US20210093087A1 - Furniture Systems and Furniture System Components - Google Patents

Furniture Systems and Furniture System Components Download PDF

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Publication number
US20210093087A1
US20210093087A1 US17/035,495 US202017035495A US2021093087A1 US 20210093087 A1 US20210093087 A1 US 20210093087A1 US 202017035495 A US202017035495 A US 202017035495A US 2021093087 A1 US2021093087 A1 US 2021093087A1
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United States
Prior art keywords
assembly
arm
seat frame
deck
support frame
Prior art date
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Abandoned
Application number
US17/035,495
Inventor
Lucas Zei
Christian Hunt
Xuan Tuong Dinh
Trung Kien Nguyen
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ALBANY INDUSTRIES
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ALBANY INDUSTRIES
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by ALBANY INDUSTRIES filed Critical ALBANY INDUSTRIES
Priority to US17/035,495 priority Critical patent/US20210093087A1/en
Publication of US20210093087A1 publication Critical patent/US20210093087A1/en
Abandoned legal-status Critical Current

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    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C4/00—Foldable, collapsible or dismountable chairs
    • A47C4/02—Dismountable chairs
    • A47C4/021—Dismountable chairs connected by slotted joints
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C13/00—Convertible chairs, stools or benches
    • A47C13/005—Modular seating
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C15/00—Other seating furniture
    • A47C15/002—Corner seating furniture, e.g. corner sofas
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C17/00—Sofas; Couches; Beds
    • A47C17/04—Seating furniture, e.g. sofas, couches, settees, or the like, with movable parts changeable to beds; Chair beds
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C4/00—Foldable, collapsible or dismountable chairs
    • A47C4/02—Dismountable chairs
    • A47C4/028—Upholstered chairs, e.g. metal, plastic or wooden chairs

Definitions

  • the present disclosure is directed to furniture systems and furniture components and, more particularly, to furniture systems and furniture components for ready to assemble furniture.
  • Furniture systems such as chairs, sofas, love seats, chaise lounges, and sectionals often include complex construction elements that require production and assembly in the same location, thereby potentially increasing labor costs when the final destinations of the systems are in high cost locations.
  • Ready-to-assemble furniture systems which require some assembly at the point of use, are becoming more popular, but often do not exhibit the strength, stability, and/or comfort of pre-assembled furniture systems.
  • many ready-to-assemble furniture systems include components that must be shipped to the end user in separate shipping containers, thereby increasing shipping and handling costs.
  • the present disclosure encompasses furniture systems and furniture system components that can be used in ready-to-assemble furniture products and other furniture products.
  • the present disclosure also encompasses furniture systems and furniture components that can reduce the total volume of shipping container space typically required to ship many conventional furniture systems and furniture components.
  • the present disclosure also encompasses furniture systems and furniture components that can enhance any one or more of the strength, solidity, stability, and/or comfort of a furniture product as compared to some conventional alternative furniture systems and furniture components.
  • the present disclosure encompasses a furniture system comprising: a seat frame assembly, a first side assembly connected to a first side of the seat frame assembly, a second side assembly connected to a second side of the seat frame assembly, wherein the second side of the seat frame assembly opposes the first side of the seat frame assembly, wherein each of the first side assembly and the second side assembly is selected from the group of an arm assembly and a sectional wedge assembly, wherein the seat frame assembly comprises a first seat frame insert projecting from the first side of the seat frame assembly, a second seat frame insert projecting from the second side of the seat frame assembly, a first load-bearing tab aligned proximal to the first seat frame insert and projecting from the first side of the seat frame assembly, a second load-bearing tab aligned proximal to the second seat frame insert and projecting from the second side of the seat frame assembly, wherein the first seat frame insert comprises a first insert body, wherein the second seat frame insert comprises a second insert body, wherein the first side assembly comprises
  • the seat frame assembly further can comprise a third seat frame insert projecting from the first side of the seat frame assembly, a fourth seat frame insert projecting from the second side of the seat frame assembly, a third load-bearing tab aligned proximal to the third seat frame insert and projecting from the first side of the seat frame assembly, a fourth load-bearing tab aligned proximal to the fourth seat frame insert and projecting from the second side of the seat frame assembly, wherein the third seat frame insert comprises a third insert body, wherein the fourth seat frame insert comprises a fourth insert body.
  • the first side assembly further can comprise a third side receiver, wherein the third side receiver comprises a third engagement section, a third locking section, and a third retention wall
  • the second side assembly comprises a fourth side receiver
  • the fourth side receiver comprises a fourth engagement section, a fourth locking section, and a fourth retention wall
  • the third seat frame insert and the third load-bearing tab are disposed in the third side receiver
  • the third load-bearing tab is seated on the third retention wall of the third end receiver
  • the third retention wall of the third end receiver is aligned proximal to the second side assembly and the third insert body of the third seat frame insert is aligned distal to the second side assembly
  • the fourth seat frame insert and the fourth load-bearing tab are disposed in the fourth side receiver, wherein the fourth load-bearing tab is seated on the fourth retention wall of the fourth end receiver, wherein the fourth retention wall of the fourth side receiver is aligned proximal to the first side assembly
  • the furniture system can further comprise a back assembly, wherein the back assembly is mounted to the first side assembly and the second side assembly.
  • the back assembly can be spaced apart from the seat frame assembly.
  • the seat assembly can further comprise a deck.
  • the deck can comprise a front deck web and a rear deck web, wherein the front deck web and the rear deck web define a deck gap.
  • the deck gap can be disposed proximal to the rear support frame member and distal to the front support frame member.
  • the front deck web can be connected to the rear deck web by a plurality of straps.
  • the seat assembly can further comprise a front support frame member and an opposing rear support frame member, wherein the deck comprises a front sleeve encasing a portion of the front support frame member and a rear sleeve encasing a portion of the rear support frame member, and wherein the deck extends between the front support frame member and the rear support frame member.
  • the seat frame assembly can further comprise a first side support frame member aligned proximal to the first side assembly and an opposing second side support frame member aligned proximal to the second side assembly, wherein the first side support frame member and the second side support frame member are connected to the front support frame member and the rear support frame member.
  • the seat assembly can comprise a first side support frame member and an opposing second side support frame member, and wherein the first loadbearing tab is formed on first side support frame member and the second load-bearing tab is formed on the second side support frame member.
  • the seat assembly further can comprise a front seat frame member, and wherein the first seat frame insert is formed on a front seat frame member.
  • the second front seat frame insert can be formed on the front seat frame member.
  • the deck can comprise a first deck section and a second deck section, wherein the first deck section is spaced apart from the second deck section.
  • the first side assembly further can comprise an arm top.
  • the present disclosure also encompasses furniture system comprising: a seat frame assembly, a first end assembly connected to a first side of the seat frame assembly, a second end assembly connected to second side of the seat frame assembly, wherein the first side of the seat frame assembly is opposed to the second side of the seat frame assembly, wherein each of the first end assembly and the second end assembly is selected from the group of an arm assembly or a sectional wedge assembly, wherein the seat frame assembly comprises a first front seat frame insert projecting from the first side of the seat frame assembly, a second front seat frame insert projecting from the second side of the seat frame assembly, a first rear seat frame insert projecting from the first side of the seat frame assembly, and a second rear seat frame insert projecting from the second side of the seat frame assembly, wherein the first front seat frame insert comprises a first front insert body, wherein the second front seat frame insert comprises a second front insert body, wherein the first rear seat frame insert comprises a first rear insert body, wherein the second rear seat frame insert comprises a second rear insert body, wherein the seat
  • furniture system can further comprise a back assembly mounted to the first end assembly and the second end assembly.
  • the back assembly can be spaced apart from the seat frame assembly.
  • the seat frame assembly further can comprise an inner frame assembly, and wherein the first front load-bearing tab, the second front load-bearing tab, the first rear load-bearing tab, and the second rear load-bearing tab are formed on the inner frame assembly.
  • the seat frame assembly further can comprise a deck.
  • the deck can comprise a front deck section and a rear deck section, wherein the front deck section is separated from the rear deck section by a deck gap.
  • the front deck section can be connected to the rear deck section by a plurality of deck straps.
  • the present disclosure also encompasses a furniture system comprising a seat frame assembly, a first arm assembly connected to the seat frame assembly, a second arm assembly connected to the seat frame assembly, wherein the seat frame assembly comprises a first front seat frame insert projecting from a first side of the seat frame assembly, a second front seat frame insert projecting from a second side of the seat frame assembly, a first rear seat frame insert projecting from the first side of the seat frame assembly, and a second rear seat frame insert projecting from the second side of the seat frame assembly, wherein each of the first front seat frame insert, the second front seat frame insert, the first rear seat frame insert, and the second rear seat frame insert comprises an insert body, wherein the seat frame assembly comprises a first front tab projecting from the first side of the seat frame assembly, a second front tab projecting from the second side of the seat frame assembly, a first rear tab projecting from the first side of the seat frame assembly, a second rear tab projecting from the second side of the seat frame assembly, wherein the first arm assembly comprises a first front arm receiver
  • first rear seat frame insert and the first rear tab are disposed in the first rear arm receiver, the first rear tab is seated on the retention wall of the first rear arm receiver, the retention wall of the first rear arm receiver is aligned proximal to the second arm assembly, and the insert body of the first rear seat frame insert is aligned distal to the second arm assembly.
  • second rear seat frame insert and the second rear tab are disposed in the second rear arm receiver, the second rear tab is seated on the retention wall of the second rear arm receiver, the retention wall of the second rear arm receiver is aligned proximal to the first arm assembly, and the insert body of the second rear seat frame insert is aligned distal to the first arm assembly.
  • the seat frame assembly further comprises a front support frame member and an opposing rear support frame member.
  • the seat frame assembly comprises a deck extending from the front support frame member to the rear support frame member, wherein the deck comprises a front deck web and a rear deck web, wherein the front deck web and the rear deck web define a deck gap.
  • the deck gap is disposed proximal to the rear support frame member and distal to the front support frame member.
  • the front deck web is connected to the rear deck web by a plurality of straps.
  • the deck comprises a front sleeve connected to the front deck web and a rear sleeve connected to the rear deck web.
  • the furniture system further comprises a back assembly connected to the first arm assembly and the second arm assembly. In a further aspect, the back assembly is spaced apart from the seat frame assembly.
  • the present disclosure also encompasses a furniture system comprising a seat frame assembly operably connected to a back assembly, wherein the seat frame assembly comprises an inner frame assembly, wherein the inner frame assembly comprises a front support frame member and an opposing rear support frame member, a first side support frame member detachably connected to the front support frame member and the rear support frame member, a second side support frame member detachably connected to the front support frame member and the rear support frame member, wherein the inner frame assembly further comprises a deck connected to and extending between the front support frame member and the rear support frame member, wherein the deck comprises a front sleeve and an opposing rear sleeve, wherein at least a portion of the front support frame member is disposed in the front sleeve and wherein at least a portion of the rear support frame member is disposed in the rear sleeve, wherein the deck comprises a front deck web connected to the front sleeve and a rear deck web connected to the rear sleeve, wherein the front deck
  • the furniture system comprises a first arm assembly connected to the seat frame assembly and a second arm assembly connected to the seat frame assembly.
  • the first arm assembly and the second arm assembly are connected to the back assembly.
  • the first arm assembly comprises a first arm receiver and the second arm assembly comprises a second arm receiver
  • the seat frame assembly comprises a first seat frame insert extending from a first side of the seat frame assembly and a second seat frame insert extending from a second side of the seat frame assembly, wherein the first seat frame insert is disposed in the first arm receiver of the first arm assembly and the second seat frame insert is disposed in the second arm receiver of the second arm assembly.
  • each of the first arm receiver and the second arm receiver comprises a retention wall, wherein a portion of the first seat frame insert is aligned distal to the second arm assembly and the retention wall of the first arm receiver is aligned proximal to the second arm assembly, and wherein a portion of the second seat frame insert is aligned distal to the first arm assembly and the retention wall of the second arm receiver is aligned proximal to the second arm assembly.
  • the inner frame assembly further comprises a first tab extending from the first side of the inner frame assembly and a second tab extending from the second side of the inner frame assembly, wherein a portion of the first tab is disposed in the first arm assembly and a portion of the second tab is disposed in the second arm assembly.
  • a male fastener connects the first side support frame member to the first arm assembly and a second male fastener connects the second side support frame member to the second arm assembly.
  • the seat frame assembly is completely supported by the first arm assembly and the second arm assembly, and wherein a portion of the weight of the seat frame assembly is distributed to the first arm assembly by the first tab and the first seat frame insert and another portion of the weight of the seat frame assembly is distributed to the second arm assembly by the second tab and the second seat frame insert.
  • the inner frame assembly comprises a stretcher extending between and connected to the front support frame member and the rear support frame member.
  • the stretcher is connected to a midpoint of the front seat support frame member and a midpoint of the rear support frame member.
  • the stretcher comprises a front stretcher arm, a rear stretcher arm, and a cross stretcher arm extending between the front stretcher arm and the rear stretcher arm.
  • the cross stretcher arm is aligned outside of a plane in which the front support frame member and the rear support frame member are disposed.
  • a majority of the stretcher is aligned outside of the plane in which the front support frame member and the rear support frame member are disposed.
  • the deck comprises a first deck section and a second deck section.
  • the stretcher is aligned between the first deck section and the second deck section.
  • the present disclosure also encompasses an inner frame assembly for use in furniture pieces comprising a support frame and a deck connected to the support frame, wherein the support frame comprises a center support frame section detachably connected to a first side support frame member and a second side support frame member, wherein the center support fame section comprises a front support frame member, an opposing rear support frame member, and a stretcher extending between the front support frame member and the rear support frame member, wherein the stretcher connects the front support frame member to the rear support frame member, wherein the stretcher comprises a front stretcher arm connected to the front support frame member, a rear stretcher arm connected to the rear support frame member, and a cross stretcher arm extending between and connected to the front stretcher arm and the rear stretcher arm, wherein the cross stretcher arm is offset from the front support frame member and the rear support frame member, the inner frame assembly further comprising a deck extending between the front support frame member and the rear support frame member, wherein the deck comprises a first deck section aligned to one side of the stretcher
  • the stretcher is connected to the midpoints of the front seat frame member and the rear seat frame member.
  • the first side support frame member comprises a first front cap disposed at a front end thereof and a first rear cap disposed at a rear end thereof, wherein the front support frame member comprises a first front receiver on a first end thereof, wherein the first front receiver is configured to receive the first front cap thereon to connect the first side support frame member to the front support frame member, wherein the rear support frame member comprises a first rear receiver on a first end thereof, wherein the first rear receiver is configured to receive the first rear cap thereon to connect the first side support frame member to the rear support frame member, wherein the second side support frame member comprises a second front cap disposed at a front end thereof and a second rear cap disposed at a rear end thereof, wherein the front support frame member comprises a second front receiver disposed on a second end thereof, wherein the second front receiver is configured to receive the second front end cap to connect the second side support frame member to the front
  • the inner frame assembly is generally rectangular.
  • the center support frame section, the first side support frame member and the second side support frame member comprise metal.
  • the first front deck web, the second front deck web, the first rear deck web, and the second rear deck web comprise a resilient woven textile.
  • the present disclosure also encompasses a deck section for a furniture system comprising a front deck web, a rear deck web connected to the front deck web by a plurality of straps, wherein the front deck web and the rear deck web define a deck gap, wherein the plurality of straps extend across the deck gap from the front deck web to the rear deck web, a front sleeve connected to the front deck web, and a rear sleeve connected to the rear deck web.
  • the front sleeve is integrally formed with the front deck web.
  • the rear sleeve is integrally formed with rear deck web.
  • the front deck web is formed of a resilient woven textile.
  • the front sleeve is formed of the resilient woven textile.
  • the rear deck web is formed of the resilient woven textile.
  • the rear sleeve is formed of the resilient woven textile.
  • the deck gap is aligned proximal to the rear sleeve and distal to the front sleeve.
  • the deck gap extends across the length of the deck section.
  • the inner frame assembly is stackable with one or more other inner frame assemblies wherein the stretcher of a top inner frame assembly extends downward between the first deck section and the second deck section of a lower inner frame assembly on which the top frame assembly is stacked.
  • the present disclosure encompasses a furniture system comprising a seat frame assembly connected to a first arm assembly and a second arm assembly, a back assembly connected to the first arm assembly and the second arm assembly, wherein the back assembly is spaced apart from the seat frame assembly, wherein the seat frame assembly comprises an inner frame assembly, a front seat frame member connected to the inner frame assembly, and a rear seat frame member connected to the inner frame assembly, wherein the inner frame assembly comprises a support frame and a deck connected thereto, wherein the deck comprises a front deck web and a rear deck web, wherein the front deck web is connected to the rear deck web by a plurality of straps, wherein the front deck web and the rear deck web define a deck gap, wherein the plurality of straps extend across the deck gap from the front deck web to the rear deck web, wherein the deck further comprises a front sleeve connected to the front deck web and a rear sleeve connected to the rear deck web, wherein the support frame comprises a front support frame member and an opposing rear support
  • the furniture system further comprises a first male fastener connecting the inner frame assembly to the first arm assembly and a second male fastener connecting the inner frame assembly to the second arm assembly.
  • the furniture system further comprises a first male fastener connecting the front seat frame member to the front support frame member and a second male fastener connecting the rear seat frame member to the rear support frame member.
