Furniture arch assembly

Abstract

A furniture arch assembly that can be shipped in a flat state and then assembled in a three-dimensional configuration by an individual by flexing a flat arched panel so that it forms an arch and then securing the arched panel within grooved surfaces on a first and second arch members, and in some embodiments first and second panel holders.

Description

FIELD OF THE INVENTION

[0001] The present invention relates generally to an arch used in furniture construction and more particular to a furniture arch that can be shipped in separate pieces in a relatively flat cuboid box and then assembled into a three-dimensional arch assembly with a footprint that exceeds the height dimension of the cuboid box.BACKGROUND OF THE INVENTION

[0002] When consumers purchase furniture at a store that is then delivered, for example, by truck, the size (i.e., volumetric footprint) of the purchased furniture is of minor importance. However, much furniture, including furniture purchased online, is shipped to consumers via common carriers, such as the U.S. Mail, United Parcel Service, or Federal Express.

[0003] When shipping via common carrier, the size of the shipped package can significantly impact the cost of delivery. The shipping of pre-fabricated three-dimensional furniture is prohibitively expensive and bulky. Thus, it is desirable to package the furniture so that it has as small a volumetric footprint as possible. One such method of decreasing the volumetric footprint of furniture being shipped is to ship ready-to-assemble furniture. With ready-to-assemble furniture, furniture items are shipped in multiple pieces accompanied by assembly instructions so that upon receipt, an individual can assemble the pieces into the desired furniture object.

[0004] To keep the size of the shipping box as small as possible, each component of the furniture being shipped is preferably a flat item, such as a flat board or a support member. As a result, ready-to-assemble furniture is often rectangular or square-shaped, replete with right angles.

[0005] However, there is a demand from consumers for ready-to-assemble furniture with designs that include other shapes that are not right-angled. One such desired shape is an arched design. Accordingly, there exists a need to develop a method of construction of a furniture arch, as part of ready-to-assemble furniture, whereby the arch components can be shipped in a flat box and then assembled into a three dimensional arch configuration by the individual upon receipt of a ready-to-assemble furniture package.SUMMARY OF THE INVENTION

[0006] A furniture arch assembly is provided. The furniture arch assembly has a first arch member and a second arch member, each comprising an inner curved surface, an outer curved surface, and a length dimension, with the inner curved surface of the first arch member and the second arch member including a grooved surface along the length dimension.

[0007] The furniture arch assembly also has a rectangular-shaped connecting panel comprising a substantially flat surface having a uniform thickness along at least a first side and a second side parallel to the first side and the connecting panel has sufficient flexibility such that the rectangular connecting panel may be held in a curved arch position along the first and second sides, and the first and second sides have a length substantially equal to the length dimension of the first arch member and the second arch member. In embodiments, the connecting panel has a thickness of 1.5 mm.

[0008] The grooved surface on the inner curved surface of the first arch member and the inner curved surface of the second arch member each has a groove width dimension sufficient to securely hold the uniform thickness of the connecting panel along the length dimension when the inner curved surfaces of the first arch member and the second arch member are disposed facing each other.

[0009] In embodiments, the first arch member, second arch member and connecting panel would be shipped in a flat box, along with other components of a furniture assembly. The arch is assembled by bending the connecting panel until its shape aligns with one of the first arch members and inserting the first side of the connecting panel into the groove of the first arch member. The second arch member would then be joined with the second side of the connecting panel at the second arch member grooved surface thus completing the assembly of the furniture arch.

[0010] In embodiments, the furniture arch assembly further includes a second arch member panel that comprises a substantially flat surface having a curved edge that coincides with the outer curve surface of the second arch member. The second arch member panel is joined to the second arch member creating a wall at one end of the assembled furniture arch, such that there is only an opening at the first arch member. This construction permits the creation of an arched storage cubicle. It is anticipated and within the scope of the invention that additional panels could be connected to the second arch member panel in a combination of either horizontal, vertical, or diagonal orientations to provide storage spaces within the volume created by the assembled furniture arch.

