Note: Descriptions are shown in the official language in which they were submitted.
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WALL SYSTEM HAVING FURNITURE MODULES AND ACCESSORIES FOR
ATTACHING AND FINISHING THE MODULES
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No.
60/961,237
filed July 19, 2007.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The invention relates to RTA (Ready-To-Assemble) furniture and more
particularly,
to furniture modules that are provided with hardware permitting easy assembly
and
disassembly while, at the same time, retaining continuity between modules to
provide the
appearance of a continuous furniture system.
Description of Related Art
[0003] The assembly and disassembly of RTA furniture modules to provide a
furniture
system often times becomes difficult because, in order for the modules to
provide an
aesthetically pleasing appearance, adjacent modules must be uniformly spaced
apart, while at
the same time, uniformly level so that they appear to be one continuous unit.
Because of the
weight of individual furniture modules, manipulating and securing adjacent
modules together
is difficult and without proper initial alignment of the modules, fasteners
that may be used to
attach modules in the end may produce an undesirable result of misaligned
furniture modules.
[0004] A system is required for aligning and securing together furniture
modules to
produce a furniture system having modules that are properly leveled, properly
aligned, and
bridged with connection pieces, thereby producing an aesthetically pleasing
and securely
mounted furniture system.
SUMMARY OF THE INVENTION
[0005] In a furniture system having a plurality of separate and distinct
modules adjacent to
one another defining interior modules and two end modules, wherein each module
has two
opposing outer walls, one embodiment of the invention is directed toward an
apparatus for
aligning and securing together adjacent modules. The apparatus has a first
mounting bracket
secured to the outer wall of one of the modules, a second mounting bracket
secured to the
outer wall of an adjacent module, and a mechanism for moving the module outer
walls toward
one another. The mechanism pulls the first mounting bracket and the second
mounting
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bracket together, thereby moving the module outer walls toward one another and
establishing
a desired gap therebetween.
[0006] In a furniture system having a plurality of separate and distinct
generally rectangular
modules, wherein each module has two opposing outer walls and, wherein when
modules are
adjacent to one another, there is a gap therebetween defined by the distance
between the outer
walls. Another embodiment of the subject invention is directed to an apparatus
for masking
the gap. The apparatus has a pad connected to an outer wall of the first
module. The pad is
connected to an outer wall of the second module. A pilaster is secured to each
pad over the
gap, wherein the pilaster has a similar color and texture to that of the
adjacent modules.
[0007] Another embodiment of the subject invention is directed to a furniture
module
having opposing walls and rollers secured thereto for moving the module back
and forth. The
module has at least three roller brackets secured to the module and an
adjustable roller frame
secured to the each roller bracket. The adjustable roller frame is movable up
and down
relative to the roller bracket to adjust the height for leveling the module. A
roller wheel is
secured within the roller frame and a locking member is movable relative to
the wheel of the
roller frame to lock and unlock the wheel from rotation.
[0008] For a furniture system having at least two modules adapted to be
positioned adjacent
to one another, wherein the outer walls of each module have exposed
undecorated ends, yet
another embodiment of the subject invention is directed to an assembly for
providing
decorative ends. The assembly has a decorative end cap, a first connector
attached to the end
cap, and a second connector mounted to the outermost face of a module adapted
to be secured
to the first connector to secure the end cap to the module. With the end caps
in place, there is
an appearance of continuity between the end caps and the modules.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Fig. 1 is a drawing of a furniture system comprised of eight separate
modules;
[0010] Fig. 2 is a drawing illustrating a front view of two modules attached
with a pair of
turnbuckles;
[0011] Fig. 3 is a drawing illustrating additional details of a turnbuckle
connecting two
modules;
[0012] Fig. 4 is a view showing connecting pads with a fully assembled
turnbuckle;
[0013] Fig. 4A is a view showing magnetic material connecting pads;
[0014] Fig. 5 is an exploded perspective of a turnbuckle and the brackets
associated with
each module for securing the turnbuckle;
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[0015] Fig. 5A is an assembled top view of the arrangement illustrated in
Fig.5;
[0016] Fig. 6 is a drawing of the connecting pads located between furniture
modules for
receiving a pilaster;
[0017] Fig. 7 is a perspective view of a module illustrating passageways
located in the rear
of the outer wall of the module;
[0018] Fig. 8 is a drawing showing two modules secured using a connecting
bracket
securing the passageways between adjacent modules;
[0019] Fig. 9 is a drawing of a roller system attached to the bottom of a
module for rolling
the module into position;
[0020] Fig. 9A is a bottom view of a typical module showing the location of
one set of
rollers;
[0021] Fig. 10 is a drawing of a view inside in a module illustrating the
access holes for the
rollers in the rear of the module;
[0022] Fig. 11 is a drawing of a left end cap used as a finishing piece on the
left side of the
end module;
[0023] Fig. 12 is a view of the end cap illustrated in Fig. 11 showing
additional details;
[0024] Fig. 13 is a perspective end view of the end cap illustrating the
manner by which the
end cap is secured to a module;
[0025] Figs. 14-18 illustrate different types of modules;
[0026] Fig. 19 illustrates a furniture system with a different configuration
from that
illustrated in Fig. 1;
[0027] Fig. 20 illustrates a single module with end caps attached thereto
which may be used
as a single furniture piece;
[0028] Fig. 21 illustrates a perspective view of an additional style of
module;
[0029] Fig. 22 illustrates a perspective view of a corner module;
[0030] Fig. 23 shows an exploded perspective view of a pilaster; and
[0031] Fig. 24 shows a perspective view of a left end cap and a right end cap
87.
DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0032] Fig. 1 illustrates a furniture system 10 comprised of a plurality of
interconnected
furniture modules. In particular, from left to right in the sequence of their
attachment are a
standard module 15, an office module 20, a library module 25, a corner module
30, a standard
module 35, another standard module 40, an entertainment module 45 and finally,
a standard
module 50. As will be seen, each of these modules is separate and distinct
from one another
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and is connected together using fasteners, pilasters and end caps that will be
hereinafter
described in detail. Standard module 15 and standard module 50, since they are
at the ends of
the system 10, are end modules while the remaining modules in the system 10
are interior
modules.
[0033] Figs. 2 and 3 illustrate a pair of modules which, for purposes of this
specification,
will be referred to as a first module 60 and a second module 65. The purpose
of such a
generic label is to make clear that the first module 60 and second module 65
are
representative of any of the previously described or other modules and any one
module may
be connected to any other module to provide an expandable independent and
portable
furniture system comprised of one or more of a variety of modules. Directing
attention to Fig.
2, first module 60 has a first opposing outer wall 70 and a second opposing
outer wall 75.
Additionally, each module may have a bottom strip of decorative molding 80 and
a top strip
of decorative molding 82. The first module 60 is connected to the second
module 65 utilizing
a mechanism for moving the module outer walls 70,75 and therefore the entire
modules 60,65
toward one another. This mechanism may be at least one turnbuckle ' 100,
although as
illustrated in Fig. 2, there are three turnbuckles 100. The purpose of the
turnbuckles 100 are
two-fold. First of all, the turnbuckle 100 is designed to urge the first
module 60 toward the
second module 65 and, second of all, the turnbuckle 100 bottoms out, such
that, in the closed
position, the distance between the first opposing outer wall 70 of the second
module 65 and
the second opposing outer wall 75 of the first module 60 is uniform for each
turnbuckle 100.
It should be noted with the turnbuckle 100 in place, there is a gap 102
between the first
module and the second module 65. Briefly returning to Fig. 1, a pilaster 105
is used to cover
the gap 102 between adjacent modules such as the standard module 15 and the
office module
20. The pilaster 105 has the same finish and same color and texture
(decorative pattern) as
the adjacent modules 15, 20 and, when properly placed and secured, provides a
continuous
appearance between adjacent modules.
[0034] Fig. 4 illustrates an enlarged view of a turnbuckle 100 connecting a
first opposing
outer wall 70 to a second opposing outer wall 75. The connecting pads 110 are
used to
connect pilasters and are not directly associated with the turnbuckle 100.
Therefore, the
connecting pads will not be discussed at this point.
[0035] An exploded view of the tumbuckle 100 and the hardware used to connect
the
turnbuckle 100 to the first opposing outer wall 70 and the second opposing
outer wall 75 is
illustrated in Fig. 5.
