Title of Invention: Article of ready-to-assemble furniture
Abstract: A corner unit for an article of sectional furniture. In an exemplary embodiment, the corner unit includes a frame having a plurality of frame members. The frame may include two internal frame members which are disposed substantially perpendicular to each other. The internal frame members provide rigidity and strength to the frame without requiring other angled cuts and connections for the frame. The frame may also include a cover assembly which provides a seat and at least one storage compartment. The frame members may be interconnected by interlocking protrusions and cutout portions, as well as by threaded fasteners received in push-in connector elements which are held in recesses within the frame members.
Detailed Description: Part general_description_paragraphs: Part BACKGROUND: 1. Field of the Disclosure
The present disclosure relates generally to custom ordered furniture and the construction and packaging of such furniture for shipment and storage. More particularly, the disclosure relates to fully upholstered, ready-to-assemble furniture which may be custom ordered by a consumer, packaged by the seller for shipment to the consumer by a parcel delivery service, and then assembled by the consumer from the packaged components.
2. Description of the Related Art
Ready-to-assemble furniture is furniture which is packaged for shipment and storage in disassembled form, with assembly to be done by the consumer or end user. Examples of existing ready-to-assemble non-upholstered furniture include bookcases, television stands, and simple chairs and benches. Mass merchandized, ready-to-assemble furniture is expected to be rather less expensive to the consumer than comparable pre-assembled furniture or to have distinctive functional features generally not available with its pre-assembled counterpart.
The genre of ready-to-assemble furniture packaged for mass merchandizing sale and home delivery has generally been limited to pieces of furniture which are utilitarian or hard-surfaced. As such, prior ready-to-assemble furniture does not satisfy the need for primary pieces of fully upholstered furniture which may be custom ordered by the consumer, and either delivered to the household of the consumer by a parcel delivery service, or taken home by the consumer from a retail location.
What is needed is ready-to-assemble furniture of high quality and stable construction which may be packaged in a compact, easily storable and transportable manner, for easy shipment via existing, non-particularized home delivery channels.
Part SUMMARY: The present disclosure provides a corner unit for an article of sectional furniture. In an exemplary embodiment, the corner unit includes a frame having a plurality of frame members. The frame may include two internal frame members which are disposed substantially perpendicular to each other. The internal frame members provide rigidity and strength to the frame without requiring other angled cuts and connections for the frame. The frame may also include a cover assembly which provides a seat and at least one storage compartment. The frame members may be interconnected by interlocking protrusions and cutout portions, as well as by threaded fasteners received in push-in connector elements which are held in recesses within the frame members.
In one form thereof, the present disclosure provides a corner unit for an article of sectional furniture, including at least a first internal frame member and a second internal frame member disposed substantially perpendicular with respect to each other; at least a first sectional facing frame member and a second sectional facing frame member, said sectional facing frame members respectively connected to said first internal frame member and said second internal frame member; and a first backrest frame member and a second backrest frame member, said first and second backrest frame members at least partially defining a backrest, said first and second backrest frame members respectively connected to said first internal frame member and said second internal frame member.
In another form thereof, the present disclosure provides a corner unit for an article of sectional furniture, including a backrest portion; a seating portion; and at least a first internal frame member and a second internal frame member each defining at least a portion of said seating portion and said backrest portion, said first internal frame member and said second internal frame member disposed in overlapping relationship and substantially perpendicular with respect to each other.
In yet another form thereof, the present disclosure provides a corner unit for an article of sectional furniture, the corner unit including a sectional facing portion and a backrest portion, including a storage area defined by a plurality of interconnected frame members having upper edges; and a cover assembly supported by said upper edges, said cover assembly defining at least two diverging planar seating surfaces.