[0011] In embodiments, the furniture arch assembly includes a first panel holder and a second panel holder each comprising a length dimension and a grooved surface comprising a groove width dimension sufficient to securely hold the uniform thickness of the connecting panel along a third side and a fourth side of the connecting panel. When the furniture arch assembly includes a first panel holder and second panel holder, the furniture arch can be assembled by first joining the first ends of the first panel holder and the second panel holder to the ends of the first arch member. The connecting panel can then be flexed (i.e., bent) so that the third and fourth sides can be inserted into the grooves of the first panel holder and second panel holder, and then slid down the length of the grooves until the second side of the connecting panel is securely held within the groove of the first arch member. The second arch member can then be placed over the arched connecting panel and the second ends of the first panel holder and the second panel holder to securely hold the connecting panel within the groove of the second arch member to form the assembled furniture arch.

[0012] In embodiments, a plurality of stabilizing members, each with a first end and a second end, provide additional connections between the first arch member and the second arch member to provide for a more stable design. In a preferred embodiment, two stabilizing members are used, but any number of stabilizing members, including one stabilizing member, may be used.

[0013] In embodiments, once assembled, the furniture arch assembly can be placed on top of another furniture component to provide an arched top to the other component.

[0014] It is an anticipated and within the scope of this invention that the components of the furniture arch assembly can be made of various materials so long as the function of the furniture arch assembly remains the same. Exemplary materials for the components include wood, PVC, composite, laminate or any other sturdy construction material known to one of ordinary skill in the art. With the exception of the connecting panel, the materials must be sturdy enough to prevent deformation of the assembled furniture arch. The connecting panel is fabricated from a material with sufficient pliability such that it can be flexed into an arched shape. Such materials for fabrication of the connecting panel may include PVC, plastic or wood laminate.

[0015] These and other features of this invention are described in, or are apparent from, the following detailed description of various exemplary embodiments of this invention.BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Exemplary embodiments of this invention will be described with reference to the accompanying figures wherein:

[0017] FIG. 1 is a perspective view of an arched storage cabinet which includes an assembled furniture arch of the present invention.

[0018] FIG. 2 is a perspective view of an exemplary shipping box that could be used to ship an arched storage cabinet including the furniture arch assembly of the present invention in an unassembled state.

[0019] FIG. 3 is a perspective view of the unassembled components of the furniture arch assembly of the present invention.

[0020] FIG. 4 is an enlarged view of a portion of the first arch member of FIG. 3 of the present invention.

[0021] FIG. 5 is a perspective view of a partially assembled furniture arch assembly of the present invention in an embodiment that includes first and second panel holders.

[0022] FIG. 6 is a perspective view of the fully assembled furniture arch assembly of FIG. 5.

[0023] FIG. 7 is a cross-sectional view of the assembled furniture arch assembly of FIG. 6 taken along the lines 7-7 in FIG. 6 in the direction shown by the arrows.

[0024] FIG. 8 is a perspective view of an embodiment of the fully assembled furniture arch assembly of the present invention that include the use of stabilizing members.DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

[0025] FIG. 1 illustrates a perspective view of arched storage cabinet 100 which includes assembled furniture arch 105 of the present invention. Furniture arch 105 includes first arch member 110, second arch member 120 and connecting panel 130.

[0026] As seen in FIG. 1, with the exception the assembled furniture arch 105, which has a curved shape, the remaining components (with the exception of hardware such as knobs, dowels, screws or cam-locks, all not shown) are flat components assembled at right angles to produce a rectangularly shaped arched storage cabinet 100. When furniture arch 105 is disassembled into its components, connecting panel 130 reverts to its non-flexed (i.e., flat) state. In such a state, the furniture arch assembly and the remaining components of arched storage cabinet 100 can be shipped in a container such as that seen in FIG. 2.

