Wooden leg assembly for furniture and method of mounting

Abstract

A wooden leg assembly 10 for mounting to furniture includes a bridge piece 12, and first and second legs 14 connected at opposed ends of a rear face of the bridge piece12. The bridge piece 12 includes

Description

TECHNICAL FIELD

[0001] The present invention relates to wooden leg assemblies for mounting on furniture, wooden furniture assemblies employing such leg assemblies, kits of leg assemblies, and methods of mounting the leg assemblies to furniture pieces. More specifically, it pertains to a novel design and arrangement of wooden leg assemblies and their interaction with furniture pieces, offering enhanced support and adaptability for various furniture styles and heights. BACKGROUND

[0002] Wooden furniture is a staple in various industries, offering aesthetic appeal, durability, and versatility. Wooden leg assemblies are a common choice for providing support to wooden furniture pieces.

[0003] Basic leg assembly methods typically involve manual craftsmanship, relying on straight-forward techniques that may not offer the degree of precision and versatility required for modem furniture design. Traditional butt joinery, for instance, often limits the applicability of wooden leg assemblies to specific furniture styles, and precise alignment can be a challenging task during manual assembly.

[0004] Accordingly, it is desirable to provide wooden leg assemblies, kits, systems and methods that allow efficient, secure, flexible and aesthetically pleasing mounting mechanisms for wooden leg assemblies and furniture pieces. It is further desirable to provide wooden leg assemblies that provide a secure support to furniture pieces and which can be readily and systematically changed in height in a way that does not change underlying efficient mounting mechanisms. Furthermore, other desirable features and characteristics of the present invention will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and background. SUMMARY

[0005] In one aspect, the present invention relates to a wooden leg assembly for mounting on furniture, comprising a bridge piece and first and second legs. The bridge piece features elongate through slots, including a front elongate slot and a rear elongate slot, with distinct major and minor axes. The major and minor axes of the front elongate slot are larger than those of the rear elongate slot, creating a step at their interface. This step provides a secure mounting surface for a male fastening component to join with a female fastening component of the furniture. This design ensures a stable and reliable connection, simplifying the assembly process.

[0006] In embodiments, the first and second legs have a tapered cone form from a base secured to the rear face of the bridge piece to a distal end. This enhances the structural integrity of the leg assembly and facilitates ease of installation.

[0007] In embodiments, the first and second legs splay relative to each other from a base secured to the rear face of the bridge piece to their distal ends. This improves load distribution and the stability of the furniture.

[0008] In embodiments, each front elongate slot opens to a front face of the bridge piece, while each rear elongate slot opens to the rear face of the bridge piece. This simplifies assembly and ensures precise alignment, making it user-friendly and reliable.

[0009] In embodiments, the front face and the rear face of the bridge piece have a stadium shape. This enhances the aesthetic appeal of the leg assembly without sacrificing functionality, offering a pleasing appearance without compromising on structural integrity.

[0010] In embodiments, the male fastening component is an externally threaded bolt, and the female fastening component is an internally threaded insert securely mounted within the furniture. This enables a secure and durable connection, ensuring longevity and reliability.

[0011] In another aspect, the present invention further extends to a wooden furniture assembly, including a furniture piece and first and second wooden leg assemblies. The wooden furniture assembly ensures stability and balance, and enables easy assembly.

[0012] In embodiments, the front face of each bridge piece abuts a rear plane of the furniture piece, and the four female fastening components are inserted flush with the rear plane. This ensures a seamless appearance and offers an elegant design.

[0013] In embodiments, the front face of each bridge piece abuts a respective mounting platform secured to a rear plane of the furniture piece, and the four female fastening components are inserted flush with a mounting surface of the mounting platform. This provides a harmonious appearance and an elegant and cohesive look.

[0014] In a further aspect, the invention extends to a kit of leg assemblies, each being a leg assembly as described, including pairs of leg assemblies of different heights. This allows for adaptability to various furniture styles and heights, providing flexibility and versatility.