  • the present disclosure also encompasses a furniture system comprising an assembled configuration for use and an unassembled configuration for storage or shipping; wherein the furniture system comprises, in the assembled configuration, a seat frame assembly connected to a first arm assembly and a second arm assembly, a back assembly connected to the first arm assembly and the second arm assembly, wherein the back assembly is separated from the seat frame assembly, wherein the seat frame assembly comprises an inner frame assembly, a front seat frame member connected to the inner frame assembly, and a back seat frame member connected to the inner frame assembly, wherein the inner frame assembly comprises a support frame and a deck connected thereto, wherein the deck comprises a front deck web and a rear deck web, wherein the front deck web is connected to the rear deck web by a plurality of straps, wherein the front deck web and the rear deck web define a deck gap, wherein the plurality of straps extend across the deck gap from the front deck web to the rear deck web, wherein the deck further comprises a front sleeve connected to the front deck web and a rear sle
  • the present disclosure also encompasses a method of assembling a ready-to-assemble furniture system comprising the steps of: providing a furniture system comprising a seat frame assembly, a first arm assembly, a second arm assembly, and a back assembly, wherein the seat frame assembly comprises a first front seat frame insert projecting from a first side of the seat frame assembly, a second front seat frame insert projecting from a second side of the seat frame assembly, a first rear seat frame insert projecting from the first side of the seat frame assembly, a second rear seat frame insert projecting from the second side of the seat frame assembly, wherein the first arm assembly comprises a first female fastener, a first front arm receiver, and a first rear arm receiver, wherein the first front arm receiver comprises a first front engagement section and a first front locking section, wherein the second arm assembly comprises a second female fastener, a second front arm receiver and a second rear arm receiver; aligning the first front seat frame insert with the first front arm receiver and the first rear seat frame insert with the first rear arm receiver; insert
  • the method of assembling a ready-to-assemble furniture system further comprises the step of connecting the seat frame assembly to the first arm assembly with a first male fastener.
  • the method of assembling a ready-to-assemble furniture system further comprises the step of connecting the seat frame assembly to the second arm assembly with a second male fastener.
  • the method of assembling a ready-to-assemble furniture system further comprises the step of connecting the back assembly to the first arm assembly and the second arm assembly.
  • the back assembly is slidably connected to the first arm assembly and the second arm assembly.
  • the first arm assembly further comprises a first back receiver
  • the second arm assembly comprises a second back receiver
  • the back assembly comprises a first arm fastener disposed on a first back side support and a second arm fastener disposed on a second back side support.
  • the first arm fastener is slidably inserted into the first back receiver and the second arm fastener is slidably inserted into the second back receiver.
  • the seat frame assembly further comprises a first front tab and a first rear tab projecting from the first side of the seat frame assembly, a second front tab and a second rear tab projecting from the second side of the seat frame assembly.
  • the first front tab is supported by a retention wall of the first front arm receiver in the first front locking alignment
  • the first rear tab is supported by a retention wall of the first rear arm receiver in the first rear locking alignment
  • the second front tab is supported by a retention wall of the second front arm receiver in the second front locking alignment
  • the second rear tab is supported by a retention wall of the second rear arm receiver in the second rear locking alignment.
  • the furniture system further comprises a plurality of legs.
  • the method further comprises threadably connecting one or more legs of the plurality legs to each of the first arm assembly and the second arm assembly.
  • the present disclosure also encompasses a method of assembling an inner frame assembly comprising the steps of: providing a center support frame section, a first side support frame member, a second side support frame member, a first deck section, and a second deck section, wherein the center support frame member comprises a front support frame member, a rear support frame member, and a stretcher extending between and connected to the front support frame member and the rear support frame member, wherein the front support frame member comprises a first front receiver on a first end thereof and a second front receiver on a second end thereof, wherein the rear support frame member comprises a first rear receiver on a first end thereof and a second rear receiver on a second end thereof, wherein the first deck section comprises a first front sleeve, an opposing first rear sleeve, and webbing extending between the first front sleeve and the first rear sleeve, wherein the second deck section comprises a second front sleeve an opposing second rear sleeve, and webbing extending between
  • first deck section comprises a first deck gap defined by the webbing of the first deck section.
  • second deck section comprises a second deck gap defined by the webbing of the second deck section.
  • FIG. 1 shows a perspective view of a furniture system encompassing aspects of the present disclosure illustrated as a sofa in an assembled configuration.
  • FIG. 2 illustrates a perspective view of the furniture system shown in FIG. 1 with the cushions, upholstery, and legs removed.
  • FIG. 3 illustrates a perspective view of an inner frame assembly for a furniture system shown in FIG. 2 , wherein the inner frame assembly encompasses aspects of the present disclosure.
  • FIG. 4 illustrates a perspective view of a support frame of the inner frame assembly shown in FIG. 3 with the deck sections removed and the second side support frame member of the support frame detached from the center support frame section of the support frame.
  • FIG. 5A illustrates a perspective view of the support frame shown in FIG. 4 with the second side support frame member removed to allow for a deck section to be slidably engaged to the support frame.
  • FIG. 5B illustrates a perspective view of a deck section of the inner frame assembly shown in FIG. 3 removed from the inner frame assembly, wherein the deck section encompasses aspects of the present disclosure.
  • FIG. 6 illustrates a perspective view of the inner frame assembly of FIG. 3 with the second deck section in a deflexed alignment as would arise if a user was sitting on a sofa comprising the inner frame assembly.
  • FIG. 7A illustrates a perspective view of a trio of inner frame assemblies, as shown in FIG. 3 , wherein the trio encompasses aspects of the present disclosure with the trio of inner frame assemblies in a stacked and nested configuration for shipping of the furniture components.
  • FIG. 7B is another perspective view of the trio of inner frame assemblies shown in FIG. 7A shown from below.
  • FIG. 8 illustrates a lower perspective view of the inner frame assembly shown in FIG. 3 with a front seat frame member and a rear seat frame member attached thereto to form a seat frame assembly encompassing aspects of the present disclosure.
  • FIG. 9 illustrates a perspective view of the seat frame assembly shown in FIG. 8 with a first arm assembly connected to a first end thereof and a second arm assembly connected to a second end thereof.
  • FIG. 10 illustrates a cutaway perspective view of the seat frame assembly shown in FIG. 8 positioned during the assembly process of a ready-to-assemble furniture system, with the seat frame assembly being positioned adjacent a first arm assembly so as to align a first front seat frame insert on the seat frame assembly with a first arm receiver on the first arm assembly and a first rear seat frame insert with a rear arm receiver on the first arm assembly for connection of the first arm assembly to the seat frame assembly.
  • FIG. 11 illustrates another cutaway perspective view of the seat frame assembly and the first arm assembly shown in FIG. 10 during another step of the assembly process of a ready-to-assemble furniture system, wherein the first arm assembly is connected to seat frame assembly in an engagement alignment that is prior to a step of forming locking alignments between the first front seat frame insert and the first arm receiver and the first rear seat frame insert and the rear arm receiver.
  • FIG. 12 illustrates yet another cutaway perspective view of the seat frame assembly and the first arm assembly shown in FIGS. 10 and 11 , during a subsequent step of the assembly process of a ready-to-assemble furniture system, wherein the seat frame assembly and the first arm assembly are connected to each other in the final step of the connection process wherein the seat frame assembly is lowered relative to the first arm assembly so as to lock the first front seat frame insert in the front arm receiver and the first rear seat frame insert in the rear arm receiver and with male fasteners engaged with both the seat frame assembly and the first arm assembly to secure further the first arm assembly to the seat frame assembly.
  • FIG. 13 illustrates a perspective view of the seat frame assembly, the first arm assembly, and the second arm assembly shown in FIG. 9 operably connected with a back assembly connected to and supported by the first arm assembly and the second arm assembly to form an assembled configuration of the furniture system.
  • FIG. 14 illustrates an inner side elevation view of the first arm assembly shown in FIG. 10 shown by itself.
  • FIG. 15 illustrates a top plan view of a front seat frame member that can be used in the furniture systems and seat frame assemblies encompassed by the present disclosure.
  • FIG. 16 illustrates a front elevation view of the front seat frame member shown in
  • FIG. 15 is a diagrammatic representation of FIG. 15 .
  • FIG. 17 is a side elevation view of the front seat frame member shown in FIGS. 15 and 16 .
  • FIG. 18 illustrates a partial cutaway side elevation view of a portion of the first arm assembly with the outer sidewall removed and a front end portion of the seat frame assembly shown in an engagement alignment with the first front seat frame insert engaged with the front arm receiver during the assembly process.
  • FIG. 19 illustrates another partial cutaway side elevation view of the portion of the first arm assembly and the front end portion of the seat frame assembly shown in FIG. 18 with the first front seat frame insert and the front arm receiver in a locking alignment.
  • FIG. 20 illustrates a partial perspective cutaway side view of the first arm assembly and the front end portion of the seat frame assembly shown in FIG. 19 with the first front seat frame insert engaged with the front arm receiver in a locking alignment.
  • FIG. 21 illustrates a partial cutaway perspective view of the seat frame assembly 10 shown in FIG. 8 with a male fastener disposed in the first side support frame female fastener.
  • FIG. 22 illustrates a partial cutaway perspective view of the first arm assembly engaged with the seat frame assembly in a locking alignment.
  • FIG. 23 illustrates a perspective view of a back receiver that can be mounted on the arm assemblies of the furniture system to receive, engage and retain a back fastener that can be mounted on either side of the back assembly of the furniture system shown in FIG. 2 to mount the back assembly to the remainder of the furniture system.
  • FIG. 24 illustrates a perspective view of an unassembled configuration of the furniture system shown in FIG. 1 with the upholstery removed, wherein the unassembled configuration is configured for insertion of the furniture system in a container for shipping and/or storage.
  • FIG. 25 illustrates a side elevation view of the unassembled configuration of the furniture system shown in FIG. 24 .
  • FIG. 26 illustrates a perspective view of some of the furniture components of the furniture system shown in FIGS. 24 and 25 with the cushions and back assembly removed from the unassembled configuration to reveal the alignment of the seat stretcher and the first and second arm assemblies in the unassembled configuration.
  • FIG. 27 is a perspective view of a sectional furniture system encompassed by the present disclosure with the furniture system in an assembled configuration.
  • FIG. 28 is a perspective view of the sectional furniture system shown in FIG. 27 with the cushions removed and selected components of the system separated from each other.
  • FIG. 29 is a perspective view of the lower right rear portion of the sectional wedge component and the rear left side of the seat frame assembly of the second sectional leg showing selected components of the sectional furniture system shown in FIG. 28 .
  • the present disclosure is directed furniture systems and furniture system components that can be used in ready-to-assemble furniture products and other furniture products.
  • the present disclosure also is directed to methods of assembling furniture systems and furniture components.
  • the furniture systems encompassed by the present disclosure can be configured in the form of sofas, love seats, chairs, sectional assemblies, benches, and/or chaise lounges.
  • the furniture systems encompassed by the present disclosure can comprise one or more side assemblies, which can be either arm assemblies or sectional wedge unit assemblies, connected to one or more seat frame assemblies.
  • the singular forms of “a,” “an,” and “the” encompass the plural form thereof unless otherwise indicated.
  • the phrase “at least one” includes all numbers of one and greater.
  • the term “and/or” refers to one or all of the listed elements or a combination of any two or more of the listed elements.
  • the term “connected” refers to the direct or indirect linking of one component to another.
  • FIGS. 1-29 illustrate various aspects of furniture systems and furniture system components that are encompassed by the present disclosure.
  • FIG. 1 illustrates a furniture system 100 in an assembled configuration 110 and encompassing aspects of the present invention.
  • the furniture system 100 is represented as an upholstered sofa, but the present disclosure also encompasses other furniture pieces, including, but not to, love seats and chairs.
  • the assembled configuration 110 of the furniture system 100 is for use.
  • the furniture system 100 comprises a seat frame assembly 112 connected to a first arm assembly 172 and an opposing second arm assembly 174 , a back assembly 190 aligned above and to the rear of the seat frame assembly 112 and connected to and supported by both the first arm assembly 172 and the second arm assembly 174 .
  • the furniture system 100 also encompasses a plurality of cushions 200 positioned on the seat frame assembly 112 in the assembled configuration 110 and legs 198 supporting the other components of the furniture system 100 and connected to the first arm assembly 172 and the second arm assembly 174 .
  • the back assembly 190 , the first arm assembly 172 , the second arm assembly 174 and portions of the seat frame assembly 112 can be upholstered with fabric, leather, laminates, and/or other cushioning and finish materials as known in the art.
  • FIG. 2 illustrates the furniture system 100 shown in FIG. 1 with the legs 198 , the cushions 200 , and the upholstery removed to show the interior features of the system.
  • the back assembly 190 is spaced apart from the seat frame assembly 112 and connected to the first arm assembly 172 and the second arm assembly 174 .
  • FIG. 3 illustrates an inner frame assembly 115 encompassed by the present disclosure.
  • the inner frame assembly 115 can be used in the furniture system 100 , with one or more components of the furniture system 100 in other furniture systems, and in other furniture systems with completely different components.
  • the inner frame assembly 115 comprises a support frame 114 , and a deck 140 operably connected to the support frame 114 .
  • the support frame 114 comprises a front support frame member 116 and a rear support frame member 118 opposing the front support frame member 116 .
  • the front support frame member 116 is connected to the rear support frame member 118 by a stretcher 139 .
  • the front support frame member 116 is aligned parallel to the rear support frame member 118 and generally perpendicular to the vertical plane in which the stretcher 139 is aligned.
  • the stretcher 139 connects to both the front support frame member 116 and the rear support frame member 118 and is aligned generally at the midpoints of each of the front support frame member 116 and the rear support frame member 118 .
  • the deck 140 comprises one or more deck sections. As shown in FIG. 3 , the deck 140 comprises a first deck section 141 and a second deck section 143 , both of which are engaged with the of the front support frame member 116 and the rear support frame member 118 .
  • Each of the first deck section 141 and the second deck section 143 comprise a front deck web 150 spaced apart from and connected to a rear deck web 152 , a front sleeve 142 formed in and/or joined to the front deck web 150 and a rear sleeve 144 formed in and/or joined to the rear deck web 152 .
  • the area of the front deck web 150 is greater than the area of the rear deck web 152 .
  • the front deck web 150 and the rear deck web 152 are formed of one or more fabrics and/or webbing materials, such as polymeric woven fabrics.
  • Each front deck web 150 is connected to the corresponding rear deck web 152 by a plurality of straps 146 .
  • Each strap 148 of each of the plurality of straps 148 spans a deck gap 145 formed in the deck section and which extends across the entire width of the deck section.
  • the deck gap 145 is aligned proximal to the rear sleeve 144 and distal to the front sleeve 142 .
  • the deck gaps 145 can be aligned in the rear third of the respective first or second deck sections 141 and 143 in which it is formed.
  • the plurality of straps 146 connects the front deck webs 150 to the rear deck webs 152 .
  • the front sleeves 142 and the rear sleeves 144 extend the entire widths of the first and second deck sections 141 and 143 .
  • the front sleeves 142 encase portions of the front support frame member 116 and the rear sleeves 144 encase portions of the rear support frame member 118 .
  • the deck 140 spans a majority of the area between the front support frame member 116 , the rear support frame member 118 , the first side support frame member 120 , and the second side support frame member 122 .
  • the first deck section 141 is aligned on a first side of the support frame 114 and the second deck section 143 is aligned on a second side of the support frame 114 with the stretcher 139 aligned in a vertical plane that separates the first deck section 141 from the section 143 .
  • the inner frame assembly 115 is generally rectangular and comprises a tab on each corner thereof. As shown in FIG. 3 , the inner frame assembly 115 comprises a first front tab 132 , a second front tab 134 , a first rear tab 136 , and a second rear tab 138 . Each of the first front tab 132 , the second front tab 134 , the first rear tab 136 , and the second rear tab 138 extend outward beyond the longitudinal outer sides of the elongated portions of the respective first side support frame member 120 and the second side support frame member 122 .
  • FIG. 4 shows, in a partially assembled view, the support frame 114 by itself, which forms part of the inner frame assembly 115 .
  • the support frame 114 is made of a metal, such as steel, aluminum, or other lightweight and rigid metal or metal alloy, or other suitably rigid and strong material or composite of materials that can resist the forces that are typically placed on a furniture system.
  • the support frame 114 comprises three separate pieces, the center support frame section 117 , the first side support frame member 120 , and the second side support frame member 122 .
  • the center support frame section 117 comprises the front support frame member 116 , the stretcher 139 connected to the front support frame member 116 , and the rear support frame member 118 .
  • the stretcher 139 connects the rear support frame member 118 to the front support frame member 116 and comprises a front stretcher arm 147 connected to the front support frame member 116 , a cross stretcher arm 155 connected to the front stretcher arm 147 , and a rear stretcher arm 149 connected to the cross stretcher arm 155 and the rear support frame member 118 .
  • the cross stretcher arm 155 is longer than both the first stretcher arm 147 and the rear stretcher arm 149 and is offset from the plane in which the front support frame member 116 and the rear support frame member 118 both lay.
  • the cross stretcher arm 155 is aligned perpendicular to the front support frame member 116 and the rear support frame member 118 and can be aligned parallel to a plane in which lie both the front support frame member 116 and the rear support frame member 118 .
  • the first stretcher arm 147 and the second stretcher arm 149 are aligned obtuse to the plane in which the front support frame member 116 and the rear support frame member 118 are aligned.
  • the second side support frame member 122 is detachable from the center support frame section 117 .
  • the second side support frame 122 can be attached to the center support frame section 117 by aligning a front cap aligned with the second front tab 134 with the second front receiver 126 disposed on the second end of the front support frame member 116 , aligning a rear cap of the second rear tab 138 with the second rear receiver 130 , which is disposed on the second end of the rear support frame member 118 , and inserting the second front receiver 126 and the second rear receiver 130 into the respective caps.
  • first side support frame member 120 is detachable from the center support frame section 117 and can be attached thereto by fitting the caps of the first front tab 132 and the first rear tab 136 over, respectively, the first front receiver 124 , located on the support member 116 , and the first rear receiver 128 , located on the rear support frame member 118 .