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[0036] Directing attention to Figs. 4 and 5, the turnbuckle 100 is used for
aligning and
securing together the first module 60 and the second module 65. A first
mounting bracket 115
is secured to the second opposing outer wall 75 of the first module 60. A
second mounting
bracket 120 is secured to the first opposing outer wall 70 of the second
module 65, which is
adjacent to the first module 60. The turnbuckle 100 is secured to the first
mounting bracket
115 and to the second mounting bracket 120. Directing attention to Fig. 5, the
turnbuckle 100
is made up of a first part 125 and a second part 130. The first part 125
includes a protrusion
127 having a circular groove 129. The protrusion 127 fits within a recess 131
within the
second part 130. A pin 132 fits within an offset passageway 133 in the second
part 130 such
that when the first part 125 is secured against the second part 130 the pin
132 engages the
circular groove 129 and restricts translation between the first part 125 and
the second part 130
but permits rotation about a central axis 135 extending therethrough. The
first part 125 has a
threaded bore 136 to accept the threaded shank 138 of bolt 140. Similarly, the
second part
130 has a threaded bore 142 which accepts the threaded shank 144 of bolt 146.
Fig. 6
illustrates the placement of the first mounting bracket 115 of the second
opposing outer wall
75 of the first module 60 and the second mounting bracket 120 on the first
opposing outer
wall 70 of the second module 65. The first mounting bracket 115 and the second
mounting
bracket 120 are secured to their respective outer walls 75, 70 using
fasteners, such as screws
148, passing through holes 150 extending through the brackets 115, 120.
[0037] Bracket 115 and bolt 146 (Fig. 5) will now be discussed with the
understanding that
these same features apply to bracket 120 and bolt 140.
[0038] Bracket 115 includes a protruding portion 152 which is spaced from the
mounting
plate portion 154 to define a recess 156 therein. Protruding portion 152
additionally has a slot
158 with a width greater than the diameter of the threaded shank 144. However,
the bolt 146
additionally has a non-circular head 160 which, in Fig. 5, is illustrated as a
square which is
larger than the slot 158. The non-circular head 160 is positioned within the
recess 156 and is
held non-rotationally therein. When the first part 125 is engaged with the
second part 130,
these two parts may rotate relative to one another but are axially restrained
by the pin 132
engaged within the circular groove 129. As illustrated in Fig. 5A, the first
part 125 and the
second part 130 each have a series of flats 162, 164 about their periphery
suitable for
receiving a wrench. Therefore, with the bolt 140 partially engaged within the
threaded bore
136 of the first part 125 and the second bolt 146 partially engaged within the
threaded bore
142 of the second part 130, the first part 125 and the second part 130 may be
rotated relative
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to one another to further engage each of the bolts 140, 146 and pull the
adjacent modules
together.
[0039] Directing attention to Fig. 4, when the tumbuckle 100 is engaged with
the first
mounting bracket 115 and the second mounting bracket 120, rotation of the
flats 162, 164 and
the tumbuckle 100 results in the second opposing outer wall 75 and the first
opposing outer
wall 70 being pulled together a predetermined distance, which occurs when the
turnbuckle
bottoms out. In its loosened state, the non-circular head 160 of each bolt
146, for example,
may be easily placed within the recess 156 (Fig. 4) of each mounting bracket
115, 120 and the
turnbuckle tightened to pull the opposing outer walls 75, 70 together.
[0040] Returning to Fig. 3, since the turnbuckle 100 must be rotated manually
with a
wrench, access to the turnbuckle 100 is important and, for that reason, the
turnbuckle 100 is
placed near the front of the furniture modules. However, it is also desirable
to secure the rear
portion of the modules.
[0041] Fig. 7 illustrates the typical first opposing outer wall 70. Of
particular interest are
two passageways 165, 166 extending through the opposing outer wall 70.
Although not
illustrated in this figure, the second opposing wall 75 has similar
passageways. As illustrated
in Fig. 8, when the first opposing outer wall 70 of a second module 65 is
aligned with the
second opposing wall 75 of a first module 60, the passageways 165, 166 are
aligned with one
another. The passageways 165, 166 are large enough to accommodate the hand of
a user and,
as a result, a spacer bracket 170 having a first U-shaped portion 172 fits
around and straddles
the thickness of the second opposing outer wal175 while the second U-shaped
portion 174 fits
around the first opposing outer wall 70. The middle portion 176 of the spacer
bracket 170 is
sized such that the distance between the first opposing outer walls 70 and the
second opposing
outer wall 75 in the region of the spacer bracket 170 is identical to the
distance between the
first opposing outer wall 70 and the second opposing outer wall 75 adjacent to
a tightened
turnbuckle 100. Additionally, the passageways are positioned away from the
turnbuckles 100
to maximize the effectiveness of the spacer brackets 170.In such a fashion,
the first opposing
outer wall and second opposing outer wall are uniformly spaced along their
entire surfaces.
