Sofa with shipping and use configuration

Abstract

A ready to assemble or knockdown sofa having a back rest that can be reconfigured between a use configuration in which the sofa is has a conventional L-shaped cross-section and a shipping or storage configuration in which the sofa is arranged in a more efficiently stacked rectangular cross-section. The rectangular cross-section allows the sofa to be more efficiently stacked with other sofas during shipping or storage. The back rest has an upper back rest portion and a lower back rest portion in which the upper back rest portion can be rotated forward toward the front of the sofa and downwardly into a nesting region against the top of the seat base to provide a more efficient shape.

Claims

1. A boxed knock down sofa in a shipping configuration and having a use configuration, the boxed knock down sofa comprising: a box: a seat base in the box, the seat base having a rectangular foot print, a top side, a bottom side, a front side, a back side, a left side and a right side, the seat base defining an open interior space; a plurality of seat cushions in the box and sized for the top side of the seat base; a seat back rest portion permanently attached to and extending upwardly at the back side of the seat base, the seat back rest portion having an upper back portion and a lower back portion hinged together, the upper back portion is folded forwardly and laying on a front surface of the lower back portion whereby, the upper back portion rotatable upwardly, when removed from the box, to the use configuration whereby a front surface of the upper back portion is positioned above and is aligned with the front surface of the lower back portion, in a shipping configuration; and a plurality of back cushions in the box, the back cushions being positioned over the top side of the seat base to fill dead space and create a rectangular cross-section and, when the sofa is in the use configuration, the plurality of back cushions are positioned upright and forward of and covering the front side of the lower back portion and the front side of the upper back portion.

2. The boxed knock down sofa of claim 1, wherein the seat back rest portion has a taper going upwardly when the upper back portion is in the upright use position.

3. The boxed knock down sofa of claim 1, wherein the rotation of the upper back portion with respect to the lower back portion is at least 160 degrees.

4. The boxed knock down sofa of claim 1, wherein the upper back portion, when in the upright use position, has a downwardly facing flat surface that is elongate and rectangular and that corresponds to and abuts against a like sized upwardly facing surface on the lower back portion.

5. The boxed knock down sofa of claim 1, wherein the downwardly facing flat surface of the upper back portion and the upwardly facing surface of the lower back portion have cooperating patches of hook and loop engagement material.

6. The boxed knock down sofa of claim 1, further comprising a pair of arm rests in the box, the pair of arm rests removably attachable on the left side and right side of the seat base.

7. The boxed knock down sofa of claim 6, wherein the pair of arm rests having a height, and the top surface of the lower back portion has a height and said height is positionable at or below the height of the arm rests when the arm rests are attached to the seat base, and the heights are within 20% of one another.

8. The boxed knock down sofa of claim 6, wherein the arm rests are removably attachable to the seat base by at a plurality of at least one of: a) bolts with manually turnable handles and b) vertically engagable brackets.

9. The boxed knock down sofa of claim 6, wherein the arm rests are removably attachable to the seat base and are stowable within the seat base during storage or shipment.

10. The boxed knock down sofa of claim 1, wherein when the sofa is in the shipping configuration the upper back portion of the seat back rest portion is resting against the lower back portion of the seat back rest portion such that a back side of the upper back portion is facing forward and the back cushions are positioned against and forwardly of the back side of the upper portion.

11. The boxed knock down sofa of claim 1, wherein the front side of the upper back portion has hook and loop material and the plurality of back cushions each have cooperating hook and loop material whereby the back cushions may be attached to a front side of the upper back portion of the seat back rest portion in the use position.

12. The boxed knock down sofa of claim 1, the upper back portion is positioned above the seat cushions when in the shipping configuration.

13. The boxed knock down sofa of claim 1, wherein when the upper back portion is in the stowed position, a lower side, when in the use position, of the upper back portion and an upper side of the lower back portion are coplanar.

14. The boxed knock down sofa of claim 1, wherein when the upper back portion is in the stowed position, an upwardly horizontal surface of the upper back portion and an upper side of the lower back portion are substantially coplanar.

15. The boxed knock down sofa of claim 1, wherein the upper back portion and lower back portion, when the upper back portion is in the upright use position, each have a front side and a front side surface, and wherein when the upper back portion is in the shipping configuration, the front side surface of the upper back portion rests against the front side surface of the lower back portion.

16. The boxed knock down sofa of claim 1, wherein the seat cushions are removably placeable within the seat base with access from a removable sheet material cover on the bottom side of the seat base.

17. The boxed knock down sofa of claim 1, wherein the upper back portion and lower back portion each present an upwardly facing surface with a total width, front to back, of at least 4 inches.

18. The boxed knock down sofa of claim 1, wherein the sofa has a shipping configuration and wherein when in the shipping configuration the upper back portion rests against the lower back portion with the front side surface of the upper back portion resting against the front side surface of the lower back portion, the seat cushions are on top of the seat base.