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate embodiments of the disclosure and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
Part DETAILED DESCRIPTION: Except as described below, article of furniture 30 includes many features similar to the articles of furniture described in U.S. Pat. No. 7,044,557, entitled ARTICLE OF READY-TO-ASSEMBLE FURNITURE; U.S. Pat. No. 6,981,747, entitled FULLY UPHOLSTERED, READY-TO-ASSEMBLE ARTICLE OF FURNITURE; U.S. Pat. No. 6,568,058, entitled METHOD OF ASSEMBLING A FULLY UPHOLSTERED READY-TO-ASSEMBLE ARTICLE OF FURNITURE; and U.S. Pat. No. 6,267,446, entitled COMPRESSED UPHOLSTERED FURNITURE ASSEMBLY KIT AND METHOD OF MANUFACTURE, all of which are assigned to the assignee of the present disclosure, the disclosures of which are expressly incorporated herein by reference.
Referring now to FIG. 1, article of furniture 30 is shown and may be formed as a sectional corner unit. Article of furniture 30 may be a portion of sectional sofa unit 31, shown in FIG. 2, which may include other sectional units 64a, 64b. 
Referring now to FIG. 3, article of furniture 30 may include frame 32 having a plurality of individual frame members 34 which are assembled together to form frame 32.
As shown in FIG. 4, frame members 34 generally may include lower front or sectional facing panels 34a, 34b, upper front or sectional facing panels 34c, 34d, lower intermediate panels 34e, 34f, upper intermediate panels 34g, 34h, lower rear panels 34i, 34j, upper rear panels 34k, 34l (FIG. 14), base panels 34m (FIG. 9A), 34n (FIG. 9A), backrest panels 34o (FIG. 15), 34p (FIG. 16), support panel 34q (FIG. 17A), and seat panels 34r (FIG. 18), 34s (FIG. 3).
Frame members 34 may also include projections 36 and cutout portions 38, which are insertable into one another to connect adjacent frame members 34. As shown with reference to upper front panel 34c in FIG. 4, for example, cutout portions 38 may include slots 38a and apertures 38b. For securing adjacent frame members 34, recesses 40 are provided and are adapted to receive push-in connector elements 42. Frame members 34 may also include apertures 44 which receive fasteners 46 (FIG. 7, for example) cooperating with connector fastener holes 43 (FIG. 5, for example) of push-in connector elements 42, as described below. As described in detail in the above-incorporated U.S. Pat. No. 6,568,058, push-in connector elements 42 may be formed of any suitable plastic and may receive fasteners 46 in connector fastener holes 43. Push-in connector elements 42 provide secure connections between frame members 34 when a fastener 46 is inserted through aperture 44 in a frame member 34 and tapped or screwed into connector fastener hole 43 of push-in connector element 42. Each frame member 34 may include number cutout 48. The numbering of frame members 34 eases assembly of frame 32 by allowing individual frame members 34 to be identified and referred to in a set of printed assembly instructions, for example. Number cutouts 48 are unrelated to the reference numerals used in the present disclosure.
Referring now to FIG. 5, an initial step of the assembly process involves attaching foot caps to a selected portion of the frame members. Some frame members 34, such as lower front panels 34a, 34b and lower intermediate panels 34e, 34f, may include feet 50 which may each be covered by foot cap 52 which is pressed onto each foot 50. Foot caps 52 engage a floor surface to prevent frame 32 from sliding thereon, and to prevent frame 32 from scratching the floor surface. Foot caps 52 also serve as a protective “boot” to protect feet 50 from water or moisture, and to protect feet 50 from contact with other objects which may cause feet 50 to dent, flake, or delaminate.
Referring to FIG. 6, the next step of the assembly process involves constructing the front, or sectional facing, and intermediate panels of frame 32. Each upper front panel 34c, 34d includes projection 36 and each lower front panel 34a, 34b includes slot 38a. Upper front panel 34c and lower front panel 34a are interlocked together by inserting projection 36 of upper front panel 34c into slot 38a of lower front panel 34a. Similarly, upper front panel 34d and lower front panel 34b are interlocked together by inserting projection 36 of upper front panel 34d into slot 38a of lower front panel 34b. Each upper intermediate panel 34g, 34h includes projection 36 and each lower intermediate panel 34e, 34f includes slot 38a. Upper intermediate panel 34g and lower intermediate panel 34e are interlocked together by inserting projection 36 of upper intermediate panel 34g into slot 38a of lower intermediate panel 34e. Similarly, upper intermediate panel 34h and lower intermediate panel 34f are interlocked together by inserting projection 36 of upper intermediate panel 34h into slot 38a of lower intermediate panel 34f. 
