Cross-Reference to Related Applications

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63/356,771, which was filed on June 29, 2022. The entire content of the foregoing provisional application is incorporated herein by reference.

Field of the Invention

[0002] The invention herein relates to furniture for dwellings and other buildings for residential and commercial occupancy.

BACKGROUND

Description of the Related Art

[0003] In the field of furniture design, there have been a variety of efforts to create items such as tables, chairs and the like whose components can be compactly packaged in a disassembled state for ease of shipping, and yet simply and quickly assembled.

[0004] Couches are large pieces of furniture found in the living room or in other large rooms of homes. They are often designed to include a fold-out bed, sometimes referred to as a sofa bed. This is particularly desirable for smaller dwellings, where the interior portions are of modest dimensions and thus have limited floor space.

[0005] The typical sofa bed includes a folded steel frame on which is placed a thin mattress. There are seating cushions positioned on the folded frame with the mattress sandwiched within the folded frame. The folded frame includes a number of pivotally linked steel arms and struts to move the folded frame over a fixed sofa footboard to an extended position, where it serves as the mattress bedframe. By virtue of this design, sofa beds are heavy, and typically are not shipped in a knocked-down state, but rather fully assembled. This in turn makes shipment expensive and movement into the home difficult.

[0006] Relatedly, the amount of storage space available in smaller dwellings is necessarily limited. It is therefore also desirable that furniture be utilizable for the storage of items such as clothing, recreational gear, etc., to reduce clutter. Conventional sofa beds provide nothing to offer in this respect, since their interior portions are largely occupied by the folded frame and mattress. SUMMARY OF THE INVENTION

[0007] The present invention describes advancements in couch design. When in a disassembled state, the components of the couch described herein can be positioned to yield a compact shipping configuration, yet quickly assembled without requiring use of any tools, to provide a rigid structure. In addition, when in the assembled state the couch described herein can be utilized in the home both as a couch for daytime use, and also as a bed for night time use, without the need to pull out a folded steel bed frame. In addition, the couch provides ample storage, which is available to the user even when the couch is positioned against a wall, and whether or not the couch is being used as a bed.

[0008] In one aspect, the present invention is directed to a couch comprising a planar rectangular box base having a first box base edge, a second box base edge opposed to the first box base edge, a third box base edge, and a fourth box base edge opposed to the third box base edge; a planar rectangular forward foundation support panel having a forward support top edge, a first forward support side edge and a second forward support side edge opposed to the first forward support side edge; and a planar rectangular rear foundation support panel having a rear support top edge, a first rear support side edge and a second rear support side edge opposed to the first rear support side edge. A first hinge element joins the forward foundation support panel to the box base proximate to the first box base edge to permit the forward foundation support panel to be rotated between an unfolded position perpendicular to the box base and a folded position lying flat against the box base, and a second hinge element joins the rear foundation support panel to the box base proximate to the box base second edge to permit the rear foundation support panel to be rotated between an unfolded position perpendicular to the box base and a folded position lying flat against the box base. There is also provided a planar rectangular foundation, and a third hinge element joins the foundation to the forward foundation support panel to permit the foundation to be rotated between an open position where the foundation is positioned above the rear support top edge and a closed position where the foundation rests on the forward support top edge and the rear support top edge. There is further provided a planar rectangular first side support panel abutting the third box base edge, the first forward support side edge and the first rear support side edge; and a first connector assembly having a first tapered pin portion with a first centerline that is positioned in a first tapered barrel portion, with the first tapered pin portion being displaceable along the first centerline to be inserted and removed from the first tapered barrel portion. A first of the first tapered pin portion and first tapered barrel portion is fastened proximate to the first forward support side edge and a second of the first tapered pin portion and first tapered barrel portion is fastened to the first side support panel. There is additionally provided a second connector assembly having a second tapered pin portion with a second centerline that is positioned in a second tapered barrel portion, with the second tapered pin portion being displaceable along the second centerline to be inserted and removed from the second tapered barrel portion. A first of the second tapered pin portion and first tapered barrel portion is fastened proximate to the first rear support side edge and a second of the second tapered pin portion and second tapered barrel portion is fastened to the second side support panel.

