MODULAR SEATING ASSEMBLY

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority to U.S. Provisional Application No. 63/734,530, entitled MODULAR SEATING ASSEMBLY, filed on Dec. 16, 2024, the entirety of which is incorporated herein by reference.

BACKGROUND

1. Technical Field

The present disclosure relates generally to furniture systems, and more particularly to modular seat constructions that allow for adjustable pitch configurations, tool-free assembly and disassembly, and compact shipping. In certain implementations, the disclosure relates to modular seat bases, seat pans, and support frames configured to provide variable seating angles and enhanced user comfort while maintaining manufacturing and logistical efficiency.

2. Background and Relevant Art

Conventional modular furniture is often primarily designed around spatial flexibility rather than ergonomic customization. Typical modular seating systems allow users to add, remove, or rearrange units to fit a desired room layout, but the structural configuration of each module is generally uniform and unchangeable. This uniformity simplifies manufacturing and assembly, yet it limits a user's ability to personalize comfort or adjust seating ergonomics, i.e., by modifying the furniture after purchase better suit individual preferences or intended uses. Accordingly, in cases where a modular system may provide customization, it is often provided through different SKU variants of the interchangeable members. As a result, traditional modular assemblies can feel static, rigid, or ergonomically generic, offering little ability to tailor the seating experience beyond basic arrangement.

Additionally, weight and bulk remain persistent challenges in modular furniture. Modular bases are often constructed from solid or over-reinforced components to ensure structural stability across various configurations, which can make the furniture heavy and difficult to move. This can hinder both shipping efficiency and user maneuverability within a space. This can also cause shipping and packaging to be cumbersome, as large and irregularly shaped cushions and bases frequently require oversized cartons or multiple shipments.

Accordingly, there are a number of shortcomings in the field of modular furniture assemblies.

The subject matter described herein is not limited to embodiments that operate only in environments such as those described above. Rather, this background is only provided to illustrate one example technology area where some embodiments described herein can be practiced.

BRIEF SUMMARY

The present disclosure can comprise systems, methods, and apparatus for constructing modular seating assemblies for providing pitched or level seating. For example, a modular seating assembly configured for providing level or pitched seating, the modular seating assembly can include a seat base and a seat pan configured to provide a seating surface in: (i) a level configuration that is substantially parallel to a support surface on which the seat base is mounted; or (ii) a pitched configuration in which the seating surface is positioned at an angle relative to the support surface on which the seat base is mounted. The user can selectively mount the seat pan in the level configuration or the pitched configuration.

In another embodiment, a modular seating assembly configured for providing level or pitched seating, the modular seating assembly can include a seat base. The seat base can include a central frame where the central frame has an upper surface, a side panel where the side panel is secured to the central frame, and a corner pillar where the corner pillar comprises a shelf. The modular seating assembly can also include a seat pan configured to provide a seating surface, in: (i) a level configuration that is substantially parallel to a support surface on which the seat base is mounted; or (ii) a pitched configuration in which the seating surface is positioned at an angle relative to the support surface on which the seat base is mounted. Furthermore, when in the pitched configuration, the seat pan engages both the shelf and the upper surface.

In another embodiment, a modular seating assembly configured for providing pitched seating can include a seat base. The seat base can include a central frame having a first edge, a side panel secured to the first edge, and a corner pillar secured to a portion of the first edge. The seat pan can provide a seating surface in either a level configuration or a pitched configuration. Furthermore, the modular seating assembly can include an outer cover configured to wrap around the seat base, and the outer cover can include an insert, wherein the insert is configured to be positioned at a first end of the side panel when the outer cover is installed around the seat base.

In another embodiment, a seat pan for use in a modular seating assembly, the seat pan can include a central frame and a suspension means. The suspension means can include a non-stretching central region, a first stretching region that extends outward from the non-stretching central region, and a second stretching region that extends outward from the non-stretching central region in a direction opposite the first stretching region. The seat pan can also include a corner coupler. The first stretching region and the second stretching region can each elastically deform around the central frame to couple the suspension means to the central frame. Additionally, the corner coupler secures the suspension means to the central frame at a corner of the central frame.