Referring to FIG. 7, the next step of the assembly process involves interlocking one of the front panels with one of the intermediate panels. Lower front panel 34a includes aperture 38b and lower intermediate panel 34e includes projection 36. Lower intermediate panel 34e is interlockingly connected to lower front panel 34a by inserting projection 36 of lower intermediate panel 34e into aperture 38b of lower front panel 34a. Fastener 46 may be inserted through aperture 44 in lower front panel 34a and into connector fastener hole 43 (FIG. 5) of push-in connector element 42 in lower intermediate panel 34e. 
Referring to FIG. 8, the next step of the assembly process involves interlocking the two front panels. Lower front panel 34a includes slot 38a and projection 36 and lower front panel 34b includes slot 38a and projection 36. Lower front panel 34a is interlockingly connected to lower front panel 34b by inserting projection 36 of lower front panel 34a into slot 38a of lower front panel 34b and by inserting projection 36 of lower front panel 34b into slot 38a of lower front panel 34a. Fasteners 46 may be inserted through apertures 44 provided in each lower front panel 34a, 34b and into connector fastener holes 43 provided in respective push-in connector elements 42 in each lower front panel 34b, 34a. 
Referring to FIGS. 9A and 9B, the next step of the assembly process involves interlocking the base panels to the front panels and one of the intermediate panels. Each lower front panel 34a, 34b and lower intermediate panel 34e includes at least two apertures 38b. Each base panel 34m, 34n includes a plurality of projections 36. As shown in FIG. 9B, lower front panel 34b and lower intermediate panel 34e may be slightly moved away from each other while still maintaining the interlocking connections with lower front panel 34a, such as to facilitate insertion of base panels 34m, 34n. For example, lower front panel 34b is moved slightly in the general direction of arrow A in FIG. 9B and lower intermediate panel 34e is moved slightly in the general direction of arrow B in FIG. 9B. Such movement of panels 34b, 34e provides a clearance for insertion of base panels 34m, 34n, specifically, such movement of panels 34b, 34e allows passage of projections 36 of base panels 34m, 34n during movement of base panels 34m, 34n in the general direction of arrow C and insertion of projections 36 into corresponding apertures 38b in each lower front panel 34a, 34b and lower intermediate panel 34e. 
Referring to FIG. 10, the next step of the assembly process involves interlocking the other intermediate panel to the front panels and the first intermediate panel. Lower intermediate panel 34e includes slot 38a. Lower front panel 34b includes slot 38a and aperture 44. Lower intermediate panel 34f includes slot 38a and projection 36. Lower intermediate panel 34f is interlockingly connected to lower intermediate panel 34e by interlocking slot 38a of lower intermediate panel 34f with slot 38a of lower intermediate panel 34e (i.e., slot 38a of intermediate panel 34e slides through slot 38a of lower intermediate panel 34f, after which slot 38a of intermediate panel 34e engages lower intermediate panel 34f above slot 38a of lower intermediate panel 34f and slot 38a of intermediate panel 34f engages lower intermediate panel 34e below slot 38a of lower intermediate panel 34e) and by engaging projection 36 of lower intermediate panel 34f with slot 38a of lower front panel 34b. A portion of lower intermediate panel 34e extends rearwardly, i.e., away from the sectional facing portions of frame 32, of the interlocking connection with lower intermediate panel 34f. Similarly, a portion of lower intermediate panel 34f extends rearwardly of the interlocking connection with lower intermediate panel 34e. Such overlapping of lower intermediate panel 34e and lower intermediate panel 34f creates added stability for frame 32. Fastener 46 may be inserted through aperture 44 provided in lower front panel 34b and into connector fastener hole 43 in push-in connector element 42 disposed in lower intermediate panel 34f. 
