FLAT-PACK CHAIR HAVING TOOL-FREE ASSEMBLY

CROSS REFERENCE TO RELATED APPLICATIONS

[0001]This application claims the priority benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application No. 63/592,021 filed 20 Oct. 2023, hereby incorporated by reference in its entirety as though fully set forth herein.

TECHNICAL FIELD

[0002]The subject matter described herein relates to a flat-pack chair that is manually assembleable without tools. This flat-pack chair has particular but not exclusive utility for outdoor use.

BACKGROUND

[0003]The concept of flat-pack furniture is known, wherein the design of a piece of furniture can be reduced to components that store flat in, for example, a cardboard box. Flat-pack design may be used for example to reduce the end-user cost of furniture by reducing a piece of furniture's shipping volume and therefore its shipping and storage costs. However, flat-pack furniture is generally expected to be assembled by the end-user, and assembly steps and instructions can be complex and time consuming, requiring significant time and space to complete. To overcome this challenge, services such as TaskRabbit exist to hire out furniture assembly services, which can then erode much of the cost savings associated with flat-pack designs. It is therefore to be appreciated that such commonly used flat-pack furniture has numerous drawbacks, including complexity, cost, assembly time, and otherwise. Accordingly, long-felt needs exist for improved flat-pack furniture that addresses the forgoing and other concerns.

[0004]The information included in this Background section of the specification, including any references cited herein and any description or discussion thereof, is included for technical reference purposes only and is not to be regarded as subject matter by which the scope of the disclosure is to be bound.

SUMMARY

[0005]Disclosed is a flat-pack chair that is assembleable from four flat-pack components, without tools, in only three steps. The flat-pack chair disclosed herein has particular, but not exclusive, utility for outdoor use, such as yards, porches, campsites, or surrounding or adjacent to a firepit.

[0006]One general aspect includes a furniture piece. The furniture piece includes a first furniture subassembly. The piece also includes a first fitting on the first furniture subassembly. The piece also includes a second furniture subassembly. The piece also includes a second fitting on the second furniture subassembly, the second fitting being selectively attachable to the first fitting to secure the first furniture subassembly to the second furniture subassembly. One of the first fitting and the second fitting is a sliding interference slot with an open end and a blind end, and the other of the first fitting and the second fitting is a sliding tongue slidably introducible in the open end of the interference slot.

[0007]Implementations may include one or more of the following features. In some embodiments, the sliding interference slot is one of T-shaped, L-shaped, or dovetail shaped. In some embodiments, the first fitting and the second fitting snap into place. In some embodiments, the first fitting may include one of a protrusion and a detent and the second fitting may include the other of the protrusion and the detent. In some embodiments, the second fitting is attached to the second furniture subassembly. In some embodiments, the first furniture subassembly may include a first frame having multiple, spaced first fittings thereon, and the second furniture subassembly may include a second frame having multiple, spaced second fittings spaced thereon to simultaneously secure to the multiple, spaced first fittings. In some embodiments, the sliding interference slot includes: a lengthwise opening extending from the open end toward the blind end, a lengthwise recess accessible through the lengthwise opening, the lengthwise opening having a first width and the lengthwise recess having a second width greater than the first width. Implementations of the described techniques may include hardware or a method or process.

[0008]One general aspect includes a chair furniture piece. The chair furniture piece includes a side subassembly. The piece also includes a first fitting on the side subassembly. The piece also includes a seat subassembly. The piece also includes a second fitting on the seat subassembly, the second fitting being selectively attachable to the first fitting to secure the side subassembly to the seat subassembly. The piece also includes where one of the first fitting and the second fitting is a sliding interference slot with an open end and a blind end, and the other of the first fitting and the second fitting is a sliding tongue slidably introducible in the open end of the interference slot.

[0009]Implementations may include one or more of the following features. In some embodiments, the sliding interference slot is one of T-shaped, L-shaped, and dovetail shaped. In some embodiments, the first fitting and the second fitting snap into place. In some embodiments, the first fitting may include one of a protrusion and a detent and the second fitting may include the other of the protrusion and the detent. In some embodiments, the side subassembly may include a first frame having multiple, spaced first fittings thereon, and the seat subassembly may include a second frame having multiple, spaced second fittings spaced thereon to simultaneously secure to the multiple, spaced first fittings. In some embodiments, the sliding interference slot includes: a lengthwise opening extending from the open end toward the blind end, a lengthwise recess accessible through the lengthwise opening, the lengthwise opening having a first width and the lengthwise recess having a second width greater than the first width. Implementations of the described techniques may include hardware or a method or process.

[0010]One general aspect includes a chair that includes a first side subassembly. The chair also includes a second side subassembly. The chair also includes a seat subassembly attachable to the first side subassembly and the second side subassembly. The chair also includes a backrest subassembly attachable to the first side subassembly and the second side subassembly. The first side subassembly, the second side subassembly, the seat subassembly; and the backrest subassembly fit within a package having a total volume within a range of about 2.3 to 6.0 cubic feet, and being assemblable without the use of a tool.