[0015] In embodiments, the elongate through slots of the bridge pieces of pairs of leg assemblies of lower heights are spaced closer together than pairs of leg assemblies of greater heights. This offers structural stability for different furniture configurations and enhances support.

[0016] In a yet further aspect, the invention provides a method of mounting first and second wooden leg assemblies to a furniture piece. This facilitates a straightforward and secure assembly process, ensuring a quick and reliable installation.

[0017] In embodiments, the method includes selecting leg assemblies from a kit of different height leg assemblies to provide for various heights of the furniture piece. This offers versatility and customization, allowing users to adapt the furniture to their specific needs.

[0018] In embodiments, the fastening process involves the use of an Allen (RTM) key. This ensures a secure and efficient attachment of the leg assemblies to the furniture piece, simplifying the assembly process and enhancing user-friendliness.: BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The exemplary embodiments will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and wherein:

[0020] FIG. 1 is a perspective view of a leg assembly, in accordance with various embodiments;

[0021] FIG. 2 is a perspective view of an upturned furniture piece, a leg assembly and male and female fastening components, in accordance with various embodiments;

[0022] FIG. 3 is a perspective view of an upturned furniture piece in which the female fastening components are included in a mounting platform rather than directly in a rear plane of the furniture piece as is the case in FIG. 2, in accordance with various embodiments;

[0023] FIG. 4 is a rear view of a bridge piece of a wooden leg assembly showing the elongate through slots and a step between a rear elongate step and a front elongate step, in accordance with various embodiments;

[0024] FIG. 5 is a front view of the bridge piece showing the front elongate slot, in accordance with various embodiments;

[0025] FIG. 6 show different height leg assemblies for a kit of leg assemblies, in accordance with various embodiments; and

[0026] FIG. 7 shows differing length bridge pieces each having a different separation between the elongate through slots. DETAILED DESCRIPTION

[0027] The present invention relates to a wooden leg assembly, referenced as leg assembly 10, designed for mounting onto furniture, referenced as furniture piece 16. In various embodiments, this leg assembly offers unique features and advantages that enhance stability, ease of assembly, adaptability, and aesthetic appeal. The detailed description below provides an in-depth exploration of these features, referencing the relevant components in the figures by their reference numbers.

[0028] FIG. 1 presents a perspective view of the leg assembly 10. This leg assembly 10 includes a bridge piece 12 and two legs 14, connected at opposed ends of the rear face of the bridge piece 12. The bridge piece 12 includes elongate through slots 26, with specific variations in major and minor axes between the front elongate slot 28 and the rear elongate slot 30. These distinct dimensions create a step 36 at the interface of the front and rear elongate slots.

[0029] FIG. 4 provides a detailed rear view of the bridge piece 12, which highlights the elongate through slots 26. The rear view clearly illustrates the step 36 between the rear elongate slot 30 and the front elongate slot 28.

[0030] In one aspect, the step 36 serves as a secure mounting surface for a male fastening component 20. This male fastening component 20 is designed to secure the leg assembly 10 to a female fastening component 18 incorporated within the furniture piece 16, as depicted in FIG. 2. A washer may be provided between an enlarged head (relative to a threaded stem) of the male fastening component 20. In this instance, the washer rather than the head rests on the step 36. In embodiments, the male fastening component 20 takes the form of an externally threaded bolt, offering robust fastening capabilities. The female fastening component 18 is typically an internally threaded insert securely mounted within the furniture piece 16.

[0031] The incorporation of the male and female fastening components enhances the stability of the leg assembly 10 and the overall furniture piece 16. This secure connection prevents unintended disassembly and wobbling, contributing to longevity and reliability. In one aspect, the rear face of the bridge piece 12 directly interfaces with a rear plane of the furniture piece 16 rear plane. As demonstrated in FIG. 2, the assembly involves inserting the male fastening component 20 through the front elongate slot 28 and securing it to the female fastening component 18 in a rear face of the furniture piece 16. This method ensures a seamless and secure attachment, maintaining a flush appearance with the rear plane of the furniture piece 16.