The partially assembled frame 32 shown in FIG. 10 is formed of four interlockingly engaged planar frame members 34 which are arranged at approximately 90° angles with respect to each other, i.e., lower front panel 34a forms an approximate 90° angle with lower front panel 34b and lower intermediate panel 34e, lower front panel 34b forms an approximate 90° angle with lower front panel 34a and lower intermediate panel 34f, lower intermediate panel 34f forms an approximate 90° angle with lower front panel 34b and lower intermediate panel 34e, and lower intermediate panel 34e forms an approximate 90° angle with lower front panel 34a and lower intermediate panel 34f. Advantageously, a 45° angled cut or intersection between these primary support frame members of frame 32 is not necessary; therefore, frame 32 is stronger and easier to assemble and manufacture than a frame requiring such frame members with 45° angled cuts and/or intersections.
Referring to FIG. 11, the next step of the assembly process involves interlocking one of the lower rear panels to the remainder of the partially assembled frame. Lower front panel 34b may include slot 38a and aperture 44. Lower rear panel 34i may include projection 36 and aperture 44. Lower rear panel 34i is interlockingly connected to lower front panel 34b by engaging projection 36 of lower rear panel 34i with slot 38a of lower front panel 34b. Fastener 46 may be inserted through aperture 44 in lower rear panel 34i and into connector fastener hole 43 in push-in connector element 42 disposed in lower front panel 34b. Similarly, fastener 46 may be inserted through aperture 44 in lower front panel 34b and into connector fastener hole 43 in push-in connector element 42 disposed in lower rear panel 34i. Lower intermediate panel 34e may include projections 36 and lower rear panel 34i may include slots 38a and aperture 44. Lower rear panel 34i is interlockingly connected to lower intermediate panel 34e by engaging projections 36 of lower intermediate panel 34e into slots 38a in lower rear panel 34i. Fastener 46 may be inserted through aperture 44 in lower rear panel 34i and into connector fastener hole 43 in push-in connector element 42 disposed in lower intermediate panel 34e. 
Referring to FIG. 12, the next step of the assembly process involves interlocking the other lower rear panel to the remainder of the partially assembled frame. Lower rear panel 34i may include slot 38a and lower rear panel 34j may include projection 36 and apertures 44. Lower rear panel 34j is interlockingly connected to lower rear panel 34i by engaging projection 36 of lower rear panel 34j into slot 38a of lower rear panel 34i. Fasteners 46 may be inserted through apertures 44 in lower rear panel 34j and into connector fastener holes 43 in push-in connector elements 42 disposed in lower rear panel 34i. Lower rear panel 34j may include at least two slots 38a and aperture 44 and lower intermediate panel 34f may include projections 36. Lower rear panel 34j is interlockingly connected to lower intermediate panel 34f by engaging projections 36 of lower intermediate panel 34f into slots 38a of lower rear panel 34j. Fastener 46 may be inserted through aperture 44 in lower rear panel 34j and into connector fastener hole 43 of push-in connector element 42 disposed in lower intermediate panel 34f. Lower front panel 34a may include projections 36, slot 38a, and aperture 44 and lower rear panel 34j may include projection 36, slots 38a, and aperture 44. Lower rear panel 34j is interlockingly connected to lower front panel 34a by engaging projections 36 of lower front panel 34a with slots 38a of lower rear panel 34j and by engaging projection 36 of lower rear panel 34j with slot 38a of lower front panel 34a. Fastener 46 may be inserted through aperture 44 in lower rear panel 34j and into connector fastener hole 43 in push-in connector element 42 disposed in lower front panel 34a. Similarly, fastener 46 may be inserted through aperture 44 in lower front panel 34a and into connector fastener hole 43 (not shown) in push-in connector element 42 disposed in lower rear panel 34j. 