[0011]Implementations may include one or more of the following features. In some embodiments, the first side subassembly is attachable to the seat subassembly, the second side subassembly is attachable to the seat subassembly, the backrest subassembly is attachable to both the first and the second armrest subassemblies, and the backrest subassembly is configured to abut but not attach to the seat subassembly. In some embodiments, the first side subassembly is attachable to the seat subassembly by snapping into place, the second side subassembly is attachable to the seat subassembly by snapping into place. Implementations of the described techniques may include hardware or a method or process.

[0012]One general aspect includes a furniture piece assembleable without the use of tools. The furniture piece includes a first furniture subassembly having a first fitting thereon. The piece also includes a second furniture subassembly having a second fitting thereon. The piece also includes the second fitting being shaped and sized to be selectively attachable to the first fitting to secure the first furniture subassembly to the second furniture subassembly.

[0013]Implementations may include one or more of the following features. In some embodiments, one of the first fitting and the second fitting is a sliding interference slot with an open end and a blind end, and the other of the first fitting and the second fitting is a sliding tongue slidably introducible in the open end of the interference slot. Implementations of the described techniques may include hardware or a method or process.

[0014]This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to limit the scope of the claimed subject matter. A more extensive presentation of features, details, utilities, and advantages of the flat-pack chair, as defined in the claims, is provided in the following written description of various embodiments of the disclosure and illustrated in the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015]Illustrative embodiments of the present disclosure will be described with reference to the accompanying drawings, of which:

[0016]FIG. 1 is a left side perspective view of an example flat-pack chair, in accordance with at least one embodiment of the present disclosure.

[0017]FIG. 2 is a left rear perspective view of an example flat-pack chair, in accordance with at least one embodiment of the present disclosure.

[0018]FIG. 3 is a left rear perspective exploded view of an example flat-pack chair, in accordance with at least one embodiment of the present disclosure.

[0019]FIG. 4A shows a first step in an assembly process for the flat-pack chair, in accordance with at least one embodiment of the present disclosure.

[0020]FIG. 4B shows a second step in an assembly process for the flat-pack chair, in accordance with at least one embodiment of the present disclosure.

[0021]FIG. 4C shows a third step in an assembly process for the flat-pack chair, in accordance with at least one embodiment of the present disclosure.

[0022]FIG. 5 is a perspective view of the backrest subassembly and left side subassembly of an example flat-pack chair, in accordance with at least one embodiment of the present disclosure,

[0023]FIG. 6 is a perspective view of a female slide-and-snap fitting and a male slide-and-snap fitting, in accordance with at least one embodiment of the present disclosure.

[0024]FIG. 7 is a perspective view of a female slide-and-snap fitting and a male slide-and-snap fitting, in accordance with at least one embodiment of the present disclosure.

[0025]FIG. 8 is a perspective view of a female slide-and-snap fitting and a male slide-and-snap fitting in a partially interlocked state, in accordance with at least one embodiment of the present disclosure.

[0026]FIG. 9 is a perspective view of a female slide-and-snap fitting and a male slide-and-snap fitting in a partially interlocked state, in accordance with at least one embodiment of the present disclosure.

[0027]FIG. 10 is a perspective view of a female slide-and-snap fitting and a male slide-and-snap fitting in a fully interlocked state, in accordance with at least one embodiment of the present disclosure.

[0028]FIG. 11 is a perspective view of a female slide-and-snap fitting and a male slide-and-snap fitting in a fully interlocked state, in accordance with at least one embodiment of the present disclosure.

[0029]FIG. 12 is a perspective view of a female slide-and-snap fitting and a male slide-and-snap fitting in a fully interlocked state, in accordance with at least one embodiment of the present disclosure.

[0030]FIG. 13A is a schematic, diagrammatic, cross-sectional view of a tongue-and-groove structure for the male slide-and-snap fitting and the female slide-and-snap fitting, in accordance with at least one embodiment of the present disclosure.

[0031]FIG. 13B is a schematic, diagrammatic, cross-sectional view of a tongue-and-groove structure for the male slide-and-snap fitting and the female slide-and-snap fitting, in accordance with at least one embodiment of the present disclosure.

[0032]FIG. 13C is a schematic, diagrammatic, cross-sectional view of a tongue-and-groove structure for the male slide-and-snap fitting and the female slide-and-snap fitting, in accordance with at least one embodiment of the present disclosure.

[0033]FIG. 14 is a bottom perspective view of a female slide-and-snap fitting fitted into a recess in the base or frame of the seat subassembly, in accordance with at least one embodiment of the present disclosure.

[0034]FIG. 15 is a bottom side perspective view of an example flat-pack chair in its flat, packable, unassembled configuration, in accordance with at least one embodiment of the present disclosure.