  • the section deck section 143 can be fitted onto the support frame 114 by detaching the second side support frame member 122 from the center support frame section 117 to expose the second front receiver 126 and the second rear receiver 130 and sliding the front sleeve 142 onto the front support frame member 116 and the rear sleeve 144 onto the rear support frame member 118 .
  • the front sleeve 142 and the rear sleeve 142 are slid to or near the centers of the front support frame member 116 and the rear support frame member 118 , and the second deck section 143 is spread evenly thereon so as to cover about half the area between the front support frame member 116 and the rear support frame member 118 .
  • the second side support frame member 122 can be attached to the center support frame section 117 so as to enclose and secure the second deck section 143 on the support frame 114 .
  • first deck section 141 can be positioned on the support frame 114 by sliding the front sleeve 142 over the first front receiver 124 and the rear sleeve 144 over the first rear receiver 128 and sliding the front and rear sleeves 142 and 144 over the front support frame member 116 and the rear support frame member 118 , respectively.
  • Each of the first deck section 141 and the second deck section 143 are sized to extend across a majority of one half of the interior area circumscribed by the support frame 114 from the stretcher 139 to the respective first and second side support frame members 120 and 122 .
  • Each of the first deck section 141 and the second deck section 143 are sized to extend taught across the entire width of the of the support frame 114 from the front support frame member 116 to the rear support frame member 118 in a planar fashion.
  • the front sleeve 142 and the rear sleeve 144 can be formed from looping the webbings of the front deck web 150 and the rear deck web 152 in a loop and sewn, ultrasonically welded, or otherwise secured to form a channel therein that receives the respective front support frame member 116 and rear support frame member 118 when the first and second deck sections 141 and 143 are installed on the center support frame section 117 .
  • the front sleeve 142 and/or the rear sleeve 144 can be formed of one or more separate pieces of webbing, loops, or other suitable structures and connected to the respective front deck web 150 and rear deck web 152 .
  • FIG. 5B shows the first deck section 141 separated from the other components of the furniture system 100 .
  • the first deck section 141 comprises a front sleeve 142 disposed at the front end of and extending the length of the first deck section 141 and an opposing rear sleeve 144 disposed at the rear end of and extending the length of the first deck section 141 .
  • the front sleeve 142 is integrally formed with the front deck web 150 and the rear sleeve 144 is integrally formed with the rear deck web 152 .
  • Each of the front sleeve 142 and the rear sleeve 144 comprises one or more deck eyelets 153 formed therein.
  • Each deck eyelet 153 is aligned with another deck eyelet on the same sleeve so as to allow for the bolt of a male fastener 182 to be inserted therein and pass through the channel of the respective front or rear sleeve 142 or 144 .
  • Each pair of deck eyelets 153 is aligned on the respective front or rear sleeve 142 or 144 so as to align with a corresponding inner frame female fastener 157 formed on either the front support frame member 116 or the rear support frame member 118 and a corresponding seat frame female fastener 156 formed on either the front seat frame member 154 or the rear seat frame member 160 .
  • a male fastener 180 can be inserted into the channel formed by the aligned deck eyelets 153 , inner frame female fasteners 157 , and seat frame female fasteners 156 so as to secure the front seat frame member 154 and the rear seat frame member 160 to the inner frame assembly 115 .
  • FIG. 5B also shows the deck gap 145 defined by the front deck web 150 and the rear deck 152 .
  • Stras 148 that connect the front deck web 150 to the rear deck web 152 .
  • the straps can be formed of the same webbing material of the front deck web 150 and/or the rear deck web 152 or be formed of a separate web material that is sewn, sonically welded, riveted, or otherwise connected to the front and rear deck webs 150 and 152 .
  • FIG. 6 shows the inner frame assembly 115 with the second deck section 143 in a deflexed alignment, as would occur when a load was placed on the second deck section 143 during use of a furniture system in which the inner frame assembly was incorporated.
  • the front deck webs 150 , the straps 148 , and the rear deck webs 152 are formed of one or more materials that flex under a load and exhibit resiliency when a load is placed on and removed from the first and second deck sections 141 and 143 . In FIG. 6 , no load is placed on the first deck section 141 .
  • each of the first deck section 141 and the second deck section 143 are configured to have a deck gap 145 aligned proximal to the rear sleeve 144 .
  • the deck gap 145 can be aligned about one third of the distance between the rear sleeve 144 and the front sleeve 142 . Such alignments of the deck gaps 145 within the first and second deck sections 141 and 143 can potentially enhance the support and feel of the furniture system experienced by a user.
  • FIGS. 7A and 7B show three separate inner frame assemblies 115 stacked on top of each other in a nested alignment.
  • the configuration of the stretchers 139 allows for two or more inner frame assemblies 115 to be stacked in a nested alignment, wherein the stretcher 139 of a first inner frame assembly 115 stacked on top of a second inner frame assembly 115 extends downward between the front support frame member 116 and the rear support frame member 118 of the second inner frame assembly 115 , thereby allowing for the nesting of parts of the first inner frame assembly 115 with parts of the second inner frame assembly 115 .
  • the ability to stack the inner frame assemblies 115 in a nested alignment allows a greater number of inner frame assemblies 115 to be shipped in a given container volume than would be possible without the nesting of the assemblies. Accordingly, the inner frame assemblies 115 can be shipped in a stacked and nested configuration from one production facility to another production and/or assembly facility.
  • FIG. 8 shows the underside of the seat frame assembly 112 separated from the other parts of the furniture system 100 .
  • the seat frame assembly 112 can be used in other furniture system configurations and encompasses aspects of the present disclosure.
  • the seat frame assembly 112 comprises the support frame 114 , the deck 140 mounted on the support frame 114 , thereby forming the inner frame assembly 115 , the front seat frame member 154 connected to the inner frame assembly 115 , and the rear seat frame member 160 connected to the inner frame assembly 115 .
  • the front seat frame member 154 comprises a plurality of seat frame female fasteners 156 .
  • the front seat frame member 154 is connected to the front support frame member 116 by a plurality of male fasteners 182 .
  • Each of the plurality of male fasteners 182 is aligned with and extends through both the inner frame female fasteners 157 formed in the front support frame member 116 and the support frame female fasteners 156 to secure the components together.
  • Each of the male fasteners 182 comprises a threaded male bolt and a knob attached thereto. The male fasteners 182 can be attached and detached from the seat frame assembly 112 by hand tightening or loosening.
  • FIG. 9 shows the seat frame assembly 112 connected to the first arm assembly 172 and the second arm assembly 174 .
  • Each of the first arm assembly 172 and the second arm assembly 174 comprise an arm top panel 173 and an opposing arm base 175 .
  • the arm base 175 of each of the first arm assembly 172 and the second arm assembly 174 is aligned adjacent the seat frame assembly 112 .
  • Male fasteners 182 are connected to both the seat frame assembly 112 and the first and second arm assemblies 172 and 174 to help secure the arm assemblies 172 and 174 to the seat frame assembly 112
  • the arm base 175 comprises a front arm receiver 176 disposed proximal to the front vertical panel of the first arm assembly 172 and a rear arm receiver 178 disposed proximal to the rear vertical panel of the first arm assembly 172 .
  • the arm base 175 also comprises one or more arm female fasteners 180 disposed between the front arm receiver 176 and the rear arm receiver 178 .
  • the second arm assembly 174 also comprises first and second arm receivers 176 and 178 and one or more arm female fasteners 180 on an opposing side thereof.
  • Each of the first and second arm receivers 176 and 178 comprise two contiguous sections—the engagement section 177 and the locking section 179 .
  • the engagement section 177 is aligned generally vertically and has a length greater than its width.
  • the engagement section 177 is generally rectangular and configured to receive the tallest portion of the first front seat frame insert 162 .
  • the locking section 179 is also generally rectangular, but is shorter and wider than the engagement section 177 .
  • the locking section 179 is configured to receive the insert body 170 of the first front seat frame insert 162 .
  • the lower edge of the locking section 179 is disposed higher on the arm base 175 than the lower edge of the engagement section 177 .
  • the upper edge of the locking section 179 is disposed lower on the arm base 175 than the upper edge of the engagement section 177 .
  • Each of the first and second arm receivers 176 and 178 also comprise a retention wall 181 disposed below the locking section 179 and adjacent the lower portion of the engagement section 177 .
  • the retention wall 181 is configured to contact a portion of an insert body 170 formed on the seat frame assembly 112 so as to prevent the removal of the insert from the respective first or second arm receivers 176 and 178 in which the insert is disposed.
  • FIGS. 15-17 illustrate the front seat frame member 154 , which attaches to the front support frame member 116 of the support frame 114 in the seat frame assembly 112 .
  • the front seat frame member 154 is an elongated, rectangular panel that comprises one or more seat frame female fasteners 156 configured to receive and retain male fasteners 182 .
  • At a first end of the front seat frame member 154 is a first front seat frame insert 162
  • a second front seat frame insert 164 At the opposing second end of the front seat frame member 154 is a second front seat frame insert 164 .
  • Each of the first front seat frame insert 162 and the second front seat frame insert 164 comprises an insert body 170 projecting from an inward side thereof.
  • FIGS. 10-12 show the relative alignment of the first arm assembly 172 and the seat frame assembly 112 during various steps of the assembly process by which the first arm assembly 172 is connected to the seat frame assembly 112 .
  • the first arm assembly 172 is aligned adjacent the seat frame assembly 112 such that arm base 175 is aligned adjacent the first side support frame member 120 of the seat frame assembly 112 .
  • the front arm receiver 176 is aligned with the first front seat frame insert 162 that extends outward from the front first side of the seat frame assembly 112
  • the rear arm receiver 178 is aligned with the first rear seat frame insert 166 that extends outward from the rear first side of the seat frame assembly 112 , so that the first front seat frame insert 162 can be inserted into the front arm receiver 176 and the first rear seat frame insert 166 can be inserted into the rear arm receiver 178 .
  • the first arm assembly 172 is shown in an engagement alignment with the seat frame assembly 112 .
  • the first front seat frame insert 162 is inserted into the front arm receiver 176 and the first rear seat frame insert 166 is inserted into the rear arm receiver 178 , but not locked therein.
  • the seat frame assembly 112 and the first arm assembly 172 are in the engagement alignment, the seat frame assembly 112 is not locked to the first arm assembly 112 because the first front seat frame insert 162 and the first rear seat frame insert 166 can move freely horizontally out and away from the front arm receiver 176 and the rear arm receiver 178 .
  • a lower portion of the arm base 175 is aligned lower than the bottom of the seat frame assembly 112 .
  • FIG. 12 shows the seat frame assembly 112 in a locking alignment with the first arm assembly 172 , wherein the two assemblies are locked together.
  • the seat frame assembly is moved downward relative to the first arm assembly 172 so that the first front seat frame insert 162 and the first rear seat frame insert 166 are locked into the front arm receiver 176 and the rear arm receiver 178 , respectively.
  • the first front seat frame insert 162 and the first rear seat frame insert 166 cannot be removed from the front arm receiver 176 and the rear arm receiver 178 , respectively, without first moving the first front seat frame insert 162 and the first rear seat frame insert 166 back into the engagement alignment shown in FIG. 11 .
  • the first front seat frame insert 162 and the first rear seat frame insert 166 be moved directly out of the front arm receiver 176 and the rear arm receiver 178 because the retention wall 181 of each of the receiver engages an insert body 170 of the respective inserts, thereby preventing the removal of the insert body 170 .
  • the two support frame side female fasteners 159 are aligned with the two arm female fastener 180 formed in the arm base 175 of the first arm assembly 172 and a male fastener 182 is threadably secured in each channel formed by the aligned support frame side female fasteners 159 and the arm female fasteners 180 , thereby providing additional anchor points for securing the seat frame assembly 112 to the first arm assembly 172 .
  • the male fasteners 180 each comprise a threaded bolt and knob that can be hand tightened to secure the male fastener 180 in place.
  • the second front seat frame insert 164 can be connected to the front arm receiver 176 of the second arm assembly 174
  • the first rear seat frame insert 166 can be connected to the rear arm receiver 178 of the first arm assembly 172
  • the second rear seat frame insert 168 can be connected to the rear arm receiver 178 of the second arm assembly 174 through first an engagement alignment followed by a locking alignment between the respective components.
  • Each of the second front seat frame insert 164 , the first rear seat frame insert 166 , and the second rear seat frame insert 168 comprise an insert body 170 that can be disposed with the respective arm assembly and engaged by a respective retention wall 181 of the respective arm receiver to lock the inserts of the seat frame assembly 112 into the first and second arm assemblies 172 and 174 . With each of the inserts disposed and locked in the arm receivers, the seat frame assembly 112 can thereby completely supported by the first and second arm assemblies 172 and 174 in the assembled configuration 110 .
  • the seat frame assembly 112 is further secured to the second arm assembly 174 with male fasteners 182 threadably disposed in the support frame side female fasteners 159 of the second side support frame member 122 and the arm female fasteners 180 of the second arm assembly 174 .
  • the legs 198 are attached to the arm base 175 of the first arm assembly 172 and the arm base 175 of the second arm assembly 174 . Consequently, the seat frame assembly 112 is suspended above the floor by the first and second arm assemblies 172 and 174 .
  • FIGS. 18-20 further illustrate alternative views of the engagement and locking alignments of the first front seat frame insert 162 with the front arm receiver 176 .
  • FIG. 18 illustrates a portion of the arm base 175 of the first arm assembly 172 and the first front seat frame insert 162 in a engagement alignment in the front arm receiver 176 as seen end on to the first front seat frame insert 162 with an outer side of the arm assembly 172 removed to reveal the interior side of the front arm receiver 176 .
  • the vertically aligned major section of the first front seat frame insert 162 is inserted in the upper portion of the engagement section 177 of the front arm receiver 176 and the minor insert body 170 is inserted in the locking section 179 along with the first front tab 132 of the inner support frame 114 , which is disposed above the insert body 170 and beside the major section of the first front seat frame insert 162 .
  • the first front seat frame insert 162 can move freely horizontally in and out of the front arm receiver 176 because there is no portion of the front arm receiver 176 that contacts or engages any part of the first front seat frame insert 162 .
  • FIGS. 19, 20, and 22 illustrate the same portion of the arm base 175 of the first arm assembly 172 and the first front seat frame insert 162 shown in FIG. 18 , but with the first front seat frame insert 162 moved into a locking alignment in the front arm receiver 176 .
  • the first front seat frame insert 162 is lowered downward so that the major section of the first front seat frame insert 162 is moved into the lower portion of the engagement section 177 and the insert body 170 is lowered past the top edge of the retention wall 181 .
  • the first front tab 132 is aligned above and/or on the top edge of the retention wall 181 .
  • At least a portion of the insert body 170 is disposed inside of the first arm assembly 172 and adjacent to the retention wall 181 .
  • the insert body 170 is shown disposed inside of the first arm assembly 172 and adjacent the retention wall 181 .
  • the first front seat frame insert 162 cannot be moved horizontally out of the front arm receiver 176 because the retention wall 181 prevents the removal of the insert body 170 therefrom.
  • the first front seat frame insert 162 must first be moved upward into the engagement alignment shown in FIG. 18 before the first front seat frame insert 162 can be removed from the front arm receiver 176 .
  • the top edge of the retention wall 181 acts as a seat for the first front tab 132 , thereby distributing the weight of the seat frame assembly 112 through the support frame 114 to the first front tab 132 and onto the first arm assembly 172 .
  • the top edges of the retention walls 181 of the front arm receiver 176 and the rear arm receiver 178 on the second arm assembly 174 and the rear arm receiver of the first arm assembly 172 serve as seats for the second front tab 134 , the second rear tab 138 , and the first rear tab 132 , respectively, thereby distributing the weight of the seat frame assembly 112 to the first and second arm assemblies 172 and 174 .
  • the front arm receivers 176 and the rear arm receivers 178 formed in the first arm assembly 172 and the second arm assembly 174 are illustrated in the form of mortises that are open cavities defined in the interior sides of the arm assemblies.
  • the first front seat frame insert 162 combined with the first front tab 132 , the second front seat frame insert 164 combined with the second front tab 134 , the first rear seat frame insert 166 combined with the first rear tab 136 , and the second rear seat frame insert 168 combined with the second rear tab 138 act as modified tenons, with each insert occupying a portion of the respective receivers to form mortise-and-tenon type joints at each corner of the support frame assembly 112 .
  • These mortise-and-tenon type joints, combined with the male fasteners 182 connecting the seat frame assembly 112 to the first and second arm assemblies 172 and 174 can potentially secure the components of the furniture system 100 along three axes.
  • the back assembly 190 is connected to and completely supported by the first arm assembly 172 and the second arm assembly 174 , as shown in FIGS. 2 and 13 .
  • the first arm assembly 172 and the second arm assembly 174 each comprise a back receiver 184 .
  • the back receiver 184 can be a bracket having a central channel defined by two side walls, each defining a retention slot therein for receiving a side ledge formed on a first arm fastener 192 and a second arm fastener 194 .
  • the first and second arm fasteners 192 and 194 can slide downward into the respective back receivers 184 and be retained therein.
  • the first arm fastener 192 is mounted to the first back side support 191 of the back assembly 190
  • the second arm fastener 194 is mounted to the second back side support 193 of the back assembly 190 .
  • the back assembly 190 is completely supported by the first arm assembly 172 and the second arm assembly 174 and does not directly contact the seat frame assembly 112 .
  • FIGS. 24 and 26 show the furniture system 100 in an unassembled configuration 210 that can be used to package the furniture system 100 in a container for storage or shipping.
  • the unassembled configuration 210 of the furniture system 100 is arranged to help reduce the total volume that the furniture system 100 would occupy in a container or other packaging.