19. A boxed knock down sofa in a shipping configuration and having a use configuration, the boxed knock down sofa comprising: a box: a seat base in the box, the seat base having a rectangular foot print, a top side, a bottom side, a front side, a back side, a left side and a right side, the seat base defining an open interior space; a plurality of seat cushions in the box and sized for the top side of the seat base; a seat back rest portion permanently attached to and extending upwardly at the back side of the seat base, the seat back rest portion having an upper back portion and a lower back portion hinged together, the upper back portion is folded forwardly and laying on a front surface of the lower back portion whereby, the upper back portion rotatable upwardly, when removed from the box, to the use configuration whereby a front surface of the upper back portion is positioned above and is aligned with the front surface of the lower back portion, in a shipping configuration; and a plurality of back cushions in the box, the back cushions being positioned inside the open interior space defined by the seat base and, when the sofa is in the use configuration, the plurality of back cushions are positioned upright and forward of and covering the front side of the lower back portion and the front side of the upper back portion.

20. A boxed knock down sofa in a shipping configuration and having a use configuration, the boxed knock down sofa comprising: a box: a seat base in the box, the seat base having a rectangular foot print, a top side, a bottom side, a front side, a back side, a left side and a right side, the seat base defining an open interior space; a plurality of seat cushions in the box and sized for the top side of the seat base; a seat back rest portion permanently attached to and extending upwardly at the back side of the seat base, the seat back rest portion having an upper back portion and a lower back portion hinged together, the upper back portion is folded forwardly and laying on a front surface of the lower back portion whereby, the upper back portion rotatable upwardly, when removed from the box, to the use configuration whereby a front surface of the upper back portion is positioned above and is aligned with the front surface of the lower back portion, in a shipping configuration; and a plurality of back cushions in the box, whereby when the sofa is in the use configuration, the plurality of back cushions are positioned upright and forward of and covering the front side of the lower back portion and the front side of the upper back portion.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention can be completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:

(2) FIG. 1a is a front perspective view of a sofa in a use position according to an embodiment of the present invention.

(3) FIG. 1b is a bottom view of a sofa, particularly the seat base, illustrating stowage regions according to an embodiment of the present invention.

(4) FIG. 1c is a side perspective view of a sofa in a storage or shipping configuration with the hinged top portion of the back rest pivoted downwardly in a storage or shipping configuration according to an embodiment of the present invention.

(5) FIG. 2 is a side view of a base and lower back portion and a raised upper back portion according to the invention described herein.

(6) FIG. 3 is a side view of a base and lower back portion and a lowered upper back portion according to the invention described herein.

(7) FIG. 4 is a perspective view of a sofa illustrating the sizing of a box that would contain said sofa when in a shipping configuration according to an embodiment of the present invention.

(8) FIG. 5 is a pictorial view of a sofa according to an embodiment of the present invention in a shipping configuration.

(9) FIG. 6 is a pictorial view of a sofa according to an embodiment of the present invention in a shipping configuration.

(10) FIG. 7 is a pictorial view of a sofa according to an embodiment of the present invention in a shipping configuration.

(11) FIG. 8 is a cross-sectional view through a sofa with the back rest rotated downwardly according to an embodiment of the present invention.

(12) FIG. 9 is a cross-sectional view through a packaged sofa in a box according to an embodiment of the present invention.

(13) While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail herein. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION

(14) As depicted in FIGS. 1-4, a sofa 20, according to an embodiment of the present invention, comprises a seat base 22 and an upright lower back rest portion 30 integral with the seat base. “Integral” in that they are fixed together at the factory with permanent fasteners, glue, and may have common frame members and they are not detachable from one another without damage. Moreover, the upholstery may run continuously between the base and lower back rest portion. In some embodiments, the sofa 20 can further comprise a pair of arm rests 24, 26. The seat base 22 comprises a box frame 40 comprising a rectangular shape and having a left side 54, a left side outwardly facing surface 55, a right side 56, a right side outwardly facing surface 58, a front side 57, and a front side outwardly facing surface 59. The back side 68 comprises a back side outwardly facing surface 69, a bottom side 60, and a top 50 comprising a top surface 52. The box frame 40 defines an open interior space 62. In some embodiments, the seat base 22 can further comprise upholstery 46, seat springs 42 and seat stretchers 44. In other embodiments, the seat base 22 comprises wood or wood products.

(15) As depicted in FIGS. 1-4, the lower back rest portion 30 comprises a front side 66, a front surface 67, a back side 68, a back side surface 69, and an upwardly facing horizontal surface 69.1 that is a seating surface for an upper back rest portion 70. The lower back rest portion 72 is affixed to the back side 68 of the seat base 22. The upper back rest portion 70 is pivotally attached to the lower back rest portion 72 with at least one hinge 74. The upper back rest portion 70 has an upright position where it is seated and secured to the lower back rest portion as shown in FIGS. 2 and 4. In said position the upper back rest portion 70 has an upper forward surface 68.1 and an upper rearward surface 68.2 and has a downward facing horizontal surface 68.4. The upper back rest portion also has a lowered downward folded position as shown in FIGS. 1C, 3, 7, and 8. In the upright position, the front surface 67 of the lower back rest portion 72 is aligned with the front surface of the upper back rest portion, and the rearward surface of the upper back rest portion 70 is in alignment with the rearward surface of the lower back rest portion 70 and the rearward surface of the base. In the folded position the horizontal surface 68.4 is aligned with the horizontal surface 69.1 of the lower back rest portion 70 to define a continual horizontal surface for supporting a box or stacked sofa 20.