Referring to FIG. 13, the next step of the assembly process involves interlocking one of the upper rear panels to the remainder of the partially assembled frame. Upper front panel 34d may include projections 36 and slot 38a and upper rear panel 34k may include projection 36, slots 38a, and aperture 44. Upper rear panel 34k is interlockingly connected to upper front panel 34d by engaging projections 36 of upper front panel 34d with slots 38a of upper rear panel 34k and by engaging projection 36 of upper rear panel 34k with slot 38a of upper front panel 34d. Fastener 46 may be inserted through aperture 44 in upper rear panel 34k and into connector fastener hole 43 in push-in connector element 42 disposed in upper front panel 34d. Upper intermediate panel 34g may include projections 36 and upper rear panel 34k may include slot 38a, aperture 38b, and aperture 44. Upper rear panel 34k is interlockingly connected to upper intermediate panel 34g by engaging projections 36 of upper intermediate panel 34g with slot 38a and aperture 38b of upper rear panel 34k. Fastener 46 may be inserted through aperture 44 in upper rear panel 34k and into connector fastener hole 43 in push-in connector element 42 disposed in upper intermediate panel 34g. 
Referring to FIG. 14, the next step of the assembly process involves interlocking the other upper rear panel to the remainder of the partially assembled frame. Upper front panel 34c may include projections 36 and slot 38a and upper rear panel 34l may include projection 36, slots 38a, and aperture 44. Upper rear panel 34l is interlockingly connected to upper front panel 34c by engaging projections 36 of upper front panel 34c with slots 38a of upper rear panel 34l and by engaging projection 36 of upper rear panel 34l with slot 38a of upper front panel 34c. Fastener 46 may be inserted through aperture 44 in upper rear panel 34l and into connector fastener hole 43 in push-in connector element 42 disposed in upper front panel 34c. Upper intermediate panel 34h may include projections 36 and upper rear panel 34l may include slot 38a, aperture 38b, and aperture 44. Upper rear panel 34l is interlockingly connected to upper intermediate panel 34h by engaging projections 36 of upper intermediate panel 34h with slot 38a and aperture 38b of upper rear panel 34l. Fastener 46 may be inserted through aperture 44 in upper rear panel 34l and into connector fastener hole 43 in push-in connector element 42 disposed in upper intermediate panel 34h. Upper rear panel 34k may include slot 38a and projection 36 and upper rear panel 34l may include projection 36, slot 38a, and aperture 44. Upper rear panel 34l is interlockingly connected to upper rear panel 34k by engaging projection 36 of upper rear panel 34k with slot 38a of upper rear panel 34l and by engaging projection 36 of upper rear panel 34l with slot 38a of upper rear panel 34k. Fastener 46 may be inserted through aperture 44 in upper rear panel 34l and into connector fastener hole 43 in push-in connector element 42 disposed in upper rear panel 34k. 
Referring to FIG. 15, the next step of the assembly process involves interlocking one of the backrest panels to the remainder of the partially assembled frame. Backrest panel 34o may include four apertures 44. Backrest panel 34o is interlockingly connected to upper front panel 34c, lower front panel 34a, lower intermediate panel 34f, and upper intermediate panel 34h. Fasteners 46 may be inserted through apertures 44 in backrest panel 34o and into connector fastener holes 43 in push-in connector elements 42 disposed in upper front panel 34c, lower front panel 34a, lower intermediate panel 34f, and upper intermediate panel 34h. Backrest panel 34o provides a backrest for a user as well as a back support for back cushion 62 (FIG. 1).
Referring to FIG. 16, the next step of the assembly process involves interlocking the other of the backrest panels to the remainder of the partially assembled frame. Backrest panel 34p may include four apertures 44. Backrest panel 34p is interlockingly connected to upper front panel 34d, lower front panel 34b, lower intermediate panel 34e, and upper intermediate panel 34g. Fasteners 46 may be inserted through apertures 44 in backrest panel 34p and into connector fastener holes 43 in push-in connector elements 42 disposed in upper front panel 34d, lower front panel 34b, lower intermediate panel 34e, and upper intermediate panel 34g. Backrest panel 34p provides a backrest for a user as well as a back support for back cushion 62 (FIG. 1).