  • the cushions 200 are shown in a compressed configuration resulting from applying a vacuum thereto. The vacuum compression of the cushions 200 reduces the volume that each cushion occupies.
  • At the bottom of the unassembled configuration 210 is the inner frame assembly 115 detached from all other components of the furniture system 100 .
  • the inner frame assembly 115 comprising the support frame 114 and the deck 140 , is aligned upside down so that the stretcher 139 is extending upward instead of downward.
  • first arm assembly 172 and the second arm assembly 174 Disposed on the inner frame assembly 115 are the first arm assembly 172 and the second arm assembly 174 . As shown in FIG. 26 , the first arm assembly 172 and the second arm assembly 174 are separated by the stretcher 139 , which projects upward there between.
  • the front seat frame member 154 and the rear frame seat member 160 are also disposed on the inner frame assembly 115 adjacent the first arm assembly 172 and the second arm assembly 174 .
  • the front seat frame member 154 is disposed between the stretcher 139 and the deck 140 and the rear seat frame member 160 is disposed above the stretcher 139 .
  • the back assembly 190 is disposed generally within the footprint inner frame assembly 115 and above the rear seat frame member 160 and at least a portion of each of the first arm assembly 172 and the second arm assembly 174 .
  • the legs 198 and the male fasteners 182 of the furniture system 100 are disposed on the back assembly 190 .
  • the first arm assembly 172 , the second arm assembly 174 , the inner frame assembly 115 , the back assembly 190 , the front seat frame member 154 , the rear seat frame member 160 , the male fasteners 182 , and the legs 198 are not connected to each other as they would be in the assembled configuration 110 . Instead, these components are stacked upon each other in the unassembled configuration 210 and can be inserted in this unassembled configuration 210 into a container for storage and/or shipping.
  • the unassembled configuration 210 of the furniture system 100 allows for the total volume of a shipping container occupied by the furniture system 100 to be reduced as compared to the overall volume occupied by the furniture system 100 in the assembled configuration 110 . Accordingly, a single shipping container can be used to ship the furniture system 100 in the unassembled configuration 210 .
  • the components of the furniture system 100 in the unassembled configuration 210 are all generally aligned within the footprint of the inner frame assembly 115 and exhibit a generally rectangular configuration when viewed from above or from the side.
  • an end user can assemble the furniture system 100 according to an assembly method comprising one or more of the following steps. Unstack the components of the furniture system 100 from the unassembled configuration. Align the front seat frame member 154 with the front support frame member 116 so that the seat frame female fasteners 156 on the front seat frame member 154 are aligned with the corresponding deck eyelets 153 on the deck 140 and the support frame female fasteners 157 .
  • Legs 198 can then be threadably inserted into corresponding female fasteners disposed on the bottom of the arm base 175 of each of the first arm assembly 172 and the second arm assembly 174 .
  • the back assembly 190 can then be secured to the first arm assembly 172 and the second arm assembly 174 by first aligning the first arm fastener 192 disposed on the first side back support member 191 with the back receiver 184 disposed on the first arm assembly 172 and the second arm fastener 194 disposed on the second side back support member 193 with the back receiver 184 disposed on the second arm assembly 172 and shifting the back assembly 190 down towards the seat frame assembly 112 so that each back receiver 184 securely engages the corresponding first and second arm fasteners 192 and 194 , thereby forming the assembled configuration 110 of the furniture system 100 .
  • FIGS. 27-29 illustrate various aspects of another furniture system encompassing aspects of the present disclosure.
  • a sectional furniture system 300 is shown in FIG. 27 supported on a plurality of legs 198 and having with a plurality of cushions 200 aligned thereon.
  • the sectional furniture system 300 is shown in an assembled configuration 310 and comprises a first leg section 304 connected to a sectional wedge unit 302 and a second leg section 306 connected to another side of the sectional wedge unit 302 .
  • the first leg section 302 is aligned generally perpendicular to the second leg section 304 .
  • the second leg section 304 is longer than the first leg section 302 .
  • the first leg section 302 comprises a first arm assembly 172 and the second leg section 304 comprises a second arm assembly 174 .
  • the second leg section 304 comprises the furniture system 100 , but, instead of a first arm assembly 172 connected to the first sides of the seat frame assembly 112 and the back assembly 190 , the sectional wedge unit 302 is connected thereto.
  • the first leg section 302 comprises a back assembly 190 and a seat frame assembly 112 that are shorter in length than the back assembly 190 and the seat frame assembly 112 of the second leg section 304 and the furniture system 100 , shown in FIG. 2 .
  • the first leg section 302 can be shorter in length than the second leg section 304 .
  • the first leg section 302 is about equal in length to the second leg section 304 .
  • Both the first and second leg sections 302 and 304 comprise first and second deck sections 141 and 143 .
  • the back assemblies 190 of the first and second leg sections 302 and 304 connect to different sides of the sectional wedge unit 302 by the mating of fasteners 192 attached to the back assemblies 190 with back receivers 184 mounted on two sides of the sectional wedge unit 302 .
  • the sectional wedge unit 302 comprises a wedge seat frame and a wedge back assembly that has a first back section connected to a second back sections.
  • the first and second back sections are configured to align generally in line with the back assemblies 190 to which each back section is connected and generally perpendicular to the other of the back sections.
  • the sectional wedge unit 302 can comprise a generally curved back section that meets and connects to both back assemblies 190 of the first and second leg sections of the sectional furniture system 300 .
  • the sectional wedge unit 302 comprises two rear wedge receivers 378 formed in two sides of thereof and two front wedge receivers 376 formed on the two sides.
  • Each of the two front wedge receivers 376 are configured to receive and secure one of the first and second front seat frame inserts 162 and 164 and one of the first and second front tabs 132 and 134 formed on the seat frame assemblies of the first and second leg sections 304 and 306 on the respective sides of the sectional wedge unit 302 .
  • Each of the two rear wedge receivers 378 are configured to receive and secure one of the first and second rear seat frame inserts 166 and 168 and one of the first and second rear tabs 136 and 138 on the seat frame assemblies of the first and second leg sections 304 and 306 on the respective sides of the sectional wedge unit 302 .
  • Each of the front and rear wedge receivers 376 and 378 comprise two contiguous sections—the engagement section 377 and the wedge receiver locking section 379 .
  • the engagement sections 377 are aligned generally vertically and have a length greater than its width.
  • the engagement sections 377 are generally rectangular and configured to receive the tallest portion of the respective seat frame insert.
  • the wedge receiver locking sections 379 are also generally rectangular, but are shorter and wider than the engagement section 377 .
  • the wedge receiver locking sections 379 are configured to receive the insert body 170 of the respective seat frame insert.
  • the lower edge of the wedge receiver locking section 379 is disposed higher on the sectional wedge unit 302 than the lower edge of the engagement section 377 .
  • the upper edge of the wedge receiver locking section 379 is disposed lower on the sectional wedge unit 302 than the upper edge of the engagement section 377 .
  • Each of the front and rear wedge receivers 376 and 378 also comprise a retention wall 181 disposed below the wedge receiver locking section 379 and adjacent the lower portion of the engagement section 377 .
  • the retention wall 181 is configured to contact a portion of an insert body 170 formed on the respective seat frame assembly 112 so as to prevent the removal of the insert from the respective front and rear wedge receivers 376 and 378 in which the insert is disposed.
  • the front wedge receivers 376 can be configured with an open top end that can facilitate the mating of the inserts and tabs on the first and second leg sections 304 and 306 therewith.
  • the front receivers 376 can comprise a closed top end and be configured similar to the front receivers formed on the arm assemblies of the furniture system 100 .
  • the sectional furniture system 300 can be stored and/or shipped in a disassembled state by stacking the components thereof and loading them into multiple containers.
  • the first and second leg sections 304 and 306 can be disconnected from the sectional wedge unit 302 and disassembled and stacked according to the arrangement shown in FIGS. 24-26 with the components of each of the first and second leg sections 304 and 306 stacked separately by section and loaded into a separate container.
  • the sectional wedge unit 302 can be disassembled with the back sections disconnected from the seat frame and/or left assembled or partially assembled and loaded into a third container for storage and/or shipping.

Abstract

Furniture systems, furniture system components, methods of assembling furniture systems, and methods of assembling furniture system components are described in the present disclosure. The furniture systems comprise a seat frame assembly connected to a first arm assembly and a second arm assembly and a back assembly, wherein the seat frame assembly is connected to the first and second arm assemblies by inserts and tabs formed thereon. Inner frame assemblies and deck sections for furniture pieces are also described and include deck webs that define deck gaps therein.

Description

    CROSS-REFERENCE TO RELATED APPLICATIONS
  • This application claims priority to and the benefit of U.S. Provisional Patent Application No. 62/907,157, entitled Furniture Systems and Furniture System Components, filed on Sep. 27, 2019, which is incorporated herein in its entirety by reference.
    • TECHNICAL FIELD
  • The present disclosure is directed to furniture systems and furniture components and, more particularly, to furniture systems and furniture components for ready to assemble furniture.
    • BACKGROUND
  • Furniture systems, such as chairs, sofas, love seats, chaise lounges, and sectionals often include complex construction elements that require production and assembly in the same location, thereby potentially increasing labor costs when the final destinations of the systems are in high cost locations. Ready-to-assemble furniture systems, which require some assembly at the point of use, are becoming more popular, but often do not exhibit the strength, stability, and/or comfort of pre-assembled furniture systems. Furthermore, many ready-to-assemble furniture systems include components that must be shipped to the end user in separate shipping containers, thereby increasing shipping and handling costs.
  • Consequently, there is a need for furniture systems and furniture system components that can potentially address some of these and other challenges.
    • SUMMARY
  • The present disclosure encompasses furniture systems and furniture system components that can be used in ready-to-assemble furniture products and other furniture products. The present disclosure also encompasses furniture systems and furniture components that can reduce the total volume of shipping container space typically required to ship many conventional furniture systems and furniture components. The present disclosure also encompasses furniture systems and furniture components that can enhance any one or more of the strength, solidity, stability, and/or comfort of a furniture product as compared to some conventional alternative furniture systems and furniture components.
  • The present disclosure encompasses a furniture system comprising: a seat frame assembly, a first side assembly connected to a first side of the seat frame assembly, a second side assembly connected to a second side of the seat frame assembly, wherein the second side of the seat frame assembly opposes the first side of the seat frame assembly, wherein each of the first side assembly and the second side assembly is selected from the group of an arm assembly and a sectional wedge assembly, wherein the seat frame assembly comprises a first seat frame insert projecting from the first side of the seat frame assembly, a second seat frame insert projecting from the second side of the seat frame assembly, a first load-bearing tab aligned proximal to the first seat frame insert and projecting from the first side of the seat frame assembly, a second load-bearing tab aligned proximal to the second seat frame insert and projecting from the second side of the seat frame assembly, wherein the first seat frame insert comprises a first insert body, wherein the second seat frame insert comprises a second insert body, wherein the first side assembly comprises a first side receiver, wherein the first side receiver comprises a first engagement section, a first locking section, and a first retention wall; wherein the second side assembly comprises a second side receiver, wherein the second side receiver comprises a second engagement section, a second locking section, and a second retention wall, wherein the first seat frame insert and the first load-bearing tab are disposed in the first side receiver, wherein the first load-bearing tab is seated on the first retention wall of the first side receiver, wherein the first retention wall of the first side receiver is aligned proximal to the second side assembly and the first insert body of the first seat frame insert is aligned distal to the second side assembly, and, wherein the second seat frame insert and the second load-bearing tab are disposed in the second side receiver, wherein the second load-bearing tab is seated on the second retention wall of the second side receiver, wherein the second retention wall of the second side receiver is aligned proximal to the first second assembly and the second insert body of the second seat frame insert is aligned distal to the first side assembly.
  • In another aspect, the seat frame assembly further can comprise a third seat frame insert projecting from the first side of the seat frame assembly, a fourth seat frame insert projecting from the second side of the seat frame assembly, a third load-bearing tab aligned proximal to the third seat frame insert and projecting from the first side of the seat frame assembly, a fourth load-bearing tab aligned proximal to the fourth seat frame insert and projecting from the second side of the seat frame assembly, wherein the third seat frame insert comprises a third insert body, wherein the fourth seat frame insert comprises a fourth insert body. In a further aspect, the first side assembly further can comprise a third side receiver, wherein the third side receiver comprises a third engagement section, a third locking section, and a third retention wall, wherein the second side assembly comprises a fourth side receiver, wherein the fourth side receiver comprises a fourth engagement section, a fourth locking section, and a fourth retention wall, wherein the third seat frame insert and the third load-bearing tab are disposed in the third side receiver, wherein the third load-bearing tab is seated on the third retention wall of the third end receiver, wherein the third retention wall of the third end receiver is aligned proximal to the second side assembly and the third insert body of the third seat frame insert is aligned distal to the second side assembly, and, wherein the fourth seat frame insert and the fourth load-bearing tab are disposed in the fourth side receiver, wherein the fourth load-bearing tab is seated on the fourth retention wall of the fourth end receiver, wherein the fourth retention wall of the fourth side receiver is aligned proximal to the first side assembly and the fourth insert body of the fourth seat frame insert is aligned distal to the first side assembly.
  • In yet another aspect, the furniture system can further comprise a back assembly, wherein the back assembly is mounted to the first side assembly and the second side assembly. In still a further aspect, the back assembly can be spaced apart from the seat frame assembly. In another aspect, the seat assembly can further comprise a deck. In still another aspect, the deck can comprise a front deck web and a rear deck web, wherein the front deck web and the rear deck web define a deck gap. In yet a further aspect, the deck gap can be disposed proximal to the rear support frame member and distal to the front support frame member. In another aspect, the front deck web can be connected to the rear deck web by a plurality of straps. In a further aspect, the seat assembly can further comprise a front support frame member and an opposing rear support frame member, wherein the deck comprises a front sleeve encasing a portion of the front support frame member and a rear sleeve encasing a portion of the rear support frame member, and wherein the deck extends between the front support frame member and the rear support frame member. In yet another aspect, the seat frame assembly can further comprise a first side support frame member aligned proximal to the first side assembly and an opposing second side support frame member aligned proximal to the second side assembly, wherein the first side support frame member and the second side support frame member are connected to the front support frame member and the rear support frame member. In still another aspect, the seat assembly can comprise a first side support frame member and an opposing second side support frame member, and wherein the first loadbearing tab is formed on first side support frame member and the second load-bearing tab is formed on the second side support frame member. In another aspect, the seat assembly further can comprise a front seat frame member, and wherein the first seat frame insert is formed on a front seat frame member. In a further aspect, the second front seat frame insert can be formed on the front seat frame member. In another aspect, the deck can comprise a first deck section and a second deck section, wherein the first deck section is spaced apart from the second deck section. In yet a further aspect, the first side assembly further can comprise an arm top.
  • The present disclosure also encompasses furniture system comprising: a seat frame assembly, a first end assembly connected to a first side of the seat frame assembly, a second end assembly connected to second side of the seat frame assembly, wherein the first side of the seat frame assembly is opposed to the second side of the seat frame assembly, wherein each of the first end assembly and the second end assembly is selected from the group of an arm assembly or a sectional wedge assembly, wherein the seat frame assembly comprises a first front seat frame insert projecting from the first side of the seat frame assembly, a second front seat frame insert projecting from the second side of the seat frame assembly, a first rear seat frame insert projecting from the first side of the seat frame assembly, and a second rear seat frame insert projecting from the second side of the seat frame assembly, wherein the first front seat frame insert comprises a first front insert body, wherein the second front seat frame insert comprises a second front insert body, wherein the first rear seat frame insert comprises a first rear insert body, wherein the second rear seat frame insert comprises a second rear insert body, wherein the seat frame assembly comprises a first front load-bearing tab projecting from the first side of the seat frame assembly, a second front load-bearing tab projecting from the second side of the seat frame assembly, a first rear load-bearing tab projecting from the first side of the seat frame assembly, a second rear load-bearing tab projecting from the second side of the seat frame assembly, wherein the first end assembly comprises a first front end receiver and a first rear end receiver, wherein the second end assembly comprises a second front end receiver and a second rear end receiver, wherein the first front end receiver comprises a first front engagement section, a first front locking section, and a first front retention wall, wherein the first front seat frame insert and the first front tab are disposed in the first front end receiver, wherein the first front load-bearing tab is seated on the first front retention wall of the first front end receiver, wherein the first front retention wall of the first front end receiver is aligned proximal to the second end assembly and the first front insert body of the first front seat frame insert is aligned distal to the second end assembly; wherein the second front end receiver comprises a second front engagement section, a second front locking section, and a second front retention wall, wherein the second front seat frame insert and the second front load-bearing tab are disposed in the second front end receiver, wherein the second front load-bearing tab is seated on the second front retention wall of the second front end receiver, wherein the second front retention wall of the second front end receiver is aligned proximal to the first end assembly and the second front insert body of the second front seat frame insert is aligned distal to the first end assembly, wherein the first rear end receiver comprises a first rear engagement section, a first rear locking section, and a first rear retention wall, wherein the first rear seat frame insert and the first rear load-bearing tab are disposed in the first rear end receiver, wherein the first rear load-bearing tab is seated on the first rear retention wall of the first rear end receiver, wherein the first rear retention wall of the first rear end receiver is aligned proximal to the second end assembly and the first rear insert body of the first rear seat frame insert is aligned distal to the second end assembly, wherein the second rear end receiver comprises a second rear engagement section, a second rear locking section, and a second rear retention wall, wherein the second rear seat frame insert and the second rear load-bearing tab are disposed in the second rear end receiver, wherein the second rear load-bearing tab is seated on the second rear retention wall of the second rear end receiver, wherein the second rear retention wall of the second rear end receiver is aligned proximal to the first end assembly and the second insert body of the second rear seat frame insert is aligned distal to the first end assembly.