[0042] Directing attention to Figs. 9 and 10, each module, for example
standard module 40,
has attached thereto rollers for moving the module 40 back and forth. In
particular, a roller
180 is comprised of a roller bracket 182 secured to the module 40. An
adjustable roller frame
184 is secured to the roller bracket 182. The adjustable roller frame 184 is
moveable up and
down relative to the roller bracket 182 to adjust the height of the module 40.
In particular, a
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leveling bolt 186 is threadingly engaged within the roller bracket 182 and
abuts the roller
frame 184 such that rotationally advancing the leveling bolt 186 urges the
roller bracket 182
away from the roller frame 184, thereby lifting the module 40. The roller 180
is further
comprised of a roller wheel 190 secured within the roller frame 184 and
permitted to rotate.
However, a locking bolt 192 is threadingly engaged with the roller frame 184
and is moveable
relative to the wheel 190 of the roller frame 184 to lock and unlock the wheel
190 from
rotation by contact with the roller wheel 190. It should be noted that the
roller 180 found in
Fig. 9 is mounted toward the front and to the outside of the module wall. The
roller 180 is
located within the gap 102 (Fig. 2) created by two adjacent modules. As a
result, both the
leveling bolt 186 and the locking bolt 192 are easily accessible from the
front of the modules.
As seen in Fig. 9A, there are two front rollers 180 mounted to the outside of
the module 40
outer walls 70, 75.
[0043] However, directing attention to Figs. 9A and 10, there are also two
rollers 195
mounted toward the rear and inside of the module 40. These rollers 195 are
identical to
rollers 180 but do not have the locking bolt 192 hardware. These rollers 195
are not as
accessible and, as a result, access holes 194 are provided in the rear and
through the bottom of
each module. A tool may be inserted therein to engage the leveling bolt 186 of
the rollers
195. Rollers 195 and rollers 180 may be adjusted to level the entire module
40. As stated, the
back portion of each module has a set of rollers 195 with a leveling bolt 186
but do not
include a locking bolt 192. This feature is present only in the front rollers
of the module 40.
[0044] As previously mentioned, Fig. 1 illustrates a left end cap 85 and a
right end cap 87
which have decorative moldings and the same color and texture as each of the
modules.
Regardless of the module selection for the furniture system, the left end cap
85 and the right
end cap 87 will always be present. The outer walls 70,75 of each module are
unfinished
surfaces and therefore the end modules have outer walls that, without end
caps, would be
exposed. As an example and as illustrated in Fig. 7, which shows a typical
first opposing
outer wall 70, the wall is plain and undecorated and the second outer opposing
wall 75 is the
same. As a result, the end caps 85, 87 and the pilasters (to be discussed) are
finishing parts
that provide a continuous appearance to any furniture system that may be
assembled in
accordance with the subject invention.
[0045] Figs. 11, 12 and 13 illustrate different views of the left end cap 85.
However, it
should be appreciated that the decorative features of the end cap 85
illustrated in Figs. 11, 12
and 13 are slightly different from those illustrated in Fig. 1. However, the
general purpose of
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the end cap 85 providing a continuous appearance at the end of the module
string is achieved
through the design associated with Figs. 11-13 and, for that reason, while it
should be noted
that the decorative trim of end cap 85 is missing in Figs. 11-13, the same
principles apply and
the same reference numbers will be utilized.
[0046] The left end cap 85 is comprised of a front pane1202 and a side panel
205 which are
designed to blend with the design of the modules in accordance with the
furniture system.
[0047] Although the left end cap 85 will be discussed, it should be
appreciated that the right
end cap 87 has identical features although reversed to accommodate the
opposite side of the
furniture system.