[0035]FIG. 16 is a left side perspective view of an example flat-pack chair, in accordance with at least one embodiment of the present disclosure.

[0036]FIGS. 17A and 17B are perspective views of an example snap fitting, in accordance with at least one embodiment of the present disclosure.

[0037]FIGS. 18A and 18B are perspective views of an example snap fitting, in accordance with at least one embodiment of the present disclosure.

[0038]FIG. 19 is a perspective view of an example flat-pack chair, in accordance with at least one embodiment of the present disclosure.

[0039]FIG. 20 is a perspective view of an example flat-pack chair with associated cushions, in accordance with at least one embodiment of the present disclosure.

[0040]FIG. 21 is a perspective view of an example flat-pack chair, in accordance with at least one embodiment of the present disclosure.

[0041]FIG. 22 is a perspective view of an example flat-pack chair, in accordance with at least one embodiment of the present disclosure.

[0042]FIG. 23 is a left side perspective view of an example flat-pack chair, in accordance with at least one embodiment of the present disclosure.

[0043]FIG. 24A is a side view of an example snap fitting, in accordance with at least one embodiment of the present disclosure.

[0044]FIG. 24B is a cross-sectional view of an example snap fitting, in accordance with at least one embodiment of the present disclosure.

[0045]FIG. 25 is a side view of an example snap fitting, in accordance with at least one embodiment of the present disclosure.

DETAILED DESCRIPTION

[0046]In accordance with at least one embodiment of the present disclosure, a flat-pack chair is provided which is assemblable from four flat-pack components, in minimal time and without the need for tools or user-manipulable fasteners. The flat-pack chair includes a right side subassembly and left side subassembly that slide and snap into place on a seat subassembly using slide and snap fittings, and a backrest subassembly that slides into a slot in the seat subassembly and forms a friction-fit attachment to the armrest assemblies by means of a pin on each side of the backrest and a receiver on each armrest. This novel and simple arrangement advantageously allows assembly of the chair in just three steps, including by novices with no prior experience with furniture assembly.

[0047]These descriptions are provided for exemplary purposes only, and should not be considered to limit the scope of the flat-pack chair. Certain features may be added, removed, or modified without departing from the spirit of the claimed subject matter.

[0048]For the purposes of promoting an understanding of the principles of the present disclosure, reference will now be made to the embodiments illustrated in the drawings, and specific language will be used to describe the same. It is nevertheless understood that no limitation to the scope of the disclosure is intended. Any alterations and further modifications to the described devices, systems, and methods, and any further application of the principles of the present disclosure are fully contemplated and included within the present disclosure as would normally occur to one skilled in the art to which the disclosure relates. In particular, it is fully contemplated that the features, components, and/or steps described with respect to one embodiment may be combined with the features, components, and/or steps described with respect to other embodiments of the present disclosure. For the sake of brevity, however, the numerous iterations of these combinations will not be described separately.

[0049]FIG. 1 is a left side perspective view of an example flat-pack chair 100, in accordance with at least one embodiment of the present disclosure. In the example shown in FIG. 1, the flat-pack chair 100 includes a right side subassembly or right armrest subassembly 110, a left side subassembly or left armrest subassembly 120, a seat subassembly 130, and a backrest subassembly 140. These four components can be snapped together without tools, in a three-step assembly process described below.

[0050]In an example, the right side subassembly 110, left side subassembly 120, seat subassembly 130, and backrest subassembly 140 are made of any suitable material. In some implementations, the subassemblies are formed of a rigid polymeric material that provides weather resistance and is lightweight, although other materials may be used instead or in addition, including but not limited to wood, metal, ceramics, composites, or combinations thereof.

[0051]Before continuing, it should be noted that the examples described above are provided for purposes of illustration, and are not intended to be limiting. Other devices and/or device configurations may be utilized to carry out the operations described herein.

[0052]FIG. 2 is a left rear perspective view of an example flat-pack chair 100, in accordance with at least one embodiment of the present disclosure. Visible are the right side subassembly 110, left side subassembly 120, seat subassembly 130, and backrest subassembly 140. In the example shown in FIG. 2, the backrest subassembly includes a left backrest portion 242 and a right backrest portion 244, as well as a top slat 246, middle slat 248, and bottom slat 249 that attach the left backrest portion 242 to the right backrest portion 244. The middle slat 240 also attaches the backrest subassembly 140 to the left side subassembly 120 and right side subassembly 110, as described below. The bottom slat 249 rests on the seat subassembly 130. Depending on the implementation, the left backrest portion 242, right backrest portion 244, top slat 246, middle slat 248, and bottom slat 249 may be attached together (e.g., with adhesive, fasteners, or otherwise), or may be formed as a single piece (e.g., by injection molding).