  • In another aspect, furniture system can further comprise a back assembly mounted to the first end assembly and the second end assembly. In a further aspect, the back assembly can be spaced apart from the seat frame assembly. In yet another aspect, the seat frame assembly further can comprise an inner frame assembly, and wherein the first front load-bearing tab, the second front load-bearing tab, the first rear load-bearing tab, and the second rear load-bearing tab are formed on the inner frame assembly. In still another aspect, the seat frame assembly further can comprise a deck. In a further aspect, the deck can comprise a front deck section and a rear deck section, wherein the front deck section is separated from the rear deck section by a deck gap. In another aspect, the front deck section can be connected to the rear deck section by a plurality of deck straps.
  • The present disclosure also encompasses a furniture system comprising a seat frame assembly, a first arm assembly connected to the seat frame assembly, a second arm assembly connected to the seat frame assembly, wherein the seat frame assembly comprises a first front seat frame insert projecting from a first side of the seat frame assembly, a second front seat frame insert projecting from a second side of the seat frame assembly, a first rear seat frame insert projecting from the first side of the seat frame assembly, and a second rear seat frame insert projecting from the second side of the seat frame assembly, wherein each of the first front seat frame insert, the second front seat frame insert, the first rear seat frame insert, and the second rear seat frame insert comprises an insert body, wherein the seat frame assembly comprises a first front tab projecting from the first side of the seat frame assembly, a second front tab projecting from the second side of the seat frame assembly, a first rear tab projecting from the first side of the seat frame assembly, a second rear tab projecting from the second side of the seat frame assembly, wherein the first arm assembly comprises a first front arm receiver and a first rear arm receiver, wherein the second arm assembly comprises a second front arm receiver and a second rear arm receiver, wherein each of the first front arm receiver, the second front arm receiver, the first rear arm receiver, and the second rear arm receiver comprises an engagement section, a locking section, and a retention wall; wherein the first front seat frame insert and the first front tab are disposed in the first front arm receiver, wherein the first front tab is seated on the retention wall of the first front arm receiver, wherein the retention wall of the first front arm receiver is aligned proximal to the second arm assembly and the insert body of the first front seat frame insert is aligned distal to the second arm assembly; wherein the second front seat frame insert and the second front tab are disposed in the second front arm receiver, wherein the second front tab is seated on the retention wall of the second front arm receiver, wherein the retention wall of the second front arm receiver is aligned distal to the first arm assembly, and wherein the insert body of the second front seat frame insert is aligned distal to the first arm assembly.
  • In another aspect, the first rear seat frame insert and the first rear tab are disposed in the first rear arm receiver, the first rear tab is seated on the retention wall of the first rear arm receiver, the retention wall of the first rear arm receiver is aligned proximal to the second arm assembly, and the insert body of the first rear seat frame insert is aligned distal to the second arm assembly. In a further aspect, the second rear seat frame insert and the second rear tab are disposed in the second rear arm receiver, the second rear tab is seated on the retention wall of the second rear arm receiver, the retention wall of the second rear arm receiver is aligned proximal to the first arm assembly, and the insert body of the second rear seat frame insert is aligned distal to the first arm assembly. In still a further aspect, the seat frame assembly further comprises a front support frame member and an opposing rear support frame member. In yet another aspect, the seat frame assembly comprises a deck extending from the front support frame member to the rear support frame member, wherein the deck comprises a front deck web and a rear deck web, wherein the front deck web and the rear deck web define a deck gap. In a further aspect, the deck gap is disposed proximal to the rear support frame member and distal to the front support frame member. In still another aspect, the front deck web is connected to the rear deck web by a plurality of straps. In another aspect, the deck comprises a front sleeve connected to the front deck web and a rear sleeve connected to the rear deck web. In yet another aspect, the furniture system further comprises a back assembly connected to the first arm assembly and the second arm assembly. In a further aspect, the back assembly is spaced apart from the seat frame assembly.
  • The present disclosure also encompasses a furniture system comprising a seat frame assembly operably connected to a back assembly, wherein the seat frame assembly comprises an inner frame assembly, wherein the inner frame assembly comprises a front support frame member and an opposing rear support frame member, a first side support frame member detachably connected to the front support frame member and the rear support frame member, a second side support frame member detachably connected to the front support frame member and the rear support frame member, wherein the inner frame assembly further comprises a deck connected to and extending between the front support frame member and the rear support frame member, wherein the deck comprises a front sleeve and an opposing rear sleeve, wherein at least a portion of the front support frame member is disposed in the front sleeve and wherein at least a portion of the rear support frame member is disposed in the rear sleeve, wherein the deck comprises a front deck web connected to the front sleeve and a rear deck web connected to the rear sleeve, wherein the front deck is connected to the rear deck by a plurality of straps, wherein the front deck web and the rear deck web define a deck gap, wherein the plurality of straps extend across the deck gap, and wherein the deck gap is aligned proximal to the rear support frame member and distal to the front support frame member.
  • In another aspect, the furniture system comprises a first arm assembly connected to the seat frame assembly and a second arm assembly connected to the seat frame assembly. In a further aspect, the first arm assembly and the second arm assembly are connected to the back assembly. In still another aspect, the first arm assembly comprises a first arm receiver and the second arm assembly comprises a second arm receiver, wherein the seat frame assembly comprises a first seat frame insert extending from a first side of the seat frame assembly and a second seat frame insert extending from a second side of the seat frame assembly, wherein the first seat frame insert is disposed in the first arm receiver of the first arm assembly and the second seat frame insert is disposed in the second arm receiver of the second arm assembly. In another aspect, each of the first arm receiver and the second arm receiver comprises a retention wall, wherein a portion of the first seat frame insert is aligned distal to the second arm assembly and the retention wall of the first arm receiver is aligned proximal to the second arm assembly, and wherein a portion of the second seat frame insert is aligned distal to the first arm assembly and the retention wall of the second arm receiver is aligned proximal to the second arm assembly. In another aspect, the inner frame assembly further comprises a first tab extending from the first side of the inner frame assembly and a second tab extending from the second side of the inner frame assembly, wherein a portion of the first tab is disposed in the first arm assembly and a portion of the second tab is disposed in the second arm assembly. In a further aspect, a male fastener connects the first side support frame member to the first arm assembly and a second male fastener connects the second side support frame member to the second arm assembly. In still another aspect, the seat frame assembly is completely supported by the first arm assembly and the second arm assembly, and wherein a portion of the weight of the seat frame assembly is distributed to the first arm assembly by the first tab and the first seat frame insert and another portion of the weight of the seat frame assembly is distributed to the second arm assembly by the second tab and the second seat frame insert. In still another aspect, the inner frame assembly comprises a stretcher extending between and connected to the front support frame member and the rear support frame member. In a further aspect, the stretcher is connected to a midpoint of the front seat support frame member and a midpoint of the rear support frame member. In another aspect, the stretcher comprises a front stretcher arm, a rear stretcher arm, and a cross stretcher arm extending between the front stretcher arm and the rear stretcher arm. In still another aspect, the cross stretcher arm is aligned outside of a plane in which the front support frame member and the rear support frame member are disposed. In another aspect, a majority of the stretcher is aligned outside of the plane in which the front support frame member and the rear support frame member are disposed. In a further aspect, the deck comprises a first deck section and a second deck section. In yet another aspect, the stretcher is aligned between the first deck section and the second deck section.
  • The present disclosure also encompasses an inner frame assembly for use in furniture pieces comprising a support frame and a deck connected to the support frame, wherein the support frame comprises a center support frame section detachably connected to a first side support frame member and a second side support frame member, wherein the center support fame section comprises a front support frame member, an opposing rear support frame member, and a stretcher extending between the front support frame member and the rear support frame member, wherein the stretcher connects the front support frame member to the rear support frame member, wherein the stretcher comprises a front stretcher arm connected to the front support frame member, a rear stretcher arm connected to the rear support frame member, and a cross stretcher arm extending between and connected to the front stretcher arm and the rear stretcher arm, wherein the cross stretcher arm is offset from the front support frame member and the rear support frame member, the inner frame assembly further comprising a deck extending between the front support frame member and the rear support frame member, wherein the deck comprises a first deck section aligned to one side of the stretcher and a second deck section aligned to an opposing side of the stretcher, wherein the first deck section comprises a first front sleeve and an opposing first rear sleeve, wherein the second deck section comprises a second front sleeve and an opposing second rear sleeve, wherein a first portion of the front support frame member is disposed in the first front sleeve and a second portion of the front support frame member is disposed in the second front sleeve, wherein a first portion of the rear support frame member is disposed in the first rear sleeve and a second portion of the rear support frame member is disposed in the second rear sleeve, wherein the first deck section comprises a first front deck web connected to the first front sleeve and a first rear deck web connected to the first rear sleeve, wherein the first front deck web is connected to the first rear deck web by a first plurality of straps, wherein the first front deck web and the first rear deck web define a first deck gap, wherein the first plurality of straps extend across the first deck gap, wherein the second deck section comprises a second front deck web and an opposing second rear deck web, wherein the second front web is connected to the second front sleeve and the second rear deck web is connected to the second rear sleeve, wherein the second front deck web is connected to the second rear deck web by a second plurality of straps, wherein the second front deck web and the second rear deck web define a second deck gap, wherein the second plurality of straps extend across the second deck gap, wherein the first deck gap is aligned generally collinearly with the second deck gap, wherein the first deck gap is aligned closer to the first rear sleeve than to the first front sleeve, wherein the second deck gap is aligned closer to the second rear sleeve than to the second front sleeve.
  • In another aspect, the stretcher is connected to the midpoints of the front seat frame member and the rear seat frame member. In a further aspect, the first side support frame member comprises a first front cap disposed at a front end thereof and a first rear cap disposed at a rear end thereof, wherein the front support frame member comprises a first front receiver on a first end thereof, wherein the first front receiver is configured to receive the first front cap thereon to connect the first side support frame member to the front support frame member, wherein the rear support frame member comprises a first rear receiver on a first end thereof, wherein the first rear receiver is configured to receive the first rear cap thereon to connect the first side support frame member to the rear support frame member, wherein the second side support frame member comprises a second front cap disposed at a front end thereof and a second rear cap disposed at a rear end thereof, wherein the front support frame member comprises a second front receiver disposed on a second end thereof, wherein the second front receiver is configured to receive the second front end cap to connect the second side support frame member to the front support frame member, wherein the rear support frame member comprises a second rear receiver on a second end thereof, wherein the second rear receiver is configured to receive the second rear cap to connect the second side support frame member to the rear support frame member. In a further aspect, the inner frame assembly is generally rectangular. In still another aspect, the center support frame section, the first side support frame member and the second side support frame member comprise metal. In yet another aspect, the first front deck web, the second front deck web, the first rear deck web, and the second rear deck web comprise a resilient woven textile.
  • The present disclosure also encompasses a deck section for a furniture system comprising a front deck web, a rear deck web connected to the front deck web by a plurality of straps, wherein the front deck web and the rear deck web define a deck gap, wherein the plurality of straps extend across the deck gap from the front deck web to the rear deck web, a front sleeve connected to the front deck web, and a rear sleeve connected to the rear deck web. In one aspect, the front sleeve is integrally formed with the front deck web. In another aspect, the rear sleeve is integrally formed with rear deck web. In a further aspect, the front deck web is formed of a resilient woven textile. In yet another aspect, the front sleeve is formed of the resilient woven textile. In a further aspect, the rear deck web is formed of the resilient woven textile. In yet another aspect, the rear sleeve is formed of the resilient woven textile. In a further aspect, the deck gap is aligned proximal to the rear sleeve and distal to the front sleeve. In yet a further aspect, the deck gap extends across the length of the deck section. In another aspect, the inner frame assembly is stackable with one or more other inner frame assemblies wherein the stretcher of a top inner frame assembly extends downward between the first deck section and the second deck section of a lower inner frame assembly on which the top frame assembly is stacked.
  • The present disclosure encompasses a furniture system comprising a seat frame assembly connected to a first arm assembly and a second arm assembly, a back assembly connected to the first arm assembly and the second arm assembly, wherein the back assembly is spaced apart from the seat frame assembly, wherein the seat frame assembly comprises an inner frame assembly, a front seat frame member connected to the inner frame assembly, and a rear seat frame member connected to the inner frame assembly, wherein the inner frame assembly comprises a support frame and a deck connected thereto, wherein the deck comprises a front deck web and a rear deck web, wherein the front deck web is connected to the rear deck web by a plurality of straps, wherein the front deck web and the rear deck web define a deck gap, wherein the plurality of straps extend across the deck gap from the front deck web to the rear deck web, wherein the deck further comprises a front sleeve connected to the front deck web and a rear sleeve connected to the rear deck web, wherein the support frame comprises a front support frame member and an opposing rear support frame member, wherein a portion of the front support frame member is disposed in the front sleeve and a portion of the rear support frame member is disposed in the rear sleeve, wherein the support frame further comprises a stretcher extending between and connected to the front support frame member and the rear support frame member, a first side support frame member connected to the front support frame member and the rear support frame member, and a second side support frame member connected to the front support frame member and the rear support frame member, wherein the support frame further comprises a first front tab extending from a first side thereof, a second front tab extending from a second side thereof, a first rear tab extending from the first side thereof, and a second rear tab extending from the second side thereof, wherein the front seat frame member comprises a first front seat frame insert projecting from one end thereof and a second front seat frame insert projecting from an opposing end thereof, wherein the rear seat frame member comprises a first rear seat frame insert projecting from one end thereof and a second seat frame insert projecting from an opposing end thereof, wherein the first arm assembly comprises a first front arm receiver and a first rear arm receiver, wherein the first front seat frame insert and the first front tab are locked in first front arm receiver, wherein the first rear seat frame insert and the first rear tab are locked in the first rear arm receiver, wherein the second arm assembly comprises a second front arm receiver and a second rear arm receiver, wherein the second front seat frame insert and the second front tab are locked in the second front arm receiver and the second rear seat frame insert and the second rear tab are locked in the second rear arm receiver.
  • In another aspect, the furniture system further comprises a first male fastener connecting the inner frame assembly to the first arm assembly and a second male fastener connecting the inner frame assembly to the second arm assembly. In a further aspect, the furniture system further comprises a first male fastener connecting the front seat frame member to the front support frame member and a second male fastener connecting the rear seat frame member to the rear support frame member.
  • The present disclosure also encompasses a furniture system comprising an assembled configuration for use and an unassembled configuration for storage or shipping; wherein the furniture system comprises, in the assembled configuration, a seat frame assembly connected to a first arm assembly and a second arm assembly, a back assembly connected to the first arm assembly and the second arm assembly, wherein the back assembly is separated from the seat frame assembly, wherein the seat frame assembly comprises an inner frame assembly, a front seat frame member connected to the inner frame assembly, and a back seat frame member connected to the inner frame assembly, wherein the inner frame assembly comprises a support frame and a deck connected thereto, wherein the deck comprises a front deck web and a rear deck web, wherein the front deck web is connected to the rear deck web by a plurality of straps, wherein the front deck web and the rear deck web define a deck gap, wherein the plurality of straps extend across the deck gap from the front deck web to the rear deck web, wherein the deck further comprises a front sleeve connected to the front deck web and a rear sleeve connected to the rear deck web, wherein the support frame comprises a front support frame member and an opposing rear support frame member, wherein a portion of the front support frame member is disposed in the front sleeve and a portion of the rear support frame member is disposed in the rear sleeve, wherein the support frame further comprises a stretcher extending between and connected to the front support frame member and the rear support frame member, wherein the stretcher projects downward from the front support frame member and the rear support frame member, a first side support frame member connected to the front support frame member and the rear support frame member, and a second side support frame member connected to the front support frame member and the rear support frame member, wherein the support frame further comprises a first front tab extending from a first side thereof, a second front tab extending from a second side thereof, a first rear tab extending from the first side thereof, and a second rear tab extending from the second side thereof, wherein the front seat frame member comprises a first front seat frame insert projecting from one end thereof and a second front seat frame insert projecting from an opposing end thereof, wherein the rear seat frame member comprises a first rear seat frame insert projecting from one end thereof and a second seat frame insert projecting from an opposing end thereof, wherein the first arm assembly comprises a first front arm receiver and a first rear arm receiver, wherein the first front seat frame insert and the first front tab are locked in first front arm receiver, wherein the first rear seat frame insert and the first rear tab are locked in the first rear arm receiver, wherein the second arm assembly comprises a second front arm receiver and a second rear arm receiver, wherein the second front seat frame insert and the second front tab are locked in the second front arm receiver and the second rear seat frame insert and the second rear tab are locked in the second rear arm receiver; wherein, in the unassembled configuration, the inner frame assembly is detached from the front seat frame member, the rear seat frame member, the first arm assembly, and the second arm assembly and inverted with the stretcher projecting upward, wherein the first arm assembly is positioned side down on one of the first deck section and the second deck section, wherein the second arm assembly is positioned side down on the other one of the first deck section and the second deck section, wherein the stretcher is disposed between the first arm assembly and the second arm assembly, wherein one of the front seat frame member and the rear seat frame member is disposed on the first deck section and the second deck section below a portion of the stretcher and adjacent to the first arm assembly and the second arm assembly, wherein the other one of the front seat frame member and the rear seat frame member is disposed above a portion of the stretcher and adjacent the first arm assembly and the second arm assembly, and wherein the back assembly is disposed above the front seat frame member and the rear seat frame member and a portion of the first arm assembly and a portion of the second arm assembly.