[0027] As seen in FIG. 2, exemplary shipping container 201 is of a narrow height that would not fit the inclusion of the furniture arch assembly of the present invention if it were not in an unassembled stated. By shipping the arched storage cabinet with the furniture arch assembly in a disassembled state, the shipper can save on shipping costs by shipping a narrower package than were the package to include a fully assembled furniture arch.

[0028] Turning to FIG. 3, a perspective view of the unassembled components of the furniture arch assembly of the present invention are shown. The primary components of furniture arch assembly 305 are first arch member 310, second arch member 320, and connecting panel 330. As seen in FIG. 3, both first arch member 310 and second arch member 320 are curved, whereas connecting panel 330 is flat (with a cuboid shape).

[0029] First arch member 310 includes an inner curved surface 311, an outer curved surface 312, a third curved surface 313 and a fourth curved surface 314. Similarly, second arch member 320 includes an inner curved surface 321, an outer curved surface 322, a third curved surface (not visible in this embodiment because of the presence of second arch member panel 335) and a fourth curved surface 324. The inner curved surfaces 311 and 321 of the first arch member 310 and second arch member 320, respectively, each include a grooved surface (first arch member inner curved surface grooved surface 315 and second arch member inner curved surface grooved surface 325) with a width “w” as shown in FIG. 4.

[0030] The width w of the grooved surfaces 315 and 325 is of a dimension sufficient to securely hold the uniform thickness of connecting panel 330 along the first side of connecting panel 331 and the second side of connecting panel 332. One of ordinary skill in the art would recognize that this width dimension would be approximately the same width (or minimally wider) as that of the width of the first and second sides 331 and 332 of connecting panel 330.

[0031] In the embodiment shown in FIG. 3, second arch member 320 includes a second arch member panel 335 joined to the second arch member along the second arch panel third curved surface. Second arch member panel 335 fills the volume within the arch formed by second arch member 320, providing a closed surface at one end of the furniture arch in its fully assembled state.

[0032] FIG. 4 presents an enlarged view of a portion of first arch member 410 to illustrate first arch member inner curved surface grooved surface 415 and the groove width w. In embodiments, the shape of the grooved surfaces present on both the first arch member (415) and the second arch member the inner grooved surface on the second arch member (not shown) is configured to mirror that of the first and second sides of the connecting panel so that the first and second sides of the connecting panel can securely hold the first and second sides of the connecting panel in contact with the inner surfaces of the first and second arch members.

[0033] FIG. 5 illustrates the assembling of the furniture arch assembly, in mid-assembly, in an embodiment that also includes first panel holder 540 and second panel holder 545. First panel holder 540 and second panel holder 545 each have a grooved surface (not shown in FIG. 5) with a groove width w, the same groove width found with the grooves present on the first arch member inner curved surface 511 and the second arch member inner curved surface 521. To assemble the furniture arch, the first ends of first panel holder 540 and second panel holder 545 are joined at the ends of the second arch member 520 such that the grooved surface on the first panel holder 540 and second panel holder 545 align perpendicularly with the grooved surface 521 of the second arch member 520.

[0034] Connecting panel 530 is flexed so that it is in an arched state, inserting third side 533 of connecting panel 530 into the grooved surface on first panel 540 (as seen on the enlarged view in FIG. 5) and inserting fourth side 534 of connecting panel 530 into the grooved surface (not shown) on second panel 545 (not shown). The assembler then directs connecting panel 530 downward until the second side 532 is secured within grooved surface 525 of second arch member 520. At the moment in time shown in FIG. 5, connecting panel 530 is partially engaged with the grooved surfaces of first member panel 540 and second member panel 545, and not yet engaged with the grooved surface 525 located on the inner curved surface of the second arch member. Once the second side 532 of connecting panel 530 is fully engaged with grooved surface 525 of second arch member 520, the assembler would engage the first arch member 510 with connecting panel 530 and the second ends of first member panel 540 and second member panel 545. In doing so, grooved surface 515 of the inner surface 511 of first arch member 510 would be brought into connection with the first side 531 of connecting panel 530, securing connecting panel 530 in an arched position.