[0032] FIG. 3 introduces an alternative assembly method. In this embodiment, the female fastening components 18 are integrated into a separate mounting platform 36. This platform 36 attaches to the rear plane of the furniture piece 16. The front face of the bridge piece 12 abuts this mounting platform 36 when the leg assembly 10 is mounted thereon. Here, the male fastening component 20 secures the leg assembly 10 to the female fastening component 18, creating a sturdy connection. The design of the bridge piece 12 aligns with the shape and size of the mounting platform 36, ensuring a harmonious and cohesive appearance.

[0033] In one aspect, the design of the front elongate slot 28 and the rear elongate slot 30 plays a vital role in facilitating the assembly process. Each front elongate slot 28 opens to the front face of the bridge piece 12, while each rear elongate slot 30 opens to the rear face of the bridge piece 12. This feature simplifies the assembly, allowing for precise alignment and user-friendly installation. The rear elongate slot 30 and the front elongate slot 28 may be stadium shaped, oval, rectangle or other suitable elongate shapes. A major axis of the rear elongate slot 30 and the front elongate slot 28 are aligned and align with a length of the bridge piece 12. That is, the major axes extend along a central axis of the bridge piece 12 and pass through a central point of a base of each of the first and second legs 14. Put another way, the major axes of each of the elongate through slots are aligned and pass along a central longitudinal axis of the bridge piece 12. The elongate through slots are separated from each other in a length direction of the bridge piece 12, i.e. in a direction of spacing of the first and second legs 14.

[0034] FIG. 5, provides a clear front view of the bridge piece 12, showcasing the front elongate slot 28.

[0035] The aesthetic appeal of the leg assembly 10 is also addressed. In one aspect, the front face and the rear face of the bridge piece 12 have a stadium shape. This design feature enhances the visual appeal of the leg assembly 10, ensuring that it complements the overall appearance of the furniture piece 16. The stadium shape contributes to a pleasing aesthetic without compromising the assembly's functionality and structural integrity.

[0036] This invention extends to a wooden furniture assembly as depicted in FIG. 2. This assembly includes the furniture piece 16, first and second wooden leg assemblies 10, and the male and female fastening components 18, 20. These components interact to establish a stable and balanced connection.

[0037] In one aspect, the present invention introduces the concept of a kit of leg assemblies, as illustrated in FIG. 6. The kit includes different height leg assemblies 32. This kit includes pairs of leg assemblies 10 (only one of each pair is shown in FIG. 6) of different heights, catering to various furniture styles and heights. The leg assemblies 10 can be selected from the kit to provide adaptability, offering versatility and customization to users.

[0038] In embodiments, the elongate through slots of the bridge pieces 12 differ in spacing between leg assemblies 10 of varying heights, as shown additionally in FIG. 7 where different length bridge pieces 34 are illustrated. This specific design ensures structural stability for different furniture configurations, enhancing support and reliability.

[0039] The invention further encompasses a method for mounting the wooden leg assemblies 10 onto a furniture piece 16. As demonstrated in FIGS. 2 and 3, the method involves inserting a male fastening component 20 through the front elongate slots 28 of each bridge piece 12 and fastening it to respective female fastening components 18 included in the underside of the furniture piece 16. The assembly process is straightforward and secure, ensuring a quick and reliable installation.

[0040] In embodiments, the method includes the selection of leg assemblies 10 from a kit of different height leg assemblies 10, providing for various heights of the furniture piece 16. This option offers versatility and customization, allowing users to adapt the furniture to their specific needs.