[0053]FIG. 3 is a left rear perspective exploded view of an example flat-pack chair 100, in accordance with at least one embodiment of the present disclosure. Visible are the right side subassembly 110, left side subassembly 120, seat subassembly 130, and backrest subassembly 140. In the example shown in FIG. 3, the left and right armrest assemblies each include an armrest 312, front vertical support 314, diagonal support 316, horizontal support 318, and rear vertical support 319. The armrest 312, front vertical support 314, diagonal support 316, horizontal support 318, and rear vertical support 319 may for example be attached together as shown (e.g., with adhesive, fasteners, or otherwise), or may be formed as a single piece (e.g., by injection molding, 3D printing, or otherwise). Although each subassembly may be formed of multiple components, these multiple components are fixed together in a manner that results in subassemblies described herein. That is, they are shipped and provided to consumers in subassembly forms for simple assembly together to form the chair 100 without the use of tools.

[0054]In the example shown, the left and right armrest assemblies each include three male snap fittings 350 that form a slide-and-snap fit with three female snap fittings 360 located on the left and right sides of the seat subassembly 130, as described below.

[0055]The left side subassembly 120 and right side subassembly 110 may for example be mirror images of each other. It is understood that, depending on the implementation, the male snap fittings 350 may be located on the seat subassembly 130 and the female snap fittings 160 may be located on the armrest assemblies, or some male snap fittings 350 may be located on the seat subassembly and some on the armrests, and some female snap fittings 360 may be located on the seat subassembly and some on the armrest assemblies, as would occur to a person of ordinary skill in the art. Other numbers of snap fitting pairs 350, 360, may be used instead or in addition, including but not limited to one pair, two pairs, four pairs, or five pairs.

[0056]In the example shown in FIG. 3, the seat subassembly 130 includes a base 339, across which are affixed a front slat 332, middle slat 334, and rear slat 338. The base 339, front slat 332, middle slat 334, and rear slat 338 may for example be attached as shown (e.g., with adhesive, fasteners, or otherwise), or may be formed as a single piece (e.g., by injection molding, 3D printing, or otherwise). The female snap fittings 160 are shown disposed in the sides of the base 339. Between the middle slat 334 and the read slat 338 is a receiving slot 336 that is configured to receive the lower portion 346 of the backrest subassembly 140.

[0057]The backrest subassembly 140 also includes friction pins 370 that are configured to form a friction fit with receiving holes 380 in each of the left and right armrest assemblies.

[0058]FIG. 4A shows a first step in an assembly process for the flat-pack chair 100, in accordance with at least one embodiment of the present disclosure. In the first assembly step, the seat subassembly 130 is snap-fit to the left side subassembly 120 using the male and female slide-and-snap fittings 350, 360, as shown above and as described below.

[0059]FIG. 4B shows a second step in an assembly process for the flat-pack chair 100, in accordance with at least one embodiment of the present disclosure. In the second assembly step, the seat subassembly 130 is snap-fit to the right side subassembly 110 using the male and female slide-and-snap fittings 350, 360, as shown above and as described below.

[0060]FIG. 4C shows a third step in an assembly process for the flat-pack chair 100, in accordance with at least one embodiment of the present disclosure. In the third assembly step, the backrest subassembly 140 is fitted into the receiving slot 336 (see FIG. 3) and is friction-fit to the left side subassembly 120 and the right side subassembly 110 using the friction pins 270 and receiving holes 380 as shown above and as described below.

[0061]FIG. 5 is a perspective view of the backrest subassembly 140 and left side subassembly 120 of an example flat-pack chair, in accordance with at least one embodiment of the present disclosure. In the example shown in FIG. 5, the pin 370 projects downward from a tab 570 projecting leftward from the middle slat 248 of the backrest subassembly. The tab 570 is configured to fit into a notch 580 in the armrest 312 of the left side subassembly 120, such that the tab 570 and notch 580, along with the friction pin 370 and receiving hole 380, form the friction fit between the backrest subassembly 140 and the left side subassembly 120. In an example, a mirror-image tab 570 and pin 370 occur on the right side of the backrest subassembly 140, and a mirror-image notch 580 and receiving hole 380 occur on the right side subassembly.

[0062]FIG. 6 is a perspective view of a female slide-and-snap fitting 360 and a male slide-and-snap fitting 350, in accordance with at least one embodiment of the present disclosure. In the example shown in FIG. 6, the female slide-and-snap fitting 360 includes a lengthwise trapezoidal recess 610 with an open end 612 and a blind end 614. The recess 610 is supported by a body or lateral flanges 615 that extend about three sides of the recess 610, as well as a number of through holes 620 formed through the flanges 615 for attaching the female slide-and-snap fitting 360 to the base of the seat assembly with fasteners. The male slide-and-snap fitting 350 includes a trapezoidal tongue 630 supported by a body or lateral flanges 631 that extend about three sides of the tongue 360, and a number of countersunk through holes 650 formed through the flanges 631, and a pair of snap protuberances 640. In some embodiments, the through holes 620, 650 may not be present, and the slide and snap fittings 350, 360 may be formed as part of the armrest subassemblies and the seat subassembly, respectively.