Referring to FIG. 17A, the next step of the assembly process involves assembling a support member for supporting at least a portion of the seat of the frame. The intersection of lower intermediate panels 34e, 34f forms rear junction 35b toward the rear of frame 32 and the intersection of lower front panels 34a, 34b forms front junction 35a toward the front of frame 32. Support panel 34q may be positioned in frame 32 to extend from rear junction 35b to front junction 35a. Support panel 34q may also include a generally tapered top edge, i.e., height H1 of support panel 34q matches height H1 of lower intermediate panels 34e, 34f at rear junction 35b and height H2 of support panel 34q matches height H2 of lower front panels 34a, 34b at front junction 35a. In an exemplary embodiment, height H2 of lower front panels 34a, 34b at front junction 35a may be greater than height H1 of lower intermediate panels 34e, 34f at rear junction 35b. Thus, support panel 34q defines a seat rise from the rear of frame 32 toward the front of frame 32. Referring to FIGS. 17A and 17B, support panel 34q also at least partially defines two separate and distinct storage compartments 54a, 54b within frame 32.
Referring to FIG. 18, the next step of the assembly process involves assembling one of the seat panels to the remainder of the partially assembled frame. Seat panel 34r may include slots 38a and handle aperture 56 and lower front panel 34a may include projection 36. Seat panel 34r is interlockingly connected to lower front panel 34a and lower intermediate panel 34f by engaging projection 36 of lower front panel 34a with slot 38a of seat panel 34r and engaging the remaining slots 38a of seat panel 34r with more rearward portions of lower front panel 34a and lower intermediate panel 34f, i.e., proximate the attachment of backrest panel 34o thereto. Handle aperture 56 may be provided for a user of article of furniture 30 to easily lift seat panel 34r to access storage compartment 54a. 
Seat panel 34r may be generally triangularly-shaped and rests upon the upper edges of lower front panel 34a, lower intermediate panel 34e, and support panel 34q, which together are disposed in the same plane which is inclined in accordance with a seat rise, as described below. When positioned on frame 32, seat panel 34r generally rises from the rear of frame 32 toward the front of frame 32 due to the increasing height of lower front panel 34a from the rear toward front junction 35a of frame 32 and due to the increasing height of support panel 34q from rear junction 35b toward front junction 35a of frame 32, i.e., height H2 defined by lower front panel 34a and support panel 34q toward front junction 35a of frame 32 is greater than height H1 defined by lower front panel 34a, support panel 34q, and lower intermediate panel 34e toward rear junction 35b of frame 32. Seat panel 34r may define a first plane.
Referring again to FIG. 3, the next step of the assembly process involves assembling the other seat panel to the remainder of the partially assembled frame. Seat panel 34s may include slots 38a and handle aperture 56 and lower front panel 34b may include projection 36. Seat panel 34s is interlockingly connected to lower front panel 34b and lower intermediate panel 34e by engaging projection 36 of lower front panel 34b with slot 38a of seat panel 34s and engaging the remaining slots 38a of seat panel 34s with more rearward portions of lower front panel 34b and lower intermediate panel 34e, i.e., proximate the attachment of backrest panel 34p thereto. Handle aperture 56 may be provided for a user of article of furniture 30 to easily lift seat panel 34s to access storage compartment 54b. Seat panels 34r, 34s provide a seating surface and a support for seat cushion 60 (FIG. 1).
Seat panel 34s may be generally triangularly-shaped and rests upon the upper edges of lower front panel 34b, lower intermediate panel 34f, and support panel 34q, which together are disposed in the same plane which is inclined in accordance with a seat rise, as described below. When positioned on frame 32, seat panel 34s generally rises from the rear of frame 32 toward the front of frame 32 due to the increasing height of lower front panel 34b from the rear toward front junction 35a of frame 32 and due to the increasing height of support panel 34q from rear junction 35b toward front junction 35a of frame 32, i.e., height H2 defined by lower front panel 34b and support panel 34q toward front junction 35a of frame 32 is greater than height H1 defined by lower front panel 34b, lower intermediate panel 34f, and support panel 34q toward rear junction 35b of frame 32. In an exemplary embodiment, seat panel 34s may define a second plane which diverges from and is non-coplanar with the first plane defined by seat panel 34r. 