[0041] In embodiments, the fastening process involves the use of an Allen (RTM) key 22, which is shown in FIG. 2. This tool 22 (which is one example of a tool 22 for fastening the male fastening component 20) ensures a secure and efficient attachment of the leg assemblies 10 to the furniture piece 16, simplifying the assembly process and enhancing user-friendliness.

[0042] The present invention, as described in this detailed description, offers a unique and innovative approach to furniture assembly, combining structural stability, ease of use, adaptability, and aesthetic appeal. These features collectively set a new standard in the field of furniture assembly, addressing common challenges and enhancing user experiences.

[0043] Accordingly, a bridge piece is described herein providing a pioneering joinery solution designed for modem furniture assembly, contrasting with traditional basic butt joiner}' through the application of precise mathematical calculations and automation, particularly with respect to the dimensions and sizes of the slots and their relative spacing. Unlike the leg assembly 10 of the present disclosure, traditional basic butt joinery relies on manual techniques and presents challenges in achieving the required level of precision and adaptability for diverse furniture designs.

[0044] The design parameters for the elongate through slots 26 may be based, at least in part, on dimensions of an Allen (RTM) bolt. Functionally, this mechanism offers unparalleled precision and substantial load-bearing capabilities, resulting in structural integrity and extended longevity. The male fastening components 20 may be pre-mounted and integrally included in the bridge piece 12. This streamlined approach simplifies the assembly process, making it more efficient.

[0045] The leg assembly 10 offers superior precision and alignment compared to traditional basic butt joinery, enhancing stability and aesthetic appeal. The mechanism's substantial load-bearing capabilities ensure reliability and longevity. The streamlined and efficient assembly process reduces the time and complexity associated with furniture assembly. The design's broad applicability enhances versatility and adaptability.

[0046] In one example, a minor axis (width) of the rear elongate slot is 20 mm and major axis thereof is 35 mm. A minor axis of the front elongate 30 is 10 mm and a major axis length is 20 mm. The oval shape’s flexibility accommodates slight variations in alignment between the spacing of the female fastening components 18 in the furniture piece 16 and the spacing between the elongate through slots 26 during assembly, simplifying component fitting, particularly in manual or semi-automated assembly lines. The elongated shape ensures better stress distribution, especially when the load is not perfectly centred, contributing to product reliability. The oval slot adapts to material expansion or contraction, ensuring secure fastening under varying conditions. The oval slot allows minor adjustments post-installation, particularly beneficial for precise positioning. The dimensions of the elongate through slots can be identical for a wide range of furniture pieces 16 and leg assembly heights including a weight range of furniture pieces 16 of 3kg to 150kg. The design accommodates product scalability, offering versatility in design. Materials with high tensile strength and durability support products ranging from lightweight (3kg) to heavyweight (150kg) without compromising safety or functionality. The oval slot design ensures consistent stress distribution, minimizing the risk of failure across different product weights. Universal sizing enables secure fastening with slight adjustments in depth or tightness, eliminating the need for different components for each weight category. Universal sizing reduces manufacturing, inventory management, and logistics costs, improving efficiency and cost-effectiveness.

[0047] The use of an oval slot in conjunction with the Allen (RTM) key screw and female insert presents a ground-breaking approach to product assembly, enhancing versatility, durability, and introducing the concept of universal sizing, paving the way for efficiency, scalability, and innovation in product design and assembly. This reinforced justification underscores the unique and vital aspects of the patent application, highlighting the need for consultation with a patent attorney for a successful submission.

[0048] A primary material for the leg assembly 10 and the furniture piece 16 is solid wood. This choice aligns seamlessly with the innovative nature of the knock-down mechanism provided by the mounting of the leg assembly 10 to the furniture piece 12. The elongate through slots 26 may be precision-manufactured by Computer Numerical Control (CNC) tools and are strategically positioned on the horizontal bridge piece 12. This elongate through slots 26 act as the connection point between the vertical legs 14 (although splaying outwardly relative to one another) of the furniture piece 16. The disclosed knock-down mechanism (including the leg assembly 10) including the integration of the CNC-cut oval slot with solid wood furniture represents a significant departure from conventional designs. The precise dimensions and depth of the elongate through slots 26 have been meticulously optimized. The disclosed knock-down mechanism can be efficiently manufactured, assembled, and integrated into various furniture pieces 16.