[0063]The shape of the trapezoidal recess 610 and trapezoidal tongue 630 means they are wider at the open end 612, such that a novice user can line up the female slide-and-snap fitting 360 onto the male slide-and-snap fitting 350 more easily than if the recess 610 and tongue 630 were rectangular in shape. This aids the user in assembling the seat subassembly onto the left and right armrest subassemblies. This is also helpful when, as in the example shown in FIG. 3, there are multiple slide-and-snap fitting 360 that all must align together to enable the subassemblies to be snapped in place.

[0064]In an example, the female slide-and-snap fitting 360 and male slide-and-snap fitting 350 are made from a plastic such as acrylonitrile butadiene styrene (ABS), although other materials may be used instead or in addition, including but not limited to wood, metals, ceramics, or composites.

[0065]FIG. 7 is a perspective view of a female slide-and-snap fitting 360 and a male slide-and-snap fitting 350, in accordance with at least one embodiment of the present disclosure. Visible are the trapezoidal recess 610, trapezoidal tongue 630, and through-holes 620, 650. In the example shown in FIG. 7, the trapezoidal recess 610 of the female slide-and-snap fitting 360 includes a dovetail-shaped interference groove 710, and the trapezoidal tongue 630 of the male slide-and-snap fitting 350 includes a dovetail-shaped ridge 720 configured to interlock with the dovetail-shaped interference groove 710, such that the male slide-and-snap fitting 350 is retained by friction when slid into the female slide-and-snap fitting 360. In addition, the female slide-and-snap fitting 360 includes a pair of detents or snap recesses 740 configured to interlock with the snap protuberances 640 of the male slide-and-snap fitting, such that the male slide-and-snap fitting 350 is retained firmly by the snap protuberances 640 when slid into the female slide-and-snap fitting 360. Thus, when the seat subassembly is attached to the armrest subassemblies, the subassemblies are retained together by the slide-and-snap fittings 350, 360.

[0066]FIG. 8 is a perspective view of a female slide-and-snap fitting 360 and a male slide-and-snap fitting 350 in a partially interlocked state, in accordance with at least one embodiment of the present disclosure. In the example shown in FIG. 8, the dovetail-shaped ridge 720 (not visible) is interlocked with the dovetail-shaped interference groove 710 (not visible), such that the female slide-and-snap fitting 360 and a male slide-and-snap fitting 350 can slide with respect to one another along a slide axis 910, but cannot move with respect to one another in any other direction. One of the snap protuberances 640 of the male slide-and-snap fitting 350 is visible.

[0067]In the configuration shown in FIG. 3, the female slide-and-snap fitting 360 and male slide-and-snap fitting 350 are oriented such that any weight on the seat subassembly presses the female slide-and-snap fitting 360 and male slide-and-snap fitting 350 together rather than apart along the slide axis 910, thus providing a sturdy weight-bearing structure.

[0068]FIG. 9 is a perspective view of a female slide-and-snap fitting 360 and a male slide-and-snap fitting 350 in a partially interlocked state, in accordance with at least one embodiment of the present disclosure. One of the snap protuberances 640 of the male slide-and-snap fitting 350 is visible.

[0069]FIG. 10 is a perspective view of a female slide-and-snap fitting 360 and a male slide-and-snap fitting 350 in a fully interlocked state, in accordance with at least one embodiment of the present disclosure. In the example shown in FIG. 10, the dovetail-shaped ridge 720 is interlocked with the dovetail-shaped interference groove 710, and the snap protuberances 640 (not visible) of the male slide-and-snap fitting 350 are interlocked with the detents or snap recesses 740 (not visible) of the female slide-and-snap fitting 360, such that the male slide-and-snap fitting 350 and the female slide-and-snap fitting 360 can no longer move with respect to one another in any direction, and thus form a sturdy weight-bearing connection (e.g., between the seat subassembly and the left or right armrest assembly).

[0070]In an example, the load-bearing capacity of six sets of male and female slide-and-snap fittings, and thus of the flat-pack chair as a whole, is in a range of about 100-600 pounds.

[0071]FIG. 11 is a perspective view of a female slide-and-snap fitting 360 and a male slide-and-snap fitting 350 in a fully interlocked state, in accordance with at least one embodiment of the present disclosure.

[0072]FIG. 12 is a perspective view of a female slide-and-snap fitting 360 and a male slide-and-snap fitting 350 in a fully interlocked state, in accordance with at least one embodiment of the present disclosure.

[0073]In some the implementation of FIG. 3, the female slide-and-snap fitting 360 is disposed on the base 339 of the chair subassembly 130 and the male slide-and-snap fitting 350 is disposed on the side subassembly. In some implementations, the base 339 includes cutouts that receive the female slide-and-snap fitting 360 or the male slide-and-snap fitting 350. These cutouts may be recesses having a depth that is about the same depth as the flanges 615, 631 of the respective slide-and-snap fittings 350, 360. As such, the surfaces of the flanges on the slide-and-snap fittings may be about flush with the surfaces of the respective base 339 or diagonal support 316. In this manner, even when assembled, any gap between sides of the base 339 and the diagonal support 316 may be minimized.

