: a first seat portion; a second seat portion; a third portion positioned between the first seat portion and the second seat portion, wherein a first space is defined between the first seat portion and the third portion and a second space is defined between the second seat portion and the third portion; and a packaging device removably installed onto the furniture assembly, the packaging device comprising: a body configured to at least partially cover the third portion of the furniture assembly, and a first leg and a second leg extending from opposing ends of the body, wherein each of the first and second legs includes a retention feature configured to engage the furniture assembly, wherein the retention features are movable between a first position in which the retention features allow the first and second legs to be inserted into the respective first and second spaces between components of the furniture assembly and a second position in which the retention features restrict removal of the first and second legs from the respective first and second spaces of the furniture assembly, wherein the body, the first leg, and the second leg are formed from a sheet of material, and wherein each of the retention features includes a first flap and a second flap attached to the first flap.

8. The furniture assembly of claim 7, wherein the first flaps are movable relative to the first and second legs, and wherein the second flaps are movable relative to the first flaps and the first and second legs.

9. The furniture assembly of claim 8, wherein: the first position is a compressed position in which the first and second flaps of each retention feature are at a first angle relative to each other, the second position is an uncompressed position in which the first and second flaps of each retention feature are at a second angle relative to each other, and the first and second angles are different from each other.

10. The furniture assembly of claim 4, wherein the sheet of material is cardboard.

11. The furniture assembly of claim 1, wherein: the third portion is a console assembly, the body and the first and second legs are configured to allow the first leg to be inserted between the first seat portion and the console assembly and to allow the second leg to be inserted between the second seat portion and the console assembly, and the body is configured to span across and at least partially cover the console assembly.

12. The furniture assembly of claim 1, wherein at least one of the components of the furniture assembly is a support beam of a base frame of the furniture assembly, and wherein at least one of the retention features engages the support beam in the second position to restrict removal of the packaging device from the furniture assembly.

13. The furniture assembly of claim 1, wherein at least one of the components of the furniture assembly is an adjustment assembly of the furniture assembly, and wherein at least one of the retention features engages the adjustment assembly in the second position to restrict removal of the packaging device from the furniture assembly.

14.-21. (canceled)

22. A furniture assembly comprising: a base frame; a seat supported by the base frame; and a packaging device configured to be removably installed onto the furniture assembly, the packaging device comprising: a body configured to at least partially cover a portion of the furniture assembly; and a first leg and a second leg extending from the body, each of the first and second legs including a retention feature movable between a first position and a second position, each of the retention features including a first flap and a second flap attached to the first flap, wherein the body, the first leg, and the second leg are formed from a sheet of material, wherein in the second position, the retention features engage the furniture assembly and restrict removal of the packaging device from the furniture assembly.

23. The furniture assembly of claim 22, wherein: the first and second legs extend from opposing ends of the body, a first end of the first leg is attached to the body, a first end of the second leg is attached to the body, and the retention features are disposed at second ends of the first and second legs, respectively.

24. The furniture assembly of claim 22, wherein the first flaps are movable relative to the first and second legs, and wherein the second flaps are movable relative to the first flaps and the first and second legs.

25. The furniture assembly of claim 24, wherein: the first position is a compressed position in which the first and second flaps of each retention feature are at a first angle relative to each other, the second position is an uncompressed position in which the first and second flaps of each retention feature are at a second angle relative to each other, and the first and second angles are different from each other.

26. The furniture assembly of claim 22, wherein the portion of the furniture assembly is a console assembly, and wherein the body is configured to span across and at least partially cover the console assembly.

27. The furniture assembly of claim 22, wherein the base frame includes a support beam, and wherein at least one of the retention features engages the support beam in the second position to restrict removal of the packaging device from the furniture assembly.

28. The furniture assembly of claim 22, the furniture assembly further comprising an adjustment assembly, wherein at least one of the retention features engages the adjustment assembly in the second position to restrict removal of the packaging device from the furniture assembly.

Description

DRAWINGS

[0042] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations and are not intended to limit the scope of the present disclosure.