[0048] On the inner surface of the side panel 205 are mounted a plurality of
identical
brackets 207 having a mounting plate portion 209 secured to the inner surface
211 of the side
panel 205 by fasteners 213. Extending from the mounting plate portion 209 is a
cantilevered
portion 215 which extends into a locking tab 217 oriented approximately
perpendicular to the
cantilevered portion 215. Fig. 13 illustrates a bottom view of the left end
cap 85 secured to an
adjacent module such as the standard module 15. Mounted upon the first
opposing outer wall
70 of the standard module 15 are mounting brackets 220 with fasteners 222. The
mounting
brackets 220 have a mid-portion 225 spaced from the first opposing outer wall
70 to define a
receiving opening 227. The locking tabs 217 of the brackets 207 fit from above
within the
receiving opening 227 to support and properly locate the left end cap 85 upon
the adjacent
standard module 15. It should be noted that the length of the cantilevered
portion 215 should
be sized such that the front panel 202 abuts with the first opposing outer
wall 70 of the
standard module 15. As ai-esult, the undecorated ends of any particular module
may be
provided with a left end cap 85 or a right end cap 87, each of which is
decorated to match the
decor or the adjacent module. The bracket 207 attached to the left end cap 85
and the
mounting bracket 220 attached to the first opposing outer wall 70 of the
module, act to secure
the end cap 85 to the module 15.
[0049] As illustrated in Fig. 1, between each of the modules is a pilaster 105
which covers
the gap 102 (Fig. 3) between each module with a panel that blends in
appearance and provides
a continuum between the modules. Directing attention to Fig. 4, pads 110 are
connected to
the first opposing outer wall 70 and the second opposing outer wall 75 of
modules that are
adjacent to one another. As a general guideline, a pair of connecting pads I
10 may be located
adjacent each of the turnbuckles 100. As illustrated in Fig. 4, each
connecting pad 110 is
comprised of a layer of plastic Velcro which mates with opposing plastic
Velcro (not shown)
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mounted upon the inside surface of the pilaster 105. In another embodiment, as
illustrated in
Fig. 4A, magnetic material connecting pads 110 may be used in place of the
plastic Velcro
connecting pads 110 to mate with opposing steel plates (not shown) on the
inner surface of
the pilaster 105. As a result, when two modules are adjacent to one another,
with a gap 102
therebetween, defined by the distance between the first opposing outer wall 70
of one module
and the second opposing outer wall 75 of another module, a pilaster 105 is
secured by
connecting pads 110 to cover the gap 102, wherein the pilaster 105 has a
decorative pattern
and profile similar to that of the modules. It should be noted that in Fig. 1,
the top and bottom
of each module has decorative trim and the pilaster will have matching
identical decorative
trim as well.
[0050] While Fig. 1 illustrated a plurality of different types of modules, all
that is required
for any customized module to be compatible with the furniture system described
herein is that
the module have a first opposing outer wall 70 and a second opposing outer
wall 75 similar to
that described herein. As a result, a module can have any number of designs or
features.
Figs. 14-18 illustrate different types of modules that are compatible with the
subject furniture
system.
[0051] Again referring to Fig. 1, eight separate modules are illustrated to
form a relatively
large furniture system 10. However, Fig. 19 illustrates an arrangement where
only the office
module 20, the standard module 15 and a second standard module 35 are
assembled. Left end
cap 85 is secured to standard module 15 and right end cap 87 is secured to
standard module
35, wherein each module is also secured to the office module 20. Pilasters 105
are secured
between the standard module 15 and the office module 20 and between the office
module 20
and the standard module 35.
[0052] Although the furniture system so far described has addressed multiple
modules,
directing attention to Fig. 20, it is entirely possible for a consumer to
purchase a single
module such as the entertainment module 230 and attach thereto the left end
cap 85 and the
right end cap 87 to provide a stand-alone furniture system with only a single
module.
[0053] Fig. 21 illustrates a perspective view of an additional style of
module.
[0054] Fig. 22 illustrates the corner module 30 showing the first opposing
outer wall 70
oriented perpendicular to the second opposing outer wall 75.
[0055] Fig. 23 shows the front portion 107 and the top portion 109 of a
typical pilaster 105,
including the top decorative molding 80 and the bottom decorative molding 82.
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[0056] Fig. 24 shows additional details of a left end cap 85 and a right end
cap 87,
including the top decorative molding 80 and the bottom decorative molding 82.
[0057] While specific embodiments of the invention have been described in
detail, it will
be appreciated by those skilled in the art that various modifications and
alternatives to those
details could be developed in light of the overall teachings of the
disclosure. The presently
preferred embodiments described herein are meant to be illustrative only and
not limiting as
to the scope of the invention which is to be given the full breadth of the
appended claims and
any and all equivalents thereof.