[0074]FIG. 13A is a schematic, diagrammatic, cross-sectional view of a tongue-and-groove structure for the male slide-and-snap fitting 350 and the female slide-and-snap fitting 360, in accordance with at least one embodiment of the present disclosure. In a first embodiment, the tongue 720 and interference groove 710 are dovetail-shaped as described above. However, other possible configurations may be used instead or in addition.

[0075]FIG. 13B is a schematic, diagrammatic, cross-sectional view of a tongue-and-groove structure for the male slide-and-snap fitting 350 and the female slide-and-snap fitting 360, in accordance with at least one embodiment of the present disclosure. In a second embodiment, the tongue 1220 and groove 1210 are both T-shaped.

[0076]FIG. 13C is a schematic, diagrammatic, cross-sectional view of a tongue-and-groove structure for the male slide-and-snap fitting 350 and the female slide-and-snap fitting 360, in accordance with at least one embodiment of the present disclosure. In a third embodiment, the tongue 1320 and groove 1310 are both L-shaped. Other cross-sectional shapes are also possible and fall explicitly within the scope of the present disclosure.

[0077]FIG. 14 is a bottom perspective view of a female slide-and-snap fitting 360 fitted into a recess 1410 in the base or frame 339 of the seat subassembly 130, in accordance with at least one embodiment of the present disclosure. The recess is configured such that the female slide-and-snap fitting 360 sits flush along the surface of the frame 339.

[0078]FIG. 15 is a bottom side perspective view of an example flat-pack chair 100 in its flat, packable, unassembled configuration 1500, in accordance with at least one embodiment of the present disclosure. Visible are the right side subassembly 110, left side subassembly 120, seat subassembly 130, and backrest subassembly 140. In an example, the flat, packable, unassembled configuration 1600 has a length L that can range between 508 mm and 870 mm, a width W that can range between 508 mm and 634 mm, and a height H that can range between 253 mm and 308 mm. In this configuration, the flat-pack chair 100 can, for example, be stored and shipped in a cardboard box. Other dimensions or ranges of dimensions, both larger and smaller, may be used instead or in addition.

[0079]FIG. 16 is a left side perspective view of an example flat-pack chair 1600, in accordance with at least one embodiment of the present disclosure. The flat-pack chair 1600 is similar to the flat-pack chair 100, except that the seat subassembly 1630 is longer and contains more slats 1632 than the seat subassembly 130, and the side assemblies 1610 and 1620 do not include armrests. Rather, the side assemblies 1610, 1620 each include a top horizontal support 1612 that attaches to the seat subassembly 1630, a short front leg 1614, a bottom horizontal support 1618, and a tall rear leg 1619 that attaches to the backrest subassembly 1640.

[0080]FIG. 17A is a front perspective view of a male snap fitting 350, in accordance with at least one embodiment of the present disclosure. Visible are the trapezoidal tongue 630, flanges 631, snap protuberances 640, and through holes 650.

[0081]FIG. 17B is a rear side perspective view of the male snap fitting 350 of FIG. 17A, in accordance with at least one embodiment of the present disclosure. Visible in this view are a plurality of stiffening features 1710 formed into the male snap fitting 350. The stiffening features are formed ribs extending transversely across the snap fitting that provide structural support with minimal weight or material increase. As can be seen the formed ribs extend into the back opening forming a cavity in the male snap fitting and in the this implementation, also extend along an outer flat surface.

[0082]FIG. 18A is a front perspective view of a female snap fitting 360, in accordance with at least one embodiment of the present disclosure. Visible are the trapezoidal recess 610, blind end 614, lateral flanges 615, through holes 620, and detents or snap recesses 740.

[0083]FIG. 18B is a side perspective view of the female snap fitting 360 of FIG. 39A, in accordance with at least one embodiment of the present disclosure. Visible in this view are a plurality of stiffening features 1810 formed into the female snap fitting 360. The stiffening features 1810 are formed ribs that extend transversely to the direction of attachment of the male and female snap fittings. The ribs are spaced apart and provide structural support with minimal with or material increase.

[0084]FIG. 19 is a front side perspective view of another embodiment of the flat pack chair, configured as a love seat 1900, in accordance with at least one embodiment of the present disclosure. The love seat 1900 includes two side assemblies or armrest assemblies 1910, 1920, a seat subassembly 1930, and backrest subassembly 1940. The seat subassembly 1930 includes a seat deck front plank 1932, seat deck middle plank 1934, and seat deck rear plank 1936. For ease of assembly and carrying, the seat deck middle plank 1934 includes two handholds 1950. The backrest subassembly 1940 includes a right backrest plank 1942, two middle backrest planks 1944, and a left backrest plank 1946.