[0043] FIG. 1 is a perspective view of a furniture assembly including a console assembly;

[0044] FIG. 2 is a perspective view of the furniture assembly and a packaging device exploded from the furniture assembly;

[0045] FIG. 3 is a perspective view of the furniture assembly and the packaging device in an installed position;

[0046] FIG. 4 is a plan view of a sheet of material from which the packaging device is formed;

[0047] FIG. 5 is a perspective view of the sheet of material with retention features of the packaging device formed thereon;

[0048] FIG. 6 is a partial plan view of a leg of the packaging device with the retention features in a compressed state;

[0049] FIG. 7 is a side view of the leg of the packaging device with the retention features in the compressed state;

[0050] FIG. 8 is a partial plan view of a leg of the packaging device with the retention features in a uncompressed state;

[0051] FIG. 9 is a side view of the leg of the packaging device with the retention features in the uncompressed state;

[0052] FIG. 10 is a partial view of components of the furniture assembly with the packaging device in an initial installation position;

[0053] FIG. 11 is a partial view of components of the furniture assembly with the packaging device in a fully installed position;

[0054] FIG. 12 is a partial perspective view of a furniture assembly with the packaging component in a fully installed position; and

[0055] FIG. 13 is a flowchart of a method of forming the packaging device.

[0056] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

[0057] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0058] Example embodiments are provided so that this disclosure will be thorough and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

[0059] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms a, an, and the may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms comprises, comprising, including, and having, are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as a required order of performance. It is also to be understood that additional or alternative steps may be employed.

[0060] When an element or layer is referred to as being on, engaged to, connected to, or coupled to another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being directly on, directly engaged to, directly connected to, or directly coupled to another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., between versus directly between, adjacent versus directly adjacent, etc.). As used herein, the term and/or includes any and all combinations of one or more of the associated listed items.

[0061] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as first, second, and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

[0062] Spatially relative terms, such as inner, outer, beneath, below, lower, above, upper, and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as below or beneath other elements or features would then be oriented above the other elements or features. Thus, the example term below can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0063] With reference to FIGS. 1-3, a seating or furniture assembly 10 is provided. While the furniture assembly 10 shown in FIGS. 1-3 is a sofa, in other configurations, the furniture assembly 10 could be a chair, loveseat, or a chaise, for example. In the configuration shown in FIGS. 1-3, the furniture assembly 10 may include a base frame 11 that supports a first seat portion 12, a second seat portion 14, and a console assembly 16. Each of the first seat portion 12 and the second seat portion 14 may include a seat bottom 18 and a seatback 20. The base frame 11 may include a plurality of support beams 21 (FIGS. 10 and 11) and first and second armrests 22, 23 that are disposed adjacent the first and second seat portions 12, 14, respectively.

[0064] The console assembly 16 may be disposed between the first and second seat portions 12, 14 and may include a console base frame 26 and a movable member 28. The console base frame 26 may be attached to or a part of the base frame 11. In some configurations, the console base frame 26 may include a storage compartment, a cupholder, a locking or latching mechanism, an electrical outlet, motion control interfaces (e.g., switches, buttons, knobs, etc. for controlling motion of the furniture assembly 10) and/or a tray table, for example. The movable member 28 may be movably attached to the console base frame 26. The movable member 28 may be or include a lid for a storage compartment, a foldable tray table, a cover for electronic components, and/or a movable armrest cushion, for example. In some configurations, the movable member 28 may include a peg (or other protrusion) 30 extending therefrom.

[0065] In some configurations the furniture assembly 10 may include one or more adjustment assemblies 34 (FIG. 12). In some configurations, the adjustment assembly 34 (and/or adjustment assemblies) may include a seatback reclining mechanism (e.g., a linkage for moving the seatback 20 relative to the seat bottom 18 between an upright position and a reclined position), a tilting mechanism (e.g., a linkage for moving the seatback 20 and seat bottom 18 relative to the base frame 11 between a nominal position and a rearward tilted position), a lumber adjustment mechanism (e.g., a linkage for moving a lumbar pad relative to the seatback 20 between an extended position and a retracted position), a headrest adjustment mechanism (e.g., a linkage for moving a headrest pad relative to the seatback 20 between an extended position and a retracted position), and/or a legrest mechanism (e.g., a linkage for moving a legrest platform relative to the seat bottom 18 between an extended position and a retracted position). The one or more adjustment assemblies 34 may be mounted to the base frame 11, either or both of the seat bottoms 18, either or both of the seatbacks 20, and/or the console assembly 16.