[0009] In accordance with embodiments of the present disclosure, an exemplary couch is provided. The couch includes a planar rectangular box base having a first box base edge, second a box base edge opposed to the box base first edge, a third box base edge, and a fourth box base edge opposed to the box base third edge. The couch includes a planar rectangular forward foundation support panel having a forward support top edge, a first forward support side edge and a second forward support side edge opposed to the first forward support side edge. The couch includes a planar rectangular rear foundation support panel having a rear support top edge, a first rear support side edge and a second rear support side edge opposed to the first rear support side edge. The couch includes a first hinge element joining the forward foundation support panel to the box base proximate to the first box base edge to permit the forward foundation support panel to be rotated between an unfolded position perpendicular to the box base and a folded position lying flat against the box base. The couch includes a second hinge element joining the rear foundation support panel to the box base proximate to the box base second edge to permit the rear foundation support panel to be rotated between an unfolded position perpendicular to the box base and a folded position lying flat against the box base. The couch includes a planar rectangular foundation. The couch includes a third hinge element joining the foundation to the forward foundation support panel to permit the foundation to be rotated between an open position where the foundation is positioned above the rear support top edge and a closed position where the foundation rests on the forward support top edge and the rear support top edge. The couch includes a planar rectangular first side support panel abutting the third box base edge, the first forward support side edge and the first rear support side edge. The couch includes a first connector assembly having a first tapered pin portion having a first centerline and positioned in a first tapered barrel portion, the first tapered pin portion being displaceable along the first centerline to be inserted and removed from the first tapered barrel portion. The couch includes a first of the first tapered pin portion and first tapered barrel portion fastened proximate to the first forward support side edge and a second of the first tapered pin portion and first tapered barrel portion fastened to the first side support panel. The couch includes a second connector assembly having a second tapered pin portion having a second centerline and positioned in a second tapered barrel portion, the second tapered pin portion being displaceable along the second centerline to be inserted and removed from the second tapered barrel portion. The couch includes a first of the second tapered pin portion and first tapered barrel portion fastened proximate to the first rear support side edge and a second of the second tapered pin portion and second tapered barrel portion fastened to the second side support panel.

[0010] The couch can include a mattress positioned on the foundation. The couch can include a planar rectangular back panel, and a fourth hinge element joining the foundation to the back panel to permit the back panel to be rotated between an unfolded position where the back panel is angularly disposed relative to the foundation and a folded position where back panel rests on the foundation. The couch can include a cushion removably fastened to the back panel. The cushion can be fastened to the back panel with a hook and loop fastener.

[0011] The couch can include a planar rectangular second side support panel abutting the fourth box base edge, the second forward support side edge and the second rear support side edge, and a third connector assembly having a third tapered pin portion having a third centerline and positioned in a third tapered barrel portion, the third tapered pin portion being displaceable along the third centerline to be inserted and removed from the third tapered barrel portion. The couch can include a first of the third tapered pin portion and third tapered barrel portion fastened proximate to the second forward support side edge and a second of the third tapered pin portion and third tapered barrel portion fastened to the second side support panel. The couch can include a fourth connector assembly having a fourth tapered pin portion having a fourth centerline and positioned in a fourth tapered barrel portion, the fourth tapered pin portion being displaceable along the fourth centerline to be inserted and removed from the fourth tapered barrel portion. The couch can include a first of the fourth tapered pin portion and fourth tapered barrel portion fastened proximate to the second rear support side edge and a second of the fourth tapered pin portion and fourth tapered barrel portion fastened to the second side support panel. [0012] The couch can include side cushioning affixed to the first side support panel. The side cushioning can extend along an interior side and exterior side of the first side support panel. The couch can include side cushioning affixed to the first side support panel. The side cushioning can extend along an interior side and exterior side of the first side support panel. The side cushioning can extend from above mattress along the interior side of the first side panel beginning at a top edge of the mattress, around over the top edge of the first side panel and down the exterior side of the first side panel. The couch can include a strut joined to the back support panel and the foundation. The strut can be removable, foldable or slidable.