[0085]FIG. 20 is a front side perspective view of the love seat 1900 of FIG. 19, with the addition of two removable seat cushions 2010 and two removable backrest cushions 2020, in accordance with at least one embodiment of the present disclosure. The cushions 2010, 2020 may provide a more aesthetic appearance, as well as added comfort for occupants of the love seat 1900. In some embodiments, the cushions 2010, 2020 are not attached to the love seat 1900. In other embodiments, the cushions 2010, 2020 may be tied to the love seat 1900 with ties, attached via toggles that slide between panels of the backrest, or otherwise attached.

[0086]FIG. 21 is a bottom side perspective view of the love seat 1900 of FIGS. 19 and 20, in accordance with at least one embodiment of the present disclosure. Visible are the armrest assemblies or side assemblies 1910, 1920, seat deck planks 1932, 1934, and 1936, and handholds 1950. Also visible are two seat deck outer supports 2110, one seat deck inner support 2120, two seat deck legs 2130, and a seat deck leg support crossbrace 2140, which may collectively provide the additional support to hold two people on the flat-pack chair. In an example, the seat deck legs 2130 and the seat deck leg support crossbrace 2140 form a single subassembly that attaches to the seat deck outer supports 2110 by slide-and-snap fittings, although other arrangements are possible and fall explicitly within the scope of the present disclosure.

[0087]FIG. 22 is a bottom rear perspective view of the love seat 1900 of FIGS. 19-21, in accordance with at least one embodiment of the present disclosure. Visible are the armrest assemblies or side assemblies 1910, 1920, seat deck outer supports 2110, seat deck inner support 2120, seat deck legs 2130, and seat deck leg support crossbrace 2140. Also visible are the backrest right plank 1942, backrest inner planks 1944, backrest left plank 1945, and backrest cushions 2020.

[0088]A back rest brace 2248 is attached to and supports the backrest planks 1942, 1944, 1945, and is also attached to and supports a backrest top support 2246 to form the backrest subassembly 1940. This attachment may for example be with screws or other fasteners 2210, at the factory, such that the assembled backrest subassembly 1940 is shipped to the end user. A seat deck cross brace 2249 attaches to and/or indexes with the backrest planks 1942, 1944, 1945, the armrest assemblies or side assemblies 1910, 1920, the seat deck outer supports 2110, the seat deck inner support 2120, and the seat planks. A seat deck front crossbeam 2220 attaches to and/or indexes with the armrest assemblies or side assemblies 1920, the seat deck outer supports 2110, the seat deck inner support 2120, and the seat planks.

[0089]FIG. 23 is a rear perspective view of the love seat 1900 of FIGS. 19-22, in accordance with at least one embodiment of the present disclosure. In some embodiments, the backrest top support or gusset 2246 is angled such that its rearmost portion is higher than its forwardmost portion. This arrangement may increase the structural integrity of the love seat 1900.

[0090]FIG. 24A is a side view of an example screw-type snap fitting 2400, in accordance with at least one embodiment of the present disclosure. Depending on the implementation, the screw-type snap fitting may be used instead of or in addition to the slide-and-snap fitting of FIG. 6, to join two components or subassemblies together. In an example, the screw-type snap fitting attaches the backrest subassembly 140 to the left and right armrest subassemblies 110, 120, whereas the slide-and-snap fitting attaches the seat subassembly 130 to the left and right armrest subassemblies 110, 120. Other arrangements or combinations are possible and fall explicitly within the scope of the present disclosure.

[0091]The screw-type snap fitting 2400 includes a female portion or receiver 2410 and a male portion or pin 2420, which can be snapped together to join two parts, such as the seat subassembly 130 and an armrest subassembly 110. The female portion 2410 may for example be made of a polymer such as high-density polyethylene (HDPE). The female portion 2410 includes male threads 2430 and a non-threaded cavity 2440. The threads 2430 can be screwed into a threaded hole of appropriate size in a part such as the seat subassembly 130, such that the face 2445 of the female portion is flush with the surface of the part.

[0092]In some implementations, the male portion 2420 may be made predominantly of a polymer such as HDPE, and includes a pin portion 2450 configured to be received by the cavity 2440 of the female portion 2410. The male portion 2420 also includes a threaded portion 2470 separated from the pin portion 2450 by a collar 2455. The threaded portion 2470 can be screwed into a threaded hole of appropriate size in a part such as the armrest subassembly such that the collar 2455 is flush with the surface of the part. The pin portion 2450 of the male portion 2420 also includes at least one spring-loaded captive bearing or tab 2460 that is configured to be received by a detent in the cavity 2440 of the female portion 2410, such that the male portion 2420 and female portion 2410 are snapped together, thus attaching the two parts into which they've been screwed. In an example, the pin portion 2450 includes two spring-loaded captive bearings or tabs 2460, although in other embodiments it may include one, three, four, or more captive bearings or tabs 2460. In an example, separating the female portion 2410 and the male portion 2420, once they have been clicked together, requires more force than is likely to happen during normal handling, but that is within the capability of a person to generate without tools, if and when separation of the components is desired.