  • The present disclosure also encompasses a method of assembling a ready-to-assemble furniture system comprising the steps of: providing a furniture system comprising a seat frame assembly, a first arm assembly, a second arm assembly, and a back assembly, wherein the seat frame assembly comprises a first front seat frame insert projecting from a first side of the seat frame assembly, a second front seat frame insert projecting from a second side of the seat frame assembly, a first rear seat frame insert projecting from the first side of the seat frame assembly, a second rear seat frame insert projecting from the second side of the seat frame assembly, wherein the first arm assembly comprises a first female fastener, a first front arm receiver, and a first rear arm receiver, wherein the first front arm receiver comprises a first front engagement section and a first front locking section, wherein the second arm assembly comprises a second female fastener, a second front arm receiver and a second rear arm receiver; aligning the first front seat frame insert with the first front arm receiver and the first rear seat frame insert with the first rear arm receiver; inserting the first front seat frame insert in the first front arm receiver to form an first front engagement alignment; inserting the first rear seat frame insert in the first rear arm receiver to form a first rear engagement alignment; shifting the first front seat frame insert in the first front arm receiver to form a first front locking alignment and the first rear seat frame insert in the first rear arm receiver to form a first rear locking alignment; aligning the second front seat frame insert with the second front arm receiver and the second rear seat frame insert with the second rear arm receiver; inserting the second front seat frame insert in the second front arm receiver to form an second front engagement alignment; inserting the second rear seat frame insert in the second rear arm receiver to form a second rear engagement alignment; and, shifting the second front seat frame insert in the second front arm receiver to form a second front locking alignment and the second rear seat frame insert in the second rear arm receiver to form a second rear locking alignment.
  • In another aspect, the method of assembling a ready-to-assemble furniture system further comprises the step of connecting the seat frame assembly to the first arm assembly with a first male fastener. In another aspect, the method of assembling a ready-to-assemble furniture system further comprises the step of connecting the seat frame assembly to the second arm assembly with a second male fastener. In another aspect, the method of assembling a ready-to-assemble furniture system further comprises the step of connecting the back assembly to the first arm assembly and the second arm assembly. In a further aspect, the back assembly is slidably connected to the first arm assembly and the second arm assembly. In still another aspect, the first arm assembly further comprises a first back receiver, the second arm assembly comprises a second back receiver, and the back assembly comprises a first arm fastener disposed on a first back side support and a second arm fastener disposed on a second back side support. In a further aspect, the first arm fastener is slidably inserted into the first back receiver and the second arm fastener is slidably inserted into the second back receiver. In yet another aspect, the seat frame assembly further comprises a first front tab and a first rear tab projecting from the first side of the seat frame assembly, a second front tab and a second rear tab projecting from the second side of the seat frame assembly. In a further aspect, the first front tab is supported by a retention wall of the first front arm receiver in the first front locking alignment, the first rear tab is supported by a retention wall of the first rear arm receiver in the first rear locking alignment, the second front tab is supported by a retention wall of the second front arm receiver in the second front locking alignment, and the second rear tab is supported by a retention wall of the second rear arm receiver in the second rear locking alignment. In still a further aspect, the furniture system further comprises a plurality of legs. In another aspect, the method further comprises threadably connecting one or more legs of the plurality legs to each of the first arm assembly and the second arm assembly.
  • The present disclosure also encompasses a method of assembling an inner frame assembly comprising the steps of: providing a center support frame section, a first side support frame member, a second side support frame member, a first deck section, and a second deck section, wherein the center support frame member comprises a front support frame member, a rear support frame member, and a stretcher extending between and connected to the front support frame member and the rear support frame member, wherein the front support frame member comprises a first front receiver on a first end thereof and a second front receiver on a second end thereof, wherein the rear support frame member comprises a first rear receiver on a first end thereof and a second rear receiver on a second end thereof, wherein the first deck section comprises a first front sleeve, an opposing first rear sleeve, and webbing extending between the first front sleeve and the first rear sleeve, wherein the second deck section comprises a second front sleeve an opposing second rear sleeve, and webbing extending between the second front sleeve and the second rear sleeve; aligning first front sleeve with the first front receiver; sliding the first front sleeve onto the first front receiver; aligning the first rear sleeve with the first rear receiver; sliding the first rear sleeve onto the first rear receiver; shifting the first deck section toward the stretcher whereby the first deck section extends between and is completely supported by the front support frame member and the rear support frame member; aligning second front sleeve with the second front receiver; sliding the second front sleeve onto the second front receiver; aligning the second rear sleeve with the second rear receiver; sliding the second rear sleeve onto the second rear receiver; shifting the second deck section toward the stretcher whereby the second deck section extends between and is completely supported by the front support frame member and the rear support frame member; connecting the first side support frame member to the first front receiver of the front support frame member and the first rear receiver of the rear support frame member; and connecting the second side support frame member to the second front receiver of the front support frame member and the second rear receiver of the rear support frame member to form the inner frame assembly.
  • In another aspect, the first deck section comprises a first deck gap defined by the webbing of the first deck section. In a further aspect, the second deck section comprises a second deck gap defined by the webbing of the second deck section.
  • These and other aspects of the present disclosure are set forth in more detail below and illustrated in the drawings, which are briefly described as follows.
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 shows a perspective view of a furniture system encompassing aspects of the present disclosure illustrated as a sofa in an assembled configuration.
  • FIG. 2 illustrates a perspective view of the furniture system shown in FIG. 1 with the cushions, upholstery, and legs removed.
  • FIG. 3 illustrates a perspective view of an inner frame assembly for a furniture system shown in FIG. 2, wherein the inner frame assembly encompasses aspects of the present disclosure.
  • FIG. 4 illustrates a perspective view of a support frame of the inner frame assembly shown in FIG. 3 with the deck sections removed and the second side support frame member of the support frame detached from the center support frame section of the support frame.
  • FIG. 5A illustrates a perspective view of the support frame shown in FIG. 4 with the second side support frame member removed to allow for a deck section to be slidably engaged to the support frame.
  • FIG. 5B illustrates a perspective view of a deck section of the inner frame assembly shown in FIG. 3 removed from the inner frame assembly, wherein the deck section encompasses aspects of the present disclosure.
  • FIG. 6 illustrates a perspective view of the inner frame assembly of FIG. 3 with the second deck section in a deflexed alignment as would arise if a user was sitting on a sofa comprising the inner frame assembly.
  • FIG. 7A illustrates a perspective view of a trio of inner frame assemblies, as shown in FIG. 3, wherein the trio encompasses aspects of the present disclosure with the trio of inner frame assemblies in a stacked and nested configuration for shipping of the furniture components.
  • FIG. 7B is another perspective view of the trio of inner frame assemblies shown in FIG. 7A shown from below.
  • FIG. 8 illustrates a lower perspective view of the inner frame assembly shown in FIG. 3 with a front seat frame member and a rear seat frame member attached thereto to form a seat frame assembly encompassing aspects of the present disclosure.
  • FIG. 9 illustrates a perspective view of the seat frame assembly shown in FIG. 8 with a first arm assembly connected to a first end thereof and a second arm assembly connected to a second end thereof.
  • FIG. 10 illustrates a cutaway perspective view of the seat frame assembly shown in FIG. 8 positioned during the assembly process of a ready-to-assemble furniture system, with the seat frame assembly being positioned adjacent a first arm assembly so as to align a first front seat frame insert on the seat frame assembly with a first arm receiver on the first arm assembly and a first rear seat frame insert with a rear arm receiver on the first arm assembly for connection of the first arm assembly to the seat frame assembly.
  • FIG. 11 illustrates another cutaway perspective view of the seat frame assembly and the first arm assembly shown in FIG. 10 during another step of the assembly process of a ready-to-assemble furniture system, wherein the first arm assembly is connected to seat frame assembly in an engagement alignment that is prior to a step of forming locking alignments between the first front seat frame insert and the first arm receiver and the first rear seat frame insert and the rear arm receiver.
  • FIG. 12 illustrates yet another cutaway perspective view of the seat frame assembly and the first arm assembly shown in FIGS. 10 and 11, during a subsequent step of the assembly process of a ready-to-assemble furniture system, wherein the seat frame assembly and the first arm assembly are connected to each other in the final step of the connection process wherein the seat frame assembly is lowered relative to the first arm assembly so as to lock the first front seat frame insert in the front arm receiver and the first rear seat frame insert in the rear arm receiver and with male fasteners engaged with both the seat frame assembly and the first arm assembly to secure further the first arm assembly to the seat frame assembly.
  • FIG. 13 illustrates a perspective view of the seat frame assembly, the first arm assembly, and the second arm assembly shown in FIG. 9 operably connected with a back assembly connected to and supported by the first arm assembly and the second arm assembly to form an assembled configuration of the furniture system.
  • FIG. 14 illustrates an inner side elevation view of the first arm assembly shown in FIG. 10 shown by itself.
  • FIG. 15 illustrates a top plan view of a front seat frame member that can be used in the furniture systems and seat frame assemblies encompassed by the present disclosure.
  • FIG. 16 illustrates a front elevation view of the front seat frame member shown in
  • FIG. 15.
  • FIG. 17 is a side elevation view of the front seat frame member shown in FIGS. 15 and 16.
  • FIG. 18 illustrates a partial cutaway side elevation view of a portion of the first arm assembly with the outer sidewall removed and a front end portion of the seat frame assembly shown in an engagement alignment with the first front seat frame insert engaged with the front arm receiver during the assembly process.
  • FIG. 19 illustrates another partial cutaway side elevation view of the portion of the first arm assembly and the front end portion of the seat frame assembly shown in FIG. 18 with the first front seat frame insert and the front arm receiver in a locking alignment.
  • FIG. 20 illustrates a partial perspective cutaway side view of the first arm assembly and the front end portion of the seat frame assembly shown in FIG. 19 with the first front seat frame insert engaged with the front arm receiver in a locking alignment.
  • FIG. 21 illustrates a partial cutaway perspective view of the seat frame assembly 10 shown in FIG. 8 with a male fastener disposed in the first side support frame female fastener.
  • FIG. 22 illustrates a partial cutaway perspective view of the first arm assembly engaged with the seat frame assembly in a locking alignment.
  • FIG. 23 illustrates a perspective view of a back receiver that can be mounted on the arm assemblies of the furniture system to receive, engage and retain a back fastener that can be mounted on either side of the back assembly of the furniture system shown in FIG. 2 to mount the back assembly to the remainder of the furniture system.
  • FIG. 24 illustrates a perspective view of an unassembled configuration of the furniture system shown in FIG. 1 with the upholstery removed, wherein the unassembled configuration is configured for insertion of the furniture system in a container for shipping and/or storage.
  • FIG. 25 illustrates a side elevation view of the unassembled configuration of the furniture system shown in FIG. 24.
  • FIG. 26 illustrates a perspective view of some of the furniture components of the furniture system shown in FIGS. 24 and 25 with the cushions and back assembly removed from the unassembled configuration to reveal the alignment of the seat stretcher and the first and second arm assemblies in the unassembled configuration.
  • FIG. 27 is a perspective view of a sectional furniture system encompassed by the present disclosure with the furniture system in an assembled configuration.
  • FIG. 28 is a perspective view of the sectional furniture system shown in FIG. 27 with the cushions removed and selected components of the system separated from each other.
  • FIG. 29 is a perspective view of the lower right rear portion of the sectional wedge component and the rear left side of the seat frame assembly of the second sectional leg showing selected components of the sectional furniture system shown in FIG. 28.
    •  FURNITURE SYSTEM AND FURNITURE SYSTEM COMPONENTS
      • Furniture system 100
      • Assembled configuration 110
      • Unassembled configuration 210
      • Seat frame assembly 112
      • Support frame 114
      • Inner frame assembly 115
      • Front support frame member 116
      • Center support frame section 117
      • Rear support frame member 118
      • First side support frame member 120
      • Second side support frame member 122
      • First front receiver 124
      • Second front receiver 126
      • First rear receiver 128
      • Second rear receiver 130
      • First front tab 132
      • Second front tab 134
      • First rear tab 136
      • Second rear tab 138
      • Stretcher 139
      • Deck 140
      • First deck section 141
      • Front sleeve 142
      • Second deck section 143
      • Rear sleeve 144
      • Deck gap 145
      • Plurality of straps 146
      • Front stretcher arm 147
      • Strap 148
      • Rear stretcher arm 149
      • Front deck web 150
      • Rear deck web 152
      • Deck eyelet 153
      • Front seat frame member 154
      • Cross stretcher arm 155
      • Seat frame female fasteners 156
      • Support frame female fasteners 157
      • Support frame side female fasteners 159
      • Rear seat frame member 160
      • First front seat frame insert 162
      • Second front seat frame insert 164
      • First rear seat frame insert 166
      • Second rear seat frame insert 168
      • Insert body 170
      • First arm assembly 172
      • Arm top 173
      • Second arm assembly 174
      • Arm base 175
      • Front arm receiver 176
      • Receiver engagement section 177
      • Rear arm receiver 178
      • Receiver locking section 179
      • Arm female fastener 180
      • Retention wall 181
      • Male fasteners 182
      • Back receiver 184
      • Back assembly 190
      • First back side support 191
      • First arm fastener 192
      • Second back side support 193
      • Second arm fastener 194
      • Leg 198
      • Cushion 200
      • Sectional Furniture System 300
      • Sectional Wedge Unit 302
      • First Sectional Leg Section 304
      • Second Sectional Leg Section 306
      • Sectional Assembled Configuration 310
      • Front Wedge Receivers 376
      • Rear Wedge Receivers 378
      • Wedge Receiver Locking Section 379
    DETAILED DESCRIPTION
  • The present disclosure is directed furniture systems and furniture system components that can be used in ready-to-assemble furniture products and other furniture products. The present disclosure also is directed to methods of assembling furniture systems and furniture components. The furniture systems encompassed by the present disclosure can be configured in the form of sofas, love seats, chairs, sectional assemblies, benches, and/or chaise lounges. The furniture systems encompassed by the present disclosure can comprise one or more side assemblies, which can be either arm assemblies or sectional wedge unit assemblies, connected to one or more seat frame assemblies.
  • As used herein, the singular forms of “a,” “an,” and “the” encompass the plural form thereof unless otherwise indicated. As used herein, the phrase “at least one” includes all numbers of one and greater. As used herein, the term “and/or” refers to one or all of the listed elements or a combination of any two or more of the listed elements. As used herein, the term “connected” refers to the direct or indirect linking of one component to another.
  • FIGS. 1-29 illustrate various aspects of furniture systems and furniture system components that are encompassed by the present disclosure. FIG. 1 illustrates a furniture system 100 in an assembled configuration 110 and encompassing aspects of the present invention. The furniture system 100 is represented as an upholstered sofa, but the present disclosure also encompasses other furniture pieces, including, but not to, love seats and chairs. The assembled configuration 110 of the furniture system 100 is for use. The furniture system 100 comprises a seat frame assembly 112 connected to a first arm assembly 172 and an opposing second arm assembly 174, a back assembly 190 aligned above and to the rear of the seat frame assembly 112 and connected to and supported by both the first arm assembly 172 and the second arm assembly 174. The furniture system 100 also encompasses a plurality of cushions 200 positioned on the seat frame assembly 112 in the assembled configuration 110 and legs 198 supporting the other components of the furniture system 100 and connected to the first arm assembly 172 and the second arm assembly 174. The back assembly 190, the first arm assembly 172, the second arm assembly 174 and portions of the seat frame assembly 112, including a front seat frame member 154 and a rear seat frame member 160, can be upholstered with fabric, leather, laminates, and/or other cushioning and finish materials as known in the art.
  • FIG. 2 illustrates the furniture system 100 shown in FIG. 1 with the legs 198, the cushions 200, and the upholstery removed to show the interior features of the system. The back assembly 190 is spaced apart from the seat frame assembly 112 and connected to the first arm assembly 172 and the second arm assembly 174.
  • FIG. 3 illustrates an inner frame assembly 115 encompassed by the present disclosure. The inner frame assembly 115 can be used in the furniture system 100, with one or more components of the furniture system 100 in other furniture systems, and in other furniture systems with completely different components. The inner frame assembly 115 comprises a support frame 114, and a deck 140 operably connected to the support frame 114. The support frame 114 comprises a front support frame member 116 and a rear support frame member 118 opposing the front support frame member 116. The front support frame member 116 is connected to the rear support frame member 118 by a stretcher 139. The front support frame member 116 is aligned parallel to the rear support frame member 118 and generally perpendicular to the vertical plane in which the stretcher 139 is aligned. The stretcher 139 connects to both the front support frame member 116 and the rear support frame member 118 and is aligned generally at the midpoints of each of the front support frame member 116 and the rear support frame member 118.
  • The deck 140 comprises one or more deck sections. As shown in FIG. 3, the deck 140 comprises a first deck section 141 and a second deck section 143, both of which are engaged with the of the front support frame member 116 and the rear support frame member 118. Each of the first deck section 141 and the second deck section 143 comprise a front deck web 150 spaced apart from and connected to a rear deck web 152, a front sleeve 142 formed in and/or joined to the front deck web 150 and a rear sleeve 144 formed in and/or joined to the rear deck web 152. The area of the front deck web 150 is greater than the area of the rear deck web 152. The front deck web 150 and the rear deck web 152 are formed of one or more fabrics and/or webbing materials, such as polymeric woven fabrics. Each front deck web 150 is connected to the corresponding rear deck web 152 by a plurality of straps 146. Each strap 148 of each of the plurality of straps 148 spans a deck gap 145 formed in the deck section and which extends across the entire width of the deck section. The deck gap 145 is aligned proximal to the rear sleeve 144 and distal to the front sleeve 142. In one aspect, the deck gaps 145 can be aligned in the rear third of the respective first or second deck sections 141 and 143 in which it is formed. The plurality of straps 146 connects the front deck webs 150 to the rear deck webs 152. The front sleeves 142 and the rear sleeves 144 extend the entire widths of the first and second deck sections 141 and 143. The front sleeves 142 encase portions of the front support frame member 116 and the rear sleeves 144 encase portions of the rear support frame member 118.