[0013] In accordance with embodiments of the present disclosure, an exemplary couch is provided. The couch includes a planar rectangular box base, and a pair of planar rectangular foundation support panels attached to opposing edges of the planar box base via first hinges. The couch includes a planar rectangular foundation attached to one of the planar rectangular foundation support panels via second hinges. The couch includes a planar back support attached to the planar rectangular foundation third hinges. In a disassembled state, the planar rectangular box base, the pair of planar rectangular foundation support panels, the planar rectangular foundation, and a planar back support are rotated about the first, second, and third hinges to lay flat on one another in a stack.

[0014] The couch can include a planar rectangular first side support panel, and a planar rectangular second side support. In an assembled state, the planar rectangular box base, the pair of planar rectangular foundation support panels, the planar rectangular foundation, and a planar back support are unfolded about the first, second, and third hinges, and the pair of foundation support panels are connected to the planar rectangular first side support panel at one of end of a length of the pair of planar rectangular foundation support panels and are connected to the planar rectangular second side support panel at an opposite of end of the length of the pair of planar rectangular foundation support panels.

[0015] These and other aspects of the present invention are described in the drawings annexed hereto, and in the description of the preferred embodiments and claims set forth below. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] FIG. 1A is a perspective view of the couch of the present invention, FIG. IB is a perspective view of the couch of the present invention with the mattress and back cushions removed, and FIG. 1C is an exploded perspective view of the couch of the present invention.

[0017] FIGS. 2A, 2B and 2C are perspective views showing the sequence of opening the couch of the present invention, to expose the storage region contained therein.

[0018] FIG. 3 is a perspective view of the couch of the present invention, at approximately the same point in opening the couch as is shown in FIG. 2B, with one of the side panels omitted for purposes of illustration.

[0019] FIG. 4 is a front perspective view of the couch of the present invention, showing two connector assemblies joining the right-side edges of the foundation support panels to the abutting side support assembly.

[0020] FIG. 5A depicts the male portion of a connector assembly, and FIG. 5B depicts a female portion of a connector assembly positioned in a rabbet located at the junction between the upper edge and a vertical edge of a foundation support panel.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] The components of couch 10 of the present invention, shown in FIGS. 1A-1C, include a mattress 900, a foundation 100, two foundation support panels 200, a box base 400, a back support assembly 500, and two side support assemblies 600. Couch 10 is able to assume two states: an assembled state and an disassembled state. In the assembled state shown in FIG. 1A, couch 10 can be utilized in the home either as a bed or a couch, and with ample storage available to the user in either configuration. In the disassembled state, couch 10 forms a compact package to facilitate shipping and movement in the dwelling.

[0022] Back support assembly 500 comprises a back panel 501 and back cushioning 506, and each side support assembly 600 comprises a side panel 601 and side cushioning 606. Each of foundation 100, foundation support panels 200, box base 400, back panel 501 and side support panels 601 is a rigid planar rectangular or square structure. The foundation 100, box base 400 and foundation support panels 200 are of equal length, whereas in the embodiment shown in the figures the width of foundation 100 is greater than the width of box base 400. It is preferred that the width of foundation 100 be the same as the width of a standard small single mattress. As an example, the width of the foundation can be the same as the width of a standard small single mattress in the United States and Canada, for example thirty inches (76 cm). Likewise it is preferred that the length of foundation 100 (along with box base 400 and foundation support panels 200) be the same as the length of a standard small single mattress. As an example, the length of foundation 100 (along with box base 400 and foundation support panels 200) can be the same of the length of a standard small single mattress in the United States and Canada, for example 75 inches (191 cm).