[0093]FIG. 24B is a side cross-sectional view of an example screw-type snap fitting 2400, in accordance with at least one embodiment of the present disclosure. Visible within the cavity 2440 of the female portion 2410 is a detent 2480 that is configured to receive the bearings or tabs 2460 of the male portion 2420. Also visible is a spring 2490 that loads the bearings 2460.

[0094]Screwing in the male portion 2420 and female portion 2410 into threaded or unthreaded holes preformed in parts such as the seat subassembly 130 and armrest subassembly 110 can be accomplished without tools, although tool guides 2499 may also be provided in the male portion 2420 and female portion 2410 to receive and cooperate with tools that may drive the male and female portions into the furniture subassemblies. In the example shown in FIG. 24B, the tool guides 2499 are hexagonal, such that hex wrenches may be used to screw in the male portion 2420 and female portion 2410. However, in other embodiments, the tool guides 2499 could be slots (e.g., for a slotted screwdriver), crosses (e.g., for a Philips screwdriver), or otherwise formed, as would occur to a person of ordinary skill in the art. It is further noted that the male portion 2420 and/or female portion 2410 can be threaded into joinable parts at the factory, such that the end-user does not need to perform this assembly step and thus does not require the tool guides or corresponding tools. Rather, the end user merely snaps the components together.

[0095]FIG. 25 is a side cross-sectional view of an example screw-type snap fitting 2400, in accordance with at least one embodiment of the present disclosure. In the example shown in FIG. 25, the female portion 2410 and male portion 2420 have been snapped together, e.g., to join together the respective parts into which they have been screwed. Visible is a bearing 2460 that is captive inside the detent 2480.

[0096]All dimensions and configurations shown in the present disclosure are exemplary. Other dimensions and configurations are possible that fall within the scope of the present disclosure. In some embodiments, the left and right side assemblies may be armrest subassemblies, as shown for example in FIGS. 1-5. In other embodiments, the left and right side assemblies may be non-armrest side assemblies, as shown for example in FIG. 16. Still other configurations are possible and fall within the scope of the present disclosure. Furthermore, the technology described herein may be applied to other furniture pieces or other types of furniture, including but not limited to tables, stools and benches.

[0097]As will be readily appreciated by those having ordinary skill in the art after becoming familiar with the teachings herein, the flat-pack chair of the present disclosure advantageously provides a sturdy weight-bearing structure that consists of only four flat-packable subassemblies that can be assembled together in only three steps, without the need for tools or complex instructions. When packed for shipping, these subassemblies can take up a volume of only 2.3-6.0 cubic feet, whereas the fully assembled chair can occupy a volume of 9.2 cubic feet to 14.2 cubic feet. Accordingly, it can be seen that the flat-pack chair fills a long-standing need in the art, by reducing the time and skill level required to assemble as compared with flat-pack furniture of comparable size and weight-bearing capacity.

[0098]A number of variations are possible on the examples and embodiments described above. For example, the flat-pack chair may be made of different materials than described herein, may be of different dimensions, may have a greater or smaller load bearing capacity, may have different numbers of legs, slats, or supports, and may have a different shape (e.g., Adirondack chair, deck chair, lounge chair, etc.), while still conforming to the principles described herein.

[0099]Accordingly, the logical operations making up the embodiments of the technology described herein are referred to variously as operations, steps, objects, elements, components, or modules. Furthermore, it should be understood that these may occur or be performed or arranged in any order, unless explicitly claimed otherwise or a specific order is inherently necessitated by the claim language.

[0100]All directional references e.g., upper, lower, inner, outer, upward, downward, left, right, lateral, front, back, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise, proximal, and distal are only used for identification purposes to aid the reader's understanding of the claimed subject matter, and do not create limitations, particularly as to the position, orientation, or use of the flat-pack chair. Connection references, e.g., attached, coupled, connected, joined, or “in communication with” are to be construed broadly and may include intermediate members between a collection of elements and relative movement between elements unless otherwise indicated. As such, connection references do not necessarily imply that two elements are directly connected and in fixed relation to each other. The term “or” shall be interpreted to mean “and/or” rather than “exclusive or.” The word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality. Unless otherwise noted in the claims, stated values shall be interpreted as illustrative only and shall not be taken to be limiting.

[0101]The above specification, examples and data provide a complete description of the structure and use of exemplary embodiments of the flat-pack chair as defined in the claims. Although various embodiments of the claimed subject matter have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of the claimed subject matter.

[0102]Still other embodiments are contemplated. It is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative only of particular embodiments and not limiting. Changes in detail or structure may be made without departing from the basic elements of the subject matter as defined in the following claims.