  • The deck 140 spans a majority of the area between the front support frame member 116, the rear support frame member 118, the first side support frame member 120, and the second side support frame member 122. The first deck section 141 is aligned on a first side of the support frame 114 and the second deck section 143 is aligned on a second side of the support frame 114 with the stretcher 139 aligned in a vertical plane that separates the first deck section 141 from the section 143.
  • The inner frame assembly 115 is generally rectangular and comprises a tab on each corner thereof. As shown in FIG. 3, the inner frame assembly 115 comprises a first front tab 132, a second front tab 134, a first rear tab 136, and a second rear tab 138. Each of the first front tab 132, the second front tab 134, the first rear tab 136, and the second rear tab 138 extend outward beyond the longitudinal outer sides of the elongated portions of the respective first side support frame member 120 and the second side support frame member 122.
  • FIG. 4 shows, in a partially assembled view, the support frame 114 by itself, which forms part of the inner frame assembly 115. The support frame 114 is made of a metal, such as steel, aluminum, or other lightweight and rigid metal or metal alloy, or other suitably rigid and strong material or composite of materials that can resist the forces that are typically placed on a furniture system. The support frame 114 comprises three separate pieces, the center support frame section 117, the first side support frame member 120, and the second side support frame member 122. The center support frame section 117 comprises the front support frame member 116, the stretcher 139 connected to the front support frame member 116, and the rear support frame member 118.
  • The stretcher 139 connects the rear support frame member 118 to the front support frame member 116 and comprises a front stretcher arm 147 connected to the front support frame member 116, a cross stretcher arm 155 connected to the front stretcher arm 147, and a rear stretcher arm 149 connected to the cross stretcher arm 155 and the rear support frame member 118. The cross stretcher arm 155 is longer than both the first stretcher arm 147 and the rear stretcher arm 149 and is offset from the plane in which the front support frame member 116 and the rear support frame member 118 both lay. The cross stretcher arm 155 is aligned perpendicular to the front support frame member 116 and the rear support frame member 118 and can be aligned parallel to a plane in which lie both the front support frame member 116 and the rear support frame member 118. The first stretcher arm 147 and the second stretcher arm 149 are aligned obtuse to the plane in which the front support frame member 116 and the rear support frame member 118 are aligned.
  • As shown in FIG. 4, the second side support frame member 122 is detachable from the center support frame section 117. The second side support frame 122 can be attached to the center support frame section 117 by aligning a front cap aligned with the second front tab 134 with the second front receiver 126 disposed on the second end of the front support frame member 116, aligning a rear cap of the second rear tab 138 with the second rear receiver 130, which is disposed on the second end of the rear support frame member 118, and inserting the second front receiver 126 and the second rear receiver 130 into the respective caps. Likewise, the first side support frame member 120 is detachable from the center support frame section 117 and can be attached thereto by fitting the caps of the first front tab 132 and the first rear tab 136 over, respectively, the first front receiver 124, located on the support member 116, and the first rear receiver 128, located on the rear support frame member 118.
  • As shown in FIG. 5A, the section deck section 143 can be fitted onto the support frame 114 by detaching the second side support frame member 122 from the center support frame section 117 to expose the second front receiver 126 and the second rear receiver 130 and sliding the front sleeve 142 onto the front support frame member 116 and the rear sleeve 144 onto the rear support frame member 118. The front sleeve 142 and the rear sleeve 142 are slid to or near the centers of the front support frame member 116 and the rear support frame member 118, and the second deck section 143 is spread evenly thereon so as to cover about half the area between the front support frame member 116 and the rear support frame member 118. With second deck section 143 fitted onto the front support frame member 116 and the rear support frame member 118, the second side support frame member 122 can be attached to the center support frame section 117 so as to enclose and secure the second deck section 143 on the support frame 114.
  • Likewise, the first deck section 141 can be positioned on the support frame 114 by sliding the front sleeve 142 over the first front receiver 124 and the rear sleeve 144 over the first rear receiver 128 and sliding the front and rear sleeves 142 and 144 over the front support frame member 116 and the rear support frame member 118, respectively. Each of the first deck section 141 and the second deck section 143 are sized to extend across a majority of one half of the interior area circumscribed by the support frame 114 from the stretcher 139 to the respective first and second side support frame members 120 and 122. Each of the first deck section 141 and the second deck section 143 are sized to extend taught across the entire width of the of the support frame 114 from the front support frame member 116 to the rear support frame member 118 in a planar fashion. The front sleeve 142 and the rear sleeve 144 can be formed from looping the webbings of the front deck web 150 and the rear deck web 152 in a loop and sewn, ultrasonically welded, or otherwise secured to form a channel therein that receives the respective front support frame member 116 and rear support frame member 118 when the first and second deck sections 141 and 143 are installed on the center support frame section 117. Alternatively, the front sleeve 142 and/or the rear sleeve 144 can be formed of one or more separate pieces of webbing, loops, or other suitable structures and connected to the respective front deck web 150 and rear deck web 152.
  • FIG. 5B shows the first deck section 141 separated from the other components of the furniture system 100. The first deck section 141 comprises a front sleeve 142 disposed at the front end of and extending the length of the first deck section 141 and an opposing rear sleeve 144 disposed at the rear end of and extending the length of the first deck section 141. The front sleeve 142 is integrally formed with the front deck web 150 and the rear sleeve 144 is integrally formed with the rear deck web 152. Each of the front sleeve 142 and the rear sleeve 144 comprises one or more deck eyelets 153 formed therein. Each deck eyelet 153 is aligned with another deck eyelet on the same sleeve so as to allow for the bolt of a male fastener 182 to be inserted therein and pass through the channel of the respective front or rear sleeve 142 or 144. Each pair of deck eyelets 153 is aligned on the respective front or rear sleeve 142 or 144 so as to align with a corresponding inner frame female fastener 157 formed on either the front support frame member 116 or the rear support frame member 118 and a corresponding seat frame female fastener 156 formed on either the front seat frame member 154 or the rear seat frame member 160. Accordingly, when the first deck section 141 is disposed on the support frame 114 and the first seat frame member 154 and the second seat frame member 160 is positioned to be mounted on the inner frame assembly 115, a male fastener 180 can be inserted into the channel formed by the aligned deck eyelets 153, inner frame female fasteners 157, and seat frame female fasteners 156 so as to secure the front seat frame member 154 and the rear seat frame member 160 to the inner frame assembly 115.
  • FIG. 5B also shows the deck gap 145 defined by the front deck web 150 and the rear deck 152. Across the deck gap 145 extend straps 148 that connect the front deck web 150 to the rear deck web 152. The straps can be formed of the same webbing material of the front deck web 150 and/or the rear deck web 152 or be formed of a separate web material that is sewn, sonically welded, riveted, or otherwise connected to the front and rear deck webs 150 and 152.
  • FIG. 6 shows the inner frame assembly 115 with the second deck section 143 in a deflexed alignment, as would occur when a load was placed on the second deck section 143 during use of a furniture system in which the inner frame assembly was incorporated. For example, when a user sits on the second side of a sofa comprising the inner frame assembly 115 the user's weight will cause the second deck section to flex downward thereunder. The front deck webs 150, the straps 148, and the rear deck webs 152 are formed of one or more materials that flex under a load and exhibit resiliency when a load is placed on and removed from the first and second deck sections 141 and 143. In FIG. 6, no load is placed on the first deck section 141. Consequently, the first deck section 141 remains in a generally planar alignment when no load is placed thereon, while the second deck section 143 is in a deflexed, curved alignment that occurs when a load is placed thereon. The area of the second deck section 143 with the greatest curvature and deflection is shown to be in the area in and around the deck gap 145. When a user sits on a sofa, chair, love seat, or other type of furniture system, the greatest load placed on the furniture piece is typically in the rear half of the furniture seat area and usually in the rear third of the seat area. Accordingly, each of the first deck section 141 and the second deck section 143 are configured to have a deck gap 145 aligned proximal to the rear sleeve 144. In one aspect, the deck gap 145 can be aligned about one third of the distance between the rear sleeve 144 and the front sleeve 142. Such alignments of the deck gaps 145 within the first and second deck sections 141 and 143 can potentially enhance the support and feel of the furniture system experienced by a user.
  • FIGS. 7A and 7B show three separate inner frame assemblies 115 stacked on top of each other in a nested alignment. The configuration of the stretchers 139 allows for two or more inner frame assemblies 115 to be stacked in a nested alignment, wherein the stretcher 139 of a first inner frame assembly 115 stacked on top of a second inner frame assembly 115 extends downward between the front support frame member 116 and the rear support frame member 118 of the second inner frame assembly 115, thereby allowing for the nesting of parts of the first inner frame assembly 115 with parts of the second inner frame assembly 115. The ability to stack the inner frame assemblies 115 in a nested alignment allows a greater number of inner frame assemblies 115 to be shipped in a given container volume than would be possible without the nesting of the assemblies. Accordingly, the inner frame assemblies 115 can be shipped in a stacked and nested configuration from one production facility to another production and/or assembly facility.
  • FIG. 8 shows the underside of the seat frame assembly 112 separated from the other parts of the furniture system 100. The seat frame assembly 112 can be used in other furniture system configurations and encompasses aspects of the present disclosure. The seat frame assembly 112 comprises the support frame 114, the deck 140 mounted on the support frame 114, thereby forming the inner frame assembly 115, the front seat frame member 154 connected to the inner frame assembly 115, and the rear seat frame member 160 connected to the inner frame assembly 115. The front seat frame member 154 comprises a plurality of seat frame female fasteners 156. The front seat frame member 154 is connected to the front support frame member 116 by a plurality of male fasteners 182. Each of the plurality of male fasteners 182 is aligned with and extends through both the inner frame female fasteners 157 formed in the front support frame member 116 and the support frame female fasteners 156 to secure the components together. Each of the male fasteners 182 comprises a threaded male bolt and a knob attached thereto. The male fasteners 182 can be attached and detached from the seat frame assembly 112 by hand tightening or loosening.
  • FIG. 9 shows the seat frame assembly 112 connected to the first arm assembly 172 and the second arm assembly 174. Each of the first arm assembly 172 and the second arm assembly 174 comprise an arm top panel 173 and an opposing arm base 175. The arm base 175 of each of the first arm assembly 172 and the second arm assembly 174 is aligned adjacent the seat frame assembly 112. Male fasteners 182 are connected to both the seat frame assembly 112 and the first and second arm assemblies 172 and 174 to help secure the arm assemblies 172 and 174 to the seat frame assembly 112
  • As shown in FIGS. 10 and 14, the arm base 175 comprises a front arm receiver 176 disposed proximal to the front vertical panel of the first arm assembly 172 and a rear arm receiver 178 disposed proximal to the rear vertical panel of the first arm assembly 172. The arm base 175 also comprises one or more arm female fasteners 180 disposed between the front arm receiver 176 and the rear arm receiver 178. The second arm assembly 174 also comprises first and second arm receivers 176 and 178 and one or more arm female fasteners 180 on an opposing side thereof. Each of the first and second arm receivers 176 and 178 comprise two contiguous sections—the engagement section 177 and the locking section 179. The engagement section 177 is aligned generally vertically and has a length greater than its width. The engagement section 177 is generally rectangular and configured to receive the tallest portion of the first front seat frame insert 162. The locking section 179 is also generally rectangular, but is shorter and wider than the engagement section 177. The locking section 179 is configured to receive the insert body 170 of the first front seat frame insert 162. The lower edge of the locking section 179 is disposed higher on the arm base 175 than the lower edge of the engagement section 177. The upper edge of the locking section 179 is disposed lower on the arm base 175 than the upper edge of the engagement section 177. Each of the first and second arm receivers 176 and 178 also comprise a retention wall 181 disposed below the locking section 179 and adjacent the lower portion of the engagement section 177. The retention wall 181 is configured to contact a portion of an insert body 170 formed on the seat frame assembly 112 so as to prevent the removal of the insert from the respective first or second arm receivers 176 and 178 in which the insert is disposed.
  • FIGS. 15-17 illustrate the front seat frame member 154, which attaches to the front support frame member 116 of the support frame 114 in the seat frame assembly 112. The front seat frame member 154 is an elongated, rectangular panel that comprises one or more seat frame female fasteners 156 configured to receive and retain male fasteners 182. At a first end of the front seat frame member 154 is a first front seat frame insert 162, and at the opposing second end of the front seat frame member 154 is a second front seat frame insert 164. Each of the first front seat frame insert 162 and the second front seat frame insert 164 comprises an insert body 170 projecting from an inward side thereof.
  • FIGS. 10-12 show the relative alignment of the first arm assembly 172 and the seat frame assembly 112 during various steps of the assembly process by which the first arm assembly 172 is connected to the seat frame assembly 112. In FIG. 10, the first arm assembly 172 is aligned adjacent the seat frame assembly 112 such that arm base 175 is aligned adjacent the first side support frame member 120 of the seat frame assembly 112. The front arm receiver 176 is aligned with the first front seat frame insert 162 that extends outward from the front first side of the seat frame assembly 112, and the rear arm receiver 178 is aligned with the first rear seat frame insert 166 that extends outward from the rear first side of the seat frame assembly 112, so that the first front seat frame insert 162 can be inserted into the front arm receiver 176 and the first rear seat frame insert 166 can be inserted into the rear arm receiver 178.
  • In FIG. 11, the first arm assembly 172 is shown in an engagement alignment with the seat frame assembly 112. In this engagement alignment, the first front seat frame insert 162 is inserted into the front arm receiver 176 and the first rear seat frame insert 166 is inserted into the rear arm receiver 178, but not locked therein. Thus, when the seat frame assembly 112 and the first arm assembly 172 are in the engagement alignment, the seat frame assembly 112 is not locked to the first arm assembly 112 because the first front seat frame insert 162 and the first rear seat frame insert 166 can move freely horizontally out and away from the front arm receiver 176 and the rear arm receiver 178. In this engagement alignment, a lower portion of the arm base 175 is aligned lower than the bottom of the seat frame assembly 112.
  • FIG. 12 shows the seat frame assembly 112 in a locking alignment with the first arm assembly 172, wherein the two assemblies are locked together. To move the seat frame assembly 112 from the engagement alignment to the locking alignment, the seat frame assembly is moved downward relative to the first arm assembly 172 so that the first front seat frame insert 162 and the first rear seat frame insert 166 are locked into the front arm receiver 176 and the rear arm receiver 178, respectively. In this locked alignment, the first front seat frame insert 162 and the first rear seat frame insert 166 cannot be removed from the front arm receiver 176 and the rear arm receiver 178, respectively, without first moving the first front seat frame insert 162 and the first rear seat frame insert 166 back into the engagement alignment shown in FIG. 11. The first front seat frame insert 162 and the first rear seat frame insert 166 be moved directly out of the front arm receiver 176 and the rear arm receiver 178 because the retention wall 181 of each of the receiver engages an insert body 170 of the respective inserts, thereby preventing the removal of the insert body 170. In the locking alignment, the two support frame side female fasteners 159 are aligned with the two arm female fastener 180 formed in the arm base 175 of the first arm assembly 172 and a male fastener 182 is threadably secured in each channel formed by the aligned support frame side female fasteners 159 and the arm female fasteners 180, thereby providing additional anchor points for securing the seat frame assembly 112 to the first arm assembly 172. The male fasteners 180 each comprise a threaded bolt and knob that can be hand tightened to secure the male fastener 180 in place.
  • As with the first front seat frame insert 162 and the front arm receiver 176 of the first arm assembly 172, the second front seat frame insert 164 can be connected to the front arm receiver 176 of the second arm assembly 174, the first rear seat frame insert 166 can be connected to the rear arm receiver 178 of the first arm assembly 172, and the second rear seat frame insert 168 can be connected to the rear arm receiver 178 of the second arm assembly 174 through first an engagement alignment followed by a locking alignment between the respective components. Each of the second front seat frame insert 164, the first rear seat frame insert 166, and the second rear seat frame insert 168 comprise an insert body 170 that can be disposed with the respective arm assembly and engaged by a respective retention wall 181 of the respective arm receiver to lock the inserts of the seat frame assembly 112 into the first and second arm assemblies 172 and 174. With each of the inserts disposed and locked in the arm receivers, the seat frame assembly 112 can thereby completely supported by the first and second arm assemblies 172 and 174 in the assembled configuration 110. The seat frame assembly 112 is further secured to the second arm assembly 174 with male fasteners 182 threadably disposed in the support frame side female fasteners 159 of the second side support frame member 122 and the arm female fasteners 180 of the second arm assembly 174. As shown in FIG. 1, the legs 198 are attached to the arm base 175 of the first arm assembly 172 and the arm base 175 of the second arm assembly 174. Consequently, the seat frame assembly 112 is suspended above the floor by the first and second arm assemblies 172 and 174.
  • FIGS. 18-20 further illustrate alternative views of the engagement and locking alignments of the first front seat frame insert 162 with the front arm receiver 176. FIG. 18 illustrates a portion of the arm base 175 of the first arm assembly 172 and the first front seat frame insert 162 in a engagement alignment in the front arm receiver 176 as seen end on to the first front seat frame insert 162 with an outer side of the arm assembly 172 removed to reveal the interior side of the front arm receiver 176. In the engagement alignment, the vertically aligned major section of the first front seat frame insert 162 is inserted in the upper portion of the engagement section 177 of the front arm receiver 176 and the minor insert body 170 is inserted in the locking section 179 along with the first front tab 132 of the inner support frame 114, which is disposed above the insert body 170 and beside the major section of the first front seat frame insert 162. In this engagement alignment, the first front seat frame insert 162 can move freely horizontally in and out of the front arm receiver 176 because there is no portion of the front arm receiver 176 that contacts or engages any part of the first front seat frame insert 162.