[0023] Foundation support panels 200 include a forward foundation support panel 210 that is secured to a first edge of box base 400 using one or more hinges 215, which enables forward foundation support panel 210 to be rotated from an unfolded position, shown in FIG. 3 and elsewhere, to a folded position. In the unfolded position, the forward foundation support panel 210 is vertically oriented perpendicular to the plane of box base 400, and in the folded position, forward foundation support panel 210 resides lying generally flat and horizontally against box base 400. The hinges 215 are secured to the interior surface 410 adjacent the first edge of box base 400 and to the interior surface 212 of forward foundation support panel 210, but inset a select distance from the bottom of forward foundation support panel 210; for example, inset distance “A” shown in FIG. 3. Thus the first edge of box base 400 acts as a “stop” to prevent further rotation of forward foundation support panel 210 beyond the fully unfolded position (e.g., in the depicted embodiment, preventing forward foundation support panel 210 from rotating beyond an interior angle of approximately 90 degrees (90°) between the forward foundation support panel 210 and the box base 400).

[0024] Foundation support panels 200 also include a rearward foundation support panel 220 that is secured to a second edge of box base 400, which is opposed to the first edge of box base 400, using one or more hinges 225, which enables forward foundation support panel 220 to be rotated from an unfolded position, shown in FIG. 3 and elsewhere, to a folded position. In the unfolded position, rearward foundation support panel 220 is vertically oriented perpendicular to the plane of box base 400, and in the folded position, rearward foundation support panel 220 resides lying generally flat and horizontally against box base 400. The hinges 225 are secured to the interior surface 410 adjacent the second edge of box base 400 and to the interior surface 222 of rearward foundation support panel 220, but inset a select distance from the bottom of rearward foundation support panel 220; for example, inset distance “A” in FIG. 3. Thus the second edge of box base 400 acts as a “stop” to prevent further rotation of rearward foundation support panel 220 beyond the fully unfolded position (e.g., in the depicted embodiment, preventing rearward foundation support panel 220 from rotating beyond an interior angle of approximately 90 degrees (90°) between the rearward foundation support panel 220 and the box base 400).

[0025] As described herein, when the couch 10 is disassembled, the foundation support panels 200 are folded inward towards each other to their folded positions and generally lay next to each other on the box base 400 such that the foundation support panels and the box base 400 form a compact stack.

[0026] When the couch 10 is fully assembled, the foundation support panels 200 are in their unfolded positions and foundation 100 rests in a closed position against a top edge of forward foundation support panel 210 and a top edge of rearward foundation support panel 220. FIG. IB depicts foundation 100 in this closed position. The foundation 100 is secured to the top edge of forward foundation support panel 210 using one or more hinges 415, which enables foundation 100 to be rotated from the closed position, where it resides in a horizontal orientation against the top edges of the foundation support panels 200, as shown from the rear in FIG. 2A, through a partly open position (FIG. 2B) to a fully open position, as shown in FIG. 2C. The hinges 415 are secured to the exterior surface of forward foundation support panel 210 adjacent the top edge of forward foundation support pane 210 and to the bottom surface 110 of foundation 100, but inset a select distance from the forward edge of foundation 100; for example, inset distance “B” shown in FIG. 3. An elongate retainer tab 135, which extends away from the top surface (surface 111) of foundation 100, can optionally be fastened to foundation 100 at its forward edge to assist in keeping mattress 900 in place.

[0027] When the couch 10 is disassembled, the foundation 100 can be rotated about hinges 415 to lay flat on top of foundation support panels 200, which in their folded positions lay flat on the base box 400, such that the foundation 100, the foundation support panels 200, and the box base 400 form a compact stack.

[0028] The hinged structural connections among box base 400 and foundation support panels 200 are rigidified by side supports 600, with a first side support assembly 600 abutting a first set of coplanar edges of box base 400 and foundation support panels 200 (the set of edges to the right, when sitting on couch 10 in the normal posture), and a second side support assembly 600 abutting a second set of coplanar edges of box base 400 and foundation support panels 200 (the set of edges to the left, when sitting on couch 10 in the normal posture). In particular, the interior surface of a first side panel 601 (part of the first side support assembly 600) is positioned abutting the right-side vertical edges of foundation support panels 200, and the interior surface of a second side panel 601 (part of the second side support assembly 600) is positioned abutting the left-side vertical edges of foundation support panels 200.