[0066] FIGS. 2 and 3 depict a packaging device 50 that can be removably installed onto the furniture assembly 10. The packaging device 50 may be configured to retain and/or protect a portion of the furniture assembly 10 from damage during the packaging, transporting, and/or shipping of the furniture assembly 10. In some configurations, the packaging device 50 may be configured to retain and protect at least a portion of the console assembly 16 to prevent unwanted movement of the movable member 28 and to protect the console assembly 16 from damage during the packaging, transporting, and/or shipping of the furniture assembly 10. The packaging device 50 can be easily installed onto the furniture assembly 10 prior to shipment or transport of the furniture assembly 10. The packaging device 50 can be easily removed from the furniture assembly 10 by a retailer or a consumer, for example, once shipment of the furniture member is complete or as desired. In some configurations, the packaging device 50 can be installed onto and removed from the furniture assembly 10 without the use of tools.

[0067] The packaging device 50 may be constructed from any of a variety of materials. The packaging device 50 may be made from a material suitable to retain and/or protect the furniture assembly 10 from damage during the packaging, transporting and/or shipping of the furniture assembly 10. In some configurations, the packaging device 50 may be made from a material that can be deformed (e.g., by cutting and/or folding). In some configurations, the packaging device 50 may be made from a flat sheet of material 49, as shown in FIG. 4. As will be described in more detail below, the packaging device 50 can be formed by cutting and folding portions of the sheet of material 49.

[0068] As shown in FIGS. 2 and 3, the packaging device 50 may include a body 52, a first leg 54, and a second leg 56. The first and second legs 54, 56 may extend from opposing ends of the body 52. In the configuration shown in the figures, the body 52 is substantially planar and rectangular. In other configurations, however, the body 52 may be contoured or shaped to correspond to a portion of the console assembly 16 with which the body 52 will contact when the packaging device 50 is fully installed. As shown in FIGS. 2 and 3, the body 52 may include an aperture 58 that may receive the peg 30 of the console assembly 16. The body 52 of the packaging device 50 may contact the movable member 28 of the console assembly 16 when the packaging device 50 is fully installed.

[0069] In the configuration shown in FIGS. 2 and 3, the legs 54, 56 may be approximately perpendicular to the body 52. As shown in FIG. 3, when the packaging device 50 is installed onto the furniture assembly 10, the first leg 54 is received in a crevice or space between the seat bottom 18 of first seat portion 12 and a lateral side of the console base frame 26, and the second leg 56 is received in a crevice or space between the seat bottom 18 of second seat portion 14 and the opposite lateral side of the console base frame 26.

[0070] Each of the first and second legs 54, 56 of the packaging device 50 may include one or more resiliently compressible retention features 60. The retention features 60 may be disposed at distal ends of the respective first and second legs 54, 56 (e.g., at ends of the leg 54, 56 opposite the ends of the legs 54, 56 that are attached to the body 52). As will be described in more detail below, when the packaging device 50 is installed onto the furniture assembly 10, the retention features 60 may releasably engage components of the furniture assembly 10 to retain the packaging device 50 on the console assembly 16.

[0071] As shown in FIGS. 2, 3, and 6-8, each of the retention features 60 may include a first flap 62 and a second flap 64. The first and second flaps 62, 64 may be attached to each other and may be movable relative to each other. An edge 66 of the first flap 62 may be attached to the leg 54, 56. The edge 66 may define fold or a living hinge about which the first and second flaps 62, 64 may be resiliently bendable or movable relative to the leg 54, 56. The second flap 64 may be attached to the first flap 62 at another edge 68 that may define another fold or living hinge about which the second flap 64 may be resiliently bendable or movable relative to the first flap 62 and the leg 54, 56.