(16) In certain embodiments, the combined width of the horizontal surface 68.4 of the upper back rest portion 70 and the horizontal surface 69.1 can be at least four inches. In other embodiments, the combined width can be at least six inches. In other embodiments, the combined width can be at least eight inches. The engagement of the forward surface 68.1 of the upper back rest portion 70 with the front surface 67 of the lower back rest portion 72 prevents further rotation of the upper back rest portion 70 allowing the horizontal surface 68.4 of the upper back rest portion 70 to support a box wall. In certain embodiments, the vertical length of the engagement portion between the upper back rest portion 70 and the lower back rest portion 72 is at least six inches. In other embodiments, the vertical length of the engagement portion is at least eight inches. In other embodiments, the vertical length of the engagement portion is at least ten inches.

(17) The hinge 90 may comprise at least two leaf portions 92 and a pin 94. Each leaf portion 92 comprises a plurality of knuckles 96 arranged in an alternating fashion with the knuckles 96 of the opposing leaf portion 92 such that the pin 94 can be inserted through the knuckles 96 to rotatably secure the leaf portions 92 together. Each leaf portion 92 defines a plane, wherein the knuckles 96 are offset from the plane defined by the leaf portion 92. Other hinges may include sheet material, fabric, or polymer living hinge. In operation, one leaf portion 92 is affixed to the upper back rest portion 70, while the opposing leaf portion 92 is affixed to the lower back rest portion 72 such that the upper back rest portion 70 is rotatable with respect to the lower back rest portion 72. The upper back rest portion 70 is rotatable between the upright position in which the upper back rest portion 70 is positioned over the lower back rest portion 72 to define a conventional L-shaped seating shape and a lowered position in which the upper back rest portion 70 is rotated forwardly and downwardly such that the upper back rest portion and lower back rest portion folded together define a generally rectangular or rhombus or quadrilateral cross-section. In the upright position, the offset arrangement of the knuckles 96 angles the upper back rest portion 70 slightly downward in the rearward direction to minimize the risk that the upper back rest portion 70 inadvertently rotates toward the lowered position when a user is seated on the sofa 20. In embodiments, the upper back rest portion 70 can further comprise a securing element 76, while the lower back rest portion 72 can further comprise a cooperating securing element 78. Hook and loop strips, known as Velcro material are suitable for the securing elements. In this configuration, the cooperating securing elements 76, 78 are positioned such that the securing elements 76, 78 are engaged together securing the upper back rest portion 70 to the lower back rest portion 72 when the upper back rest portion 70 is positioned in the upright position. As illustrated, the upper back rest portion 70 is rotated such that the front side 66 of the upper back rest portion 70 is positioned against the front side 66 of the lower back rest portion 72.

(18) As depicted in FIGS. 5-7, the sofa 20 can further comprise at least one back rest cushion 38 affixable to the front side 66 of the back rest 30. In this configuration, the back rest cushion 38 can further comprise a releasable securing element 88 for releasably securing the back rest cushion 30 to the front side 66 of the back rest 30. The releasable securing element 88 can comprise Velcro, a zipper, a button or other conventional means of releasably securing the back rest cushion 30 to the back rest 30. In this configuration, the back rest cushions 38 can be removed from the back rest 30 and stored within the interior space 62. Alternatively, the back rest cushions 38 can be positioned on the top 50 of the seat base 22 or on a seat cushion 36 secured to the top 50 of the seat base 22 to fill the dead space and create a rectangular cross-section for efficient packing.

(19) Referring to FIGS. 2 and 3, and generally the other figures, the arm rests 24, 26 can be attached to the left side 54 and the right side 56 of the box frame 40. In embodiments, the arm rests 24, 26 can be releasably secured to the seat base 22 and lower back rest such that the arm rests 24, 26 can be separated from the seat base 22 and stored within the interior space 62 during shipping or storage. The arm rests 24, 26 can be secured with corresponding alignment brackets 80, fasteners extending through respective walls or brackets of the arm rests and seat base apertures 82 and other known means.

(20) When used herein, “removably attachable” means without damage to the respectable components using brackets and threaded connectors.

(21) As illustrated in FIGS. 4-8, the configuration described herein provides significant packaging advantages. The lower base portion fixed to the base provides an inherently strong robust rectilinear box shape structure ideal for shipping. Securing the otherwise protruding armrests below the base provides a secure location for them. The two horizontal faces on each side of the hinge of the upper and lower back rest portions provide a structurally sound surface abutting, typically with padding, the inside surface 98 of the box 100. A rotatable seat stretcher 108 may be rotated upwardly to accommodate stowage in the base and rotated downward to provide clearance for spring travel.

(22) While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and described in detail herein. It is understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.