[0029] Two connector assemblies 615 join each of the right-side and left-side vertical edges of foundation support panels 200 to the side panel which foundational support panels 200 abut. Each connector assembly 615 comprises a male portion 617 that is received in and mates with a female portion 621. In particular, each male portion 617 includes a tapered cylindrical truncated cone 617, which is received in a corresponding tapered cylindrical barrel 622 formed in female portion 621. Referring to FIG. 5B as an example, the top and bottom of each vertical side of each foundation support panel 200 is provided with a rabbet cut to receive the female portion 621 (four female portions 621 for each foundation support panel 200), where the female portions 621 are each secured in one of the rabbet cuts as for example by screws. Likewise four male portions 616 are secured to the interior surface 612 of each side support 600 at positions to engage with the corresponding four female portions 621 on the vertical sides of each foundation support panel 200, as shown for one side in FIG. 4. The mated portions 616, 621 are not permanently fastened together, so that the user can separate and join each side support 600 from the foundation support panels 200 as desired.

[0030] Back support panel 501 is secured to the top surface 111 of foundation support 100 using one or more hinges 515, which enables back support panel 501 to be rotated from an unfolded position, shown for example in FIG. IB, to a folded position where it rests flat against the upper surface of foundation 100. The hinges 515 are secured to the front surface of back support panel 501 adjacent to its bottom edge, and to the top surface 111 of foundation 100 inset a select distance approximately equal to the thickness of back support panel 101 in the embodiment shown. This arrangement permits top surface 111 of foundation 100 to act as a “stop” preventing rotation of back support panel 501 beyond the fully unfolded position. In addition, a strut 525 can be used to join the adjacent vertical edges of back support panel 501 to the adjacent horizontal edge of foundation 100, as shown in FIGS. IB and 2B-2C. Use of struts 525 provides an additional support for back support 500 when in use. The struts can be removable, foldable or slidable as desired to permit the rotation of back support panel 501 to its folded position. Back cushioning 506 can be removably fastened to back support panel 501 using for example hook and loop fasteners. [0031] When the couch 10 is disassembled, the back support 501 can be rotated about the one or more hinges 515 to its folded position lying flat on the upper surface of the foundation 100, such that the back support 501, the foundation 100, the foundation support panels 200, and the base box 400 form a compact stack of interconnected components (via hinges) which has an aggregate thickness of the thickness of the base box 400, one of the foundation support panels 200, the foundation 100, and the back support 501.

[0032] The side cushioning 606 of each side support assembly 600 extends along the interior and exterior sides of the side panel 601 of that assembly 600, starting from above mattress 900 on the interior side of side panel 601, around over the top edge and down the exterior side, where it terminates for example above the floor, as shown in FIG. 1A.

[0033] Foundation 100, foundation support panels 200, box base 400, back panel 501 and side support panels 601 can be formed of plywood, medium density fiber board (MDF), plastic and such other similar materials as have a hard surface and are resistive to bending.

[0034] When disassembled and appropriately positioned together, the components of couch 10 apart from the mattress 900 form a compact package. In particular, there are five major interlinked components - back support panel 501, foundation 100, foundation support panels 200 and box base 400 - which are readily folded flat and stacked together. At the same time, they can be quickly unfolded and rigidified to form a strong rectangular structure by appropriately positioning the side support assemblies 600. In addition, when assembled, couch 10 includes a storage region 231, shown in FIGS. 2B and 5, which is accessible to the user simply by pulling on the integral pull handles 535 located proximate to each of the two junctions between the top and vertical edges of back panel 501.

[0035] The foregoing detailed description is for illustration only and is not to be deemed as limiting the inventions disclosed herein, which are defined in the appended claims.