[0049] In the assembly process, the female counterpart of the screw mechanism, known as the threaded insert (female fastening component 18), is embedded securely in the foundational structure of the furniture piece 16. Subsequently, the bridge piece 12 or mounting plate is precisely positioned atop this insert. Hexagonal wrench-compatible fasteners, referred to as Allen (RTM) screws (male fastening component 20), are then used to securely affix the bridge piece or mounting plate to the foundational region of the furniture piece 16.

[0050] While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing the exemplary embodiment or exemplary embodiments. It should be understood that various changes can be made in the function and arrangement of elements without departing from the scope of the disclosure as set forth in the appended claims and the legal equivalents thereof.

Claims

1. A wooden leg assembly for mounting to furniture, the leg assembly comprising:a bridge piece; andfirst and second legs connected at opposed ends of a rear face of the bridge piece;wherein the bridge piece includes elongate through slots comprising a front elongate slot and a rear elongate slot, wherein major and minor axes of the front elongate slot are larger than the major and minor axes of the rear elongate slot, respectively, so as to form a step at the interface of the front elongate slot and the rear elongate slot, andwherein the step provides a mounting surface for a male fastening component to secure the leg assembly to a female fastening component of the furniture.

2. The wooden leg assembly of Claim 1, wherein the first and second legs have a tapered cone form from a base secured to the rear face of the bridge piece to a distal end.

3. The wooden leg assembly of Claim 1 or 2, wherein the first and second legs splay relative to each other from a base secured to the rear face of the bridge piece to the distal ends.

4. The wooden leg assembly of any preceding Claim, wherein each front elongate slot opens to a front face of the bridge piece and each rear elongate slot opens to the rear face of the bridge piece.

5. The wooden leg assembly of any preceding Claim, wherein the male fastening component is an externally threaded bolt, and the female fastening component is an internally threaded insert securely mounted within the furniture.

6. A wooden furniture assembly, comprising:a furniture piece;a first wooden leg assembly of any preceding claim;a second wooden leg assembly of any preceding claim; andwherein a rear surface of the furniture piece includes four female fastening components inserted therein for receiving four male fastening components respectively therein that are received through respective ones of the elongate through slots of each of the bridge pieces of the first wooden leg assembly and the second wooden leg assembly.

7. The wooden furniture assembly of Claim 6, wherein a front face of each bridge piece abuts a rear plane of the furniture piece and the four female fastening components are inserted flush with the rear plane.

8. The wooden furniture assembly of Claim 6, wherein a front face of each bridge piece abuts a respective mounting platform secured to a rear plane of the furniture piece and the four female fastening components are inserted flush with a mounting surface of the mounting platform.

9. The wooden furniture assembly Claim 8, wherein the bridge piece is the same shape and size as the mounting platform so that their outer profiles match.

10. A kit of leg assemblies, each leg assembly being a leg assembly of any one of Claims 1 to 5, wherein the kit includes pairs of leg assemblies of different heights to other pairs of leg assemblies.

11. The kit of Claim 10, wherein the elongate through slots of the bridge pieces of pairs of leg assemblies of lower heights are spaced closer together than pairs of leg assemblies of greater heights.

12. A method of mounting first and second wooden leg assemblies to a furniture piece, the first and second leg assemblies being according to the leg assembly of any one of Claims 1 to 5, the method comprising: inserting a male fastening component through the front elongate slots of each bridge piece and fastening the male fastening component to respective female fastening components included in an underside of furniture piece.

13. The method of Claim 12, comprising selecting from a kit of different height first and second leg assemblies to provide for different heights for the furniture piece.

Images