  • FIGS. 19, 20, and 22 illustrate the same portion of the arm base 175 of the first arm assembly 172 and the first front seat frame insert 162 shown in FIG. 18, but with the first front seat frame insert 162 moved into a locking alignment in the front arm receiver 176. In the locking alignment, the first front seat frame insert 162 is lowered downward so that the major section of the first front seat frame insert 162 is moved into the lower portion of the engagement section 177 and the insert body 170 is lowered past the top edge of the retention wall 181. The first front tab 132 is aligned above and/or on the top edge of the retention wall 181. At least a portion of the insert body 170 is disposed inside of the first arm assembly 172 and adjacent to the retention wall 181. In FIG. 19, all of the insert body 170 is shown disposed inside of the first arm assembly 172 and adjacent the retention wall 181. In the locking alignment, the first front seat frame insert 162 cannot be moved horizontally out of the front arm receiver 176 because the retention wall 181 prevents the removal of the insert body 170 therefrom. In the locking alignment, the first front seat frame insert 162 must first be moved upward into the engagement alignment shown in FIG. 18 before the first front seat frame insert 162 can be removed from the front arm receiver 176. The top edge of the retention wall 181 acts as a seat for the first front tab 132, thereby distributing the weight of the seat frame assembly 112 through the support frame 114 to the first front tab 132 and onto the first arm assembly 172.
  • Likewise, the top edges of the retention walls 181 of the front arm receiver 176 and the rear arm receiver 178 on the second arm assembly 174 and the rear arm receiver of the first arm assembly 172 serve as seats for the second front tab 134, the second rear tab 138, and the first rear tab 132, respectively, thereby distributing the weight of the seat frame assembly 112 to the first and second arm assemblies 172 and 174.
  • The front arm receivers 176 and the rear arm receivers 178 formed in the first arm assembly 172 and the second arm assembly 174 are illustrated in the form of mortises that are open cavities defined in the interior sides of the arm assemblies. The first front seat frame insert 162 combined with the first front tab 132, the second front seat frame insert 164 combined with the second front tab 134, the first rear seat frame insert 166 combined with the first rear tab 136, and the second rear seat frame insert 168 combined with the second rear tab 138 act as modified tenons, with each insert occupying a portion of the respective receivers to form mortise-and-tenon type joints at each corner of the support frame assembly 112. These mortise-and-tenon type joints, combined with the male fasteners 182 connecting the seat frame assembly 112 to the first and second arm assemblies 172 and 174, can potentially secure the components of the furniture system 100 along three axes.
  • The back assembly 190 is connected to and completely supported by the first arm assembly 172 and the second arm assembly 174, as shown in FIGS. 2 and 13. As shown in FIGS. 9, 10, and 14, the first arm assembly 172 and the second arm assembly 174 each comprise a back receiver 184. As shown in FIG. 23, the back receiver 184 can be a bracket having a central channel defined by two side walls, each defining a retention slot therein for receiving a side ledge formed on a first arm fastener 192 and a second arm fastener 194. The first and second arm fasteners 192 and 194 can slide downward into the respective back receivers 184 and be retained therein. The first arm fastener 192 is mounted to the first back side support 191 of the back assembly 190, and the second arm fastener 194 is mounted to the second back side support 193 of the back assembly 190. As shown in FIGS. 2 and 13, the back assembly 190 is completely supported by the first arm assembly 172 and the second arm assembly 174 and does not directly contact the seat frame assembly 112.
  • FIGS. 24 and 26 show the furniture system 100 in an unassembled configuration 210 that can be used to package the furniture system 100 in a container for storage or shipping. The unassembled configuration 210 of the furniture system 100 is arranged to help reduce the total volume that the furniture system 100 would occupy in a container or other packaging. The cushions 200 are shown in a compressed configuration resulting from applying a vacuum thereto. The vacuum compression of the cushions 200 reduces the volume that each cushion occupies. At the bottom of the unassembled configuration 210 is the inner frame assembly 115 detached from all other components of the furniture system 100. The inner frame assembly 115, comprising the support frame 114 and the deck 140, is aligned upside down so that the stretcher 139 is extending upward instead of downward. Disposed on the inner frame assembly 115 are the first arm assembly 172 and the second arm assembly 174. As shown in FIG. 26, the first arm assembly 172 and the second arm assembly 174 are separated by the stretcher 139, which projects upward there between. The front seat frame member 154 and the rear frame seat member 160 are also disposed on the inner frame assembly 115 adjacent the first arm assembly 172 and the second arm assembly 174. The front seat frame member 154 is disposed between the stretcher 139 and the deck 140 and the rear seat frame member 160 is disposed above the stretcher 139. The back assembly 190 is disposed generally within the footprint inner frame assembly 115 and above the rear seat frame member 160 and at least a portion of each of the first arm assembly 172 and the second arm assembly 174. The legs 198 and the male fasteners 182 of the furniture system 100 are disposed on the back assembly 190. The first arm assembly 172, the second arm assembly 174, the inner frame assembly 115, the back assembly 190, the front seat frame member 154, the rear seat frame member 160, the male fasteners 182, and the legs 198 are not connected to each other as they would be in the assembled configuration 110. Instead, these components are stacked upon each other in the unassembled configuration 210 and can be inserted in this unassembled configuration 210 into a container for storage and/or shipping. The unassembled configuration 210 of the furniture system 100 allows for the total volume of a shipping container occupied by the furniture system 100 to be reduced as compared to the overall volume occupied by the furniture system 100 in the assembled configuration 110. Accordingly, a single shipping container can be used to ship the furniture system 100 in the unassembled configuration 210. The components of the furniture system 100 in the unassembled configuration 210 are all generally aligned within the footprint of the inner frame assembly 115 and exhibit a generally rectangular configuration when viewed from above or from the side.
  • Upon receipt of the shipping container in which the furniture system 100, in the unassembled configuration 210 which can be considered a ready-to-assemble configuration, is contained, an end user can assemble the furniture system 100 according to an assembly method comprising one or more of the following steps. Unstack the components of the furniture system 100 from the unassembled configuration. Align the front seat frame member 154 with the front support frame member 116 so that the seat frame female fasteners 156 on the front seat frame member 154 are aligned with the corresponding deck eyelets 153 on the deck 140 and the support frame female fasteners 157. Insert, threadably insert, if appropriate, a male fastener 182 in each group of aligned seat frame female fastener 156, deck eyelet 153, and support frame female fastener 157 to connect the front seat frame member 156 to the inner frame assembly 115. Align the rear seat frame member 160 with the rear support frame member 118 so that the seat frame female fasteners 156 on the rear seat frame member 160 are aligned with the corresponding deck eyelets 153 on the deck 140 and the support frame female fasteners 157 on the rear support frame member 118. Insert, threadably insert, if appropriate, a male fastener 182 in each group of aligned seat frame female fastener 156, deck eyelet 153, and support frame female fastener 157 to connect the rear seat frame member 160 to the inner frame assembly 115, thereby forming the seat frame assembly 112.
  • Align the first arm assembly 172 with the first side of the seat frame assembly 112 so that the front arm receiver 176 of the first arm assembly 172 is aligned with the first front seat frame insert 162 and the first front tab 132 and the rear arm receiver 178 of the first arm assembly 172 is aligned with the first rear seat frame insert 166 and the first rear tab 136. Insert the first front seat frame insert 162 and the first front tab 132 into the first arm receiver 176 to form an engagement alignment, and insert the first rear seat frame insert 166 and the first rear tab 136 in the rear arm receiver 178 of the first arm assembly 172 to form another engagement alignment. Shift the seat frame assembly 112 down relative to the first arm assembly 172 so that the insert body 170 of each of the first front seat frame insert 162 and the first rear seat frame insert 166 moves down beside the retention wall 181 of each of the front arm receiver 176 and the rear arm receiver 178 and each of the first front tab 132 and the first rear tab 136 rests on the retention wall 181 of the corresponding front arm receiver 176 and the rear arm receiver 178 to form locking alignments therein. When the seat frame assembly 112 is in the locking alignment relative to the first arm assembly 172, the support frame side female fasteners 159 disposed on the first side support frame member 120 are aligned with the arm female fasteners 180. Accordingly, a male fastener 182 can be inserted, threadably inserted, if appropriate, into each group of aligned support frame side female fasteners 159 and arm female fasteners 180.
  • Align the second arm assembly 174 with the second side of the seat frame assembly 112 so that the front arm receiver 176 of the second arm assembly 174 is aligned with the second front seat frame insert 164 and the second front tab 134 and the rear arm receiver 178 of the second arm assembly 174 is aligned with the second rear seat frame insert 168 and the second rear tab 138. Insert the second front seat frame insert 164 and the second front tab 134 into the front arm receiver 176 to form an engagement alignment, and insert the second rear seat frame insert 168 and the second rear tab 138 into the rear arm receiver 178 of the second arm assembly 174 to form another engagement alignment. Shift the seat frame assembly 112 down relative to the second arm assembly 174 so that the insert body 170 of each of the second front seat frame insert 164 and the second rear seat frame insert 168 moves down beside the retention wall 181 of each of the front arm receiver 176 and the rear arm receiver 178 and each of the second front tab 134 and the second rear tab 138 rests on the retention wall 181 of the corresponding front arm receiver 176 and the rear arm receiver 178 to form locking alignments therein. When the seat frame assembly 112 is in the locking alignment relative to the second arm assembly 172, the support frame side female fasteners 159 disposed on the second side support frame member 122 are aligned with the arm female fasteners 180. Accordingly, a male fastener 182 can be inserted, threadably inserted, if appropriate, into each group of aligned support frame side female fasteners 159 and arm female fasteners 180.
  • Legs 198 can then be threadably inserted into corresponding female fasteners disposed on the bottom of the arm base 175 of each of the first arm assembly 172 and the second arm assembly 174. The back assembly 190 can then be secured to the first arm assembly 172 and the second arm assembly 174 by first aligning the first arm fastener 192 disposed on the first side back support member 191 with the back receiver 184 disposed on the first arm assembly 172 and the second arm fastener 194 disposed on the second side back support member 193 with the back receiver 184 disposed on the second arm assembly 172 and shifting the back assembly 190 down towards the seat frame assembly 112 so that each back receiver 184 securely engages the corresponding first and second arm fasteners 192 and 194, thereby forming the assembled configuration 110 of the furniture system 100.
  • FIGS. 27-29 illustrate various aspects of another furniture system encompassing aspects of the present disclosure. A sectional furniture system 300 is shown in FIG. 27 supported on a plurality of legs 198 and having with a plurality of cushions 200 aligned thereon. The sectional furniture system 300 is shown in an assembled configuration 310 and comprises a first leg section 304 connected to a sectional wedge unit 302 and a second leg section 306 connected to another side of the sectional wedge unit 302. The first leg section 302 is aligned generally perpendicular to the second leg section 304. The second leg section 304 is longer than the first leg section 302. The first leg section 302 comprises a first arm assembly 172 and the second leg section 304 comprises a second arm assembly 174. The second leg section 304 comprises the furniture system 100, but, instead of a first arm assembly 172 connected to the first sides of the seat frame assembly 112 and the back assembly 190, the sectional wedge unit 302 is connected thereto.
  • As shown in FIG. 28, the first leg section 302 comprises a back assembly 190 and a seat frame assembly 112 that are shorter in length than the back assembly 190 and the seat frame assembly 112 of the second leg section 304 and the furniture system 100, shown in FIG. 2. In one aspect, the first leg section 302 can be shorter in length than the second leg section 304. In another aspect, the first leg section 302 is about equal in length to the second leg section 304. Both the first and second leg sections 302 and 304 comprise first and second deck sections 141 and 143. The back assemblies 190 of the first and second leg sections 302 and 304 connect to different sides of the sectional wedge unit 302 by the mating of fasteners 192 attached to the back assemblies 190 with back receivers 184 mounted on two sides of the sectional wedge unit 302.
  • The sectional wedge unit 302 comprises a wedge seat frame and a wedge back assembly that has a first back section connected to a second back sections. The first and second back sections are configured to align generally in line with the back assemblies 190 to which each back section is connected and generally perpendicular to the other of the back sections. Alternatively, the sectional wedge unit 302 can comprise a generally curved back section that meets and connects to both back assemblies 190 of the first and second leg sections of the sectional furniture system 300.
  • The sectional wedge unit 302 comprises two rear wedge receivers 378 formed in two sides of thereof and two front wedge receivers 376 formed on the two sides. Each of the two front wedge receivers 376 are configured to receive and secure one of the first and second front seat frame inserts 162 and 164 and one of the first and second front tabs 132 and 134 formed on the seat frame assemblies of the first and second leg sections 304 and 306 on the respective sides of the sectional wedge unit 302. Each of the two rear wedge receivers 378 are configured to receive and secure one of the first and second rear seat frame inserts 166 and 168 and one of the first and second rear tabs 136 and 138 on the seat frame assemblies of the first and second leg sections 304 and 306 on the respective sides of the sectional wedge unit 302.
  • Each of the front and rear wedge receivers 376 and 378 comprise two contiguous sections—the engagement section 377 and the wedge receiver locking section 379. The engagement sections 377 are aligned generally vertically and have a length greater than its width. The engagement sections 377 are generally rectangular and configured to receive the tallest portion of the respective seat frame insert. The wedge receiver locking sections 379 are also generally rectangular, but are shorter and wider than the engagement section 377. The wedge receiver locking sections 379 are configured to receive the insert body 170 of the respective seat frame insert. The lower edge of the wedge receiver locking section 379 is disposed higher on the sectional wedge unit 302 than the lower edge of the engagement section 377. The upper edge of the wedge receiver locking section 379 is disposed lower on the sectional wedge unit 302 than the upper edge of the engagement section 377. Each of the front and rear wedge receivers 376 and 378 also comprise a retention wall 181 disposed below the wedge receiver locking section 379 and adjacent the lower portion of the engagement section 377. The retention wall 181 is configured to contact a portion of an insert body 170 formed on the respective seat frame assembly 112 so as to prevent the removal of the insert from the respective front and rear wedge receivers 376 and 378 in which the insert is disposed.
  • As shown in FIG. 28, the front wedge receivers 376 can be configured with an open top end that can facilitate the mating of the inserts and tabs on the first and second leg sections 304 and 306 therewith. Alternatively, the front receivers 376 can comprise a closed top end and be configured similar to the front receivers formed on the arm assemblies of the furniture system 100.
  • The sectional furniture system 300 can be stored and/or shipped in a disassembled state by stacking the components thereof and loading them into multiple containers. The first and second leg sections 304 and 306 can be disconnected from the sectional wedge unit 302 and disassembled and stacked according to the arrangement shown in FIGS. 24-26 with the components of each of the first and second leg sections 304 and 306 stacked separately by section and loaded into a separate container. The sectional wedge unit 302 can be disassembled with the back sections disconnected from the seat frame and/or left assembled or partially assembled and loaded into a third container for storage and/or shipping.
  • It will be apparent to those skilled in the art that various modifications and variations can be made to the furniture systems and furniture system components set forth herein and such modifications and variations are contemplated and encompassed by the present disclosure.

Claims (5)

What is claimed is:
1. A furniture system as set forth herein.
2. An inner frame assembly for a furniture piece as set forth herein.
3. A deck section for a furniture piece as set forth herein.
4. A method of assembling a ready-to-assemble furniture system as set forth herein.
5. A method of assembling an inner frame assembly for a furniture system as set forth herein.
US17/035,495 2019-09-27 2020-09-28 Furniture Systems and Furniture System Components Abandoned US20210093087A1 (en)

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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11166565B2 (en) * 2019-01-31 2021-11-09 Max Home, Llc Unitary component for sectional seating apparatus
US11178973B2 (en) * 2019-02-15 2021-11-23 The Lovesac Company Furniture spring system
US11253073B2 (en) 2005-06-10 2022-02-22 The Lovesac Company Modular furniture system with storage base
US11297949B1 (en) * 2020-08-05 2022-04-12 Benjamin Andrew Galjour System for joining components of modular furniture
US11659936B2 (en) 2019-02-15 2023-05-30 The Lovesac Company Modular furniture support systems
US20230200538A1 (en) * 2021-12-28 2023-06-29 Zinus Inc. Packable assemblies and support members for packable assemblies
US11903487B1 (en) 2023-08-04 2024-02-20 Williams-Smith Limited, LLC Support bridge for modular furniture

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11253073B2 (en) 2005-06-10 2022-02-22 The Lovesac Company Modular furniture system with storage base
US11166565B2 (en) * 2019-01-31 2021-11-09 Max Home, Llc Unitary component for sectional seating apparatus
US11690458B2 (en) 2019-01-31 2023-07-04 Max Home, Llc Unitary component for sectional seating apparatus
US11178973B2 (en) * 2019-02-15 2021-11-23 The Lovesac Company Furniture spring system
US11191364B2 (en) * 2019-02-15 2021-12-07 The Lovesac Company Furniture storage base
US11659936B2 (en) 2019-02-15 2023-05-30 The Lovesac Company Modular furniture support systems
US11659933B2 (en) 2019-02-15 2023-05-30 The Lovesac Company Furniture spring system
US11297949B1 (en) * 2020-08-05 2022-04-12 Benjamin Andrew Galjour System for joining components of modular furniture
US20230200538A1 (en) * 2021-12-28 2023-06-29 Zinus Inc. Packable assemblies and support members for packable assemblies
US11896140B2 (en) * 2021-12-28 2024-02-13 Zinus Inc. Packable assemblies and support members for packable assemblies
US11903487B1 (en) 2023-08-04 2024-02-20 Williams-Smith Limited, LLC Support bridge for modular furniture

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