[0035] FIG. 6 illustrates the fully assembled furniture arch described in FIG. 5. As seen in FIG. 6, connecting panel 630 is secured in the grooved surfaces of first arch member 610, second arch member 620, first panel holder 640, and second panel holder 645. In embodiments, one or more of the first and second arch members and the first and second panel holders may be further joined to connecting panel 630 through the use of any number of conventional means, including glue, dowels, screws or a cam-lock system. One of ordinary skill in the art will appreciate that such additional joining means would help secure the connecting panel in its flexed position and assist in preventing the assembled furniture arch components from decoupling.

[0036] FIG. 7, a cross-sectional view of the assembled furniture arch assembly of FIG. 6 taken along the lines 7-7 in FIG. 6 in the direction shown by the arrows, further illustrates the mating (i.e., joining) of connecting panel 730 with first panel holder 740. As seen in FIG. 7, third side 733 of connecting panel 730 is secured within first panel holder groove 741.

[0037] FIG. 8 illustrates an embodiment that includes stabilizing members connecting the first arch member panel and second arch member panel. One or more stabilizing members can be used to enhance the structural integrity of the assembled furniture arch. In the embodiment shown in FIG. 8, three stabilizing members, namely first stabilizing member 850, second stabilizing member 851 and third stabilizing member 852, are positioned between first panel holder 840 and second panel holder 845. The stabilizing members are joined to the inner surfaces of the first and second arch members, namely first arch member inner curved surface 811 and second arch member inner curved surface 821. The stabilizing members can be joined to the inner surfaces of the first and second arch members through the use of any number of conventional means, including glue, dowels, screws or a cam-lock system. An enlarged view on FIG. 8, illustrates the junction of first panel holder 840, second arch member 820 (with second arch member panel 835) and connecting panel 830, which is securely held in the grooved surfaces of first panel holder 840 and second arch member 820.

[0038] Now that embodiments of the present invention have been shown and described in detail, various modifications and improvements thereon will become readily apparent to those skilled in the art. Accordingly, the exemplary embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. The spirit and scope of the present invention is to be construed broadly.

Claims

1. A furniture arch assembly comprising:a first arch member and a second arch member, each comprising an inner curved surface, an outer curved surface, and a length dimension, wherein the inner curved surface of the first arch member and the second arch member comprises a grooved surface along the length dimension; anda rectangular-shaped connecting panel comprising a substantially flat surface having a uniform thickness along at least a first side and a second side parallel to the first side, wherein the connecting panel has sufficient flexibility such that the rectangular connecting panel may be held in a curved arch position along the first and second sides, and the first and second sides have a length substantially equal to the length dimension of the first arch member and the second arch member,wherein the grooved surface has a groove width dimension sufficient to securely hold the uniform thickness of the connecting panel along the length dimension when the inner curve surfaces of the first arch member and the second arch member are disposed facing each other.

2. The furniture arch assembly of claim 1 further comprising a second arch member panel joined to the second arch member, wherein the panel comprises a substantially flat surface having a curved edge that coincides with a third surface of the second arch member, the third surface of the second arch member located between the second arch member inner curved surface and second arch member outer curved surface.

3. The furniture arch assembly of claim 1 further comprising a first panel holder and a second panel holder each comprising a length dimension and a grooved surface comprising a groove width dimension sufficient to securely hold the uniform thickness of the connecting panel along a third side and a fourth side of the connecting panel.

4. The furniture arch assembly of claim 1 further comprising a plurality of stabilizing members, each comprising a first end and a second end, wherein the first end is connected to the first arch member and the second end is connected to the second arch member.

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