The final steps of construction for article of furniture 30 of FIG. 1 are described in detail in the above-incorporated U.S. Pat. No. 6,568,058. Fabric upholstery covers are draped over frame 32 and secured thereto via hook-and-loop fasteners, for example. Fabric covers are also designed to fit over foam padding elements or pillows made for the various cushions of article of furniture 30. For example, back cushions 62 are constructed using a fabric cover fitted over a pillow. In contrast, for example, seat cushion 60 may be constructed using a fabric cover fitted over a foam pad. The cushions are then placed on upholstered frame 32 in an arrangement, for example, as shown in FIGS. 1 and 2.
Although described above in a particular order of assembly, frame members 34 and other associated portions of frame 32 may be assembled in a different order than described herein. For example, lower intermediate panel 34e and lower intermediate panel 34f could be assembled together prior to assembling either lower front panel 34a or lower front panel 34b to the lower intermediate panels.
Frame 32 may be joined with other sectional units 64a, 64b of sectional sofa unit 31 via a plurality of connector bolts (not shown) which extend through connector bolt apertures 66 (FIG. 3) in lower front panels 34a, 34b and into similar connector bolt apertures (not shown) in each sectional unit 64a, 64b. 
Each of the above-described planar frame members are of a suitable size so they may be packaged for non-particularized parcel delivery service, as discussed above. The ease of transportation of the shipping packages by merchants or carriers advantageously reduces shipping costs and/or labor. Further, the smaller frame members advantageously allow for compact packaging and gives consumers the option of either receiving home delivery of the furniture by a parcel delivery service, or easily taking the furniture home from a retail location at the time of sale in their own vehicles, rather than requiring them to wait for particularized delivery by the retailer or another carrier.
The number, size and shape of frame members discussed above will vary depending on the article of furniture to be produced. The frame members may be formed of any suitable supporting material, such as pre-finished plywood, oriented strand board (“OSB”), medium density fiberboard (“MDF”), laminated veneer lumber (“LVL”), solid wood boards, laminated particle board, pre-formed plastic or metal pieces, other varieties of fiber board or strand board, or structural cardboard of honeycombed paperboard. Furthermore, fasteners may not be required for securing the frame members. For example, the interconnection of the frame assembly may instead consist of interlocking frame members which may include slots for mutual engagement, or adhesives may be used to join the frame members. The frame members may be pre-finished or may consist of unfinished pieces that the consumers may stain and varnish or paint to suit their individual tastes.
In an exemplary embodiment, the frame members discussed above may be planar sheets or panels, and may be made of medium density fiberboard (“MDF”). MDF is made from fibers of various types of wood which are refined and pressed to form lightweight fiberboard sheets having a strong outer surface which can be finished with most commercial finishing materials such as sealer, varnish, or paint. MDF is available in sheets which may range from ⅜″ thick to 1½″ thick, for example, and the length and width of MDF sheets may vary widely depending upon the supplier. One such MDF material is ½″ GP Superior, available from Georgia-Pacific Co., and manufactured at their Sault Ste. Marie plant in Ontario, Canada. However, MDF is generally widely available from many commercial suppliers. Frame members 34 may be cut from large sheets of MDF using widely-available machinery such as computer-controlled cutting saws and routers, for example.
The construction and size of the various components of the present disclosure advantageously provide to consumers ready-to-assemble upholstered furniture of high quality and low cost. For shipment, the article of furniture may be packaged such that the frame members, connector elements, and fasteners are packaged in a first container, the padding elements are packaged in a second container, and the upholstery covers are packaged in a third container. Each one of the first, second, and third containers may weigh about 70 pounds or less to allow them to be delivered directly to the home of a consumer by a parcel delivery service.
While this disclosure has been described as having exemplary designs, the present disclosure can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the disclosure using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this disclosure pertains and which fall within the limits of the appended claims.


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