[0072] The retention features 60 may be movable (e.g., by bending or moving about hinges 66, 68) relative to the legs 54, 56 between a compressed position (shown in FIGS. 6, 7, and 10) and an uncompressed position (shown in FIGS. 8, 9, and 11). To move the retention features 60 into the compressed position, the flaps 62, 64 can be squeezed flat against the respective leg 54, 56 (e.g., by bending or moving about hinges 66, 68). Removing the forces squeezing the flaps 62, 64 flat against the leg 54, 56 allows the flaps 62, 64 to spring back to the uncompressed position. As shown in FIGS. 8, 9, and 11, when the retention feature 60 is in the uncompressed position, the first flap 62 may be approximately perpendicular to the leg 54, 56, and the second flap 64 may extend laterally outward from the first flap 62. As shown in FIG. 10, moving the retention features 60 of the first leg 54 to the compressed position allows the first leg 54 and its retention features 60 to be inserted into the crevice or space between the console assembly 16 and the first seat portion 12 and into a space between adjacent components (e.g., adjacent support beams 21). Likewise, moving the retention features 60 of the second leg 56 to the compressed position allows the second leg 56 and its retention features 60 to be inserted into the crevice or space between the console assembly 16 and the second seat portion 14 and into a space between adjacent components (e.g., adjacent support beams 21). Once the legs 54, 56 and retention features 60 have been inserted far enough so that catch surfaces (e.g., an edge of each of the first flaps 62) 70 of the retention features 60 have been moved below an edge of one of the adjacent components (e.g., a lower edge of the support beam 21), the flaps 62, 64 may spring back to the uncompressed position. In this manner, interference or engagement between the catch surfaces 70 and the lower edges of the support beams 21 restricts or prevents removal of the leg 54, 56 from the space between the support beams 21 (as shown in FIG. 11), thereby retaining the packaging device 50 in an installed position. In the configuration shown in the figures, the catch surfaces 70 may be approximately perpendicular to the edges 66 and the legs 54, 56 when the retention features 60 are in the uncompressed position. In the compressed position, the catch surfaces 70 may be nearly parallel to the legs 54, 56. In the configuration shown in the figures, edge 68 of each retention feature 60 may extend from the respective edge 66 to the respective catch surface 70.

[0073] FIG. 12 shows an alternative configuration in which the retention features 60 in the uncompressed position interfere with or engage one or more of the adjustment assemblies 34 (e.g., links of one or more of the adjustment assemblies 34) to retain the packaging device 50 in the installed position. It will be appreciated that the packaging device 50 could be configured such that the retention features 60 interfere with or engage any other suitable component of the furniture assembly 10.

[0074] FIG. 13 is a flow chart illustrating a method 100 of making the packaging device. At step 110 of the method 100, the flat sheet of material (e.g., cardboard, a fibrous material, plastic, a composite material, or any other suitable material) 49 is provided. At step 120, a plurality of cuts can be made in the sheet of material 49 at cut lines 122 (shown in FIG. 4). The cuts could be made with scissors, a utility knife, or a saw, for example. The cuts at cut lines 122 may define the catch surfaces 70 of the retention features 60 described above. At step 130, a plurality of folds can be made at first fold lines 132 (shown in FIG. 4). These folds may form the edges (or hinges) 66 of the retention features 60 and partially define the first flaps 62 of the retention features 60. At step 140, another plurality of folds can be made at second fold lines 142 (shown in FIG. 4). These folds may form the edges (or hinges) 68 of the retention features 60 and define the first and second flaps 62, 64 of the retention features 60 (see FIGS. 4 and 5). At step 150, the first and second flaps 62, 64 can be compressed into or toward the compressed position described above to define the desired angles between the first and second flaps 62, 64 and between the flaps 62, 64 and the legs 54, 56. At step 160, folds can be made at third fold lines 162 (shown in FIG. 4). These folds may form the first and second legs 54, 56 of the packaging device 50 and may define ends of the body 52 and the legs 54, 56. At step 170, one or more cuts (or a drilling) can be made at line 172 to form the aperture 58 in the body 52 of the packaging device 50. After forming the packaging device 50 according to the method above, the packaging device 50 can be installed onto the furniture assembly 10 in the manner described above.

[0075] It will be appreciated that some of steps 120-170 could be performed in different orders than in the order described above and shown in FIG. 13. Furthermore, the use of the terms first, second, and third with reference to fold lines 132, 142, and 162 do not indicate a sequence or order in which the folds must be made. Rather, the folds at fold lines 132, 142, and 162 could be performed in any order.

[0076] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.