In another embodiment, a modular seating assembly configured for providing pitched seating, the modular seating assembly can include a seat base. The seat base can include a first side panel and a second side panel positioned perpendicular to the first side panel. Further, an end of the first side panel and an end of the second side panel define a gap. The modular seating assembly can also include a removable outer cover. The removable outer cover can include an insert, and the insert can be positioned within the gap. Thus, the insert can provide a soft corner to the seat base.

Additional features and advantages of exemplary implementations of the invention will be set forth in the description which follows, and in part will be obvious from the description, or can be learned by the practice of such exemplary implementations. The features and advantages of such implementations can be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims, or can be learned by the practice of such exemplary implementations as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to describe the manner in which the above recited and other advantages and features of the invention can be obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1 illustrates corner supports configured to provide a degree of inclination or pitch to a seat pan; One corner support in each corner; One or more pitch options per support;

FIG. 2 illustrates a flat orientation of a metal seat pan; bi-directional spring and suspension system; and inward sloped frame members;

FIG. 3 illustrates a pitched orientation wherein two corners are at a top setting and two corners are at a bottom setting; Orientation agnostic, meaning it can have and one or two corners “dipped” or set to a lower setting while the rest are in an elevated setting;

FIG. 4 illustrates a wood framed seat pan; Can be metal, plastic, or similar materials; fabric or woven straps; s-bend springs; secured to frame directly, can be secured in a plurality of ways; not pitched here; can see 4 soft supports, one on each side;

FIG. 5 illustrates pitch orientation/storage and electronics below; Two corners of seat pan on lower tier/shelf while two are on the highest corner supports;

FIG. 6 illustrates additional orientation for a pitch; Orientation can be agnostic; The seat pan can pitch downwards along any of the four sides of the seat frame; Still able to have a storage system below;

FIG. 7 illustrates a top down view of a seat pan;

FIG. 8 illustrates a bottom perspective view of a seat pan; and

FIG. 9 illustrates a cross-sectional view according to an implementation of the present disclosure.

DETAILED DESCRIPTION

The present disclosure comprises systems, methods, and apparatus configured to allow for the construction and use of modular seating assemblies. The modular seating assemblies disclosed here provide ergonomic configurability through user-adjustable seating pitch while maintaining the modular interchangeability and aesthetic uniformity characteristic of modern seating systems. The disclosed assemblies are designed to be lightweight, structurally robust, and shippable in compact form, thereby improving manufacturing efficiency, transport, and end-user assembly. Pitchable seat pans of the present disclosure provide end users with the ability to adjust the pitch of a seating surface without the use of bulky mechanical devices embedded into the seat base. This allows a user to tailor the seating angle for various comfort preferences or seating arrangements. For example, a rearward pitch for lounging or a forward pitch for more active seating without using tools or requiring permanent modification. In certain embodiments, this functionality is achieved through multi-tiered corner supports or shelf features formed within a corner pillar structure of the base, which enable the seat pan to rest securely in multiple engagement positions.

The present disclosure also advantageously provides for various seat base and seat pan constructions that can provide a lightweight and structurally sound foundation for use in modular furniture assemblies. The seat bases of the present disclosure can include a central frame, side panels, and corner pillars (or corner members) that define discrete engagement positions for a seat pan. These elements can be fabricated from materials such as wood, metal, composite, or reinforced polymer, and can be coupled together through interlocking joints, fasteners, or friction-fit connectors to achieve both strength and ease of assembly. Such construction enables the seat base to maintain structural rigidity under repeated loads, while remaining sufficiently modular to be disassembled, transported, or reconfigured by the end user. In certain implementations, the modularity of the seat base also enables it to be coupled with adjacent seat bases to form larger seating systems, such as couches or sectional arrangements, without sacrificing stability or visual cohesion.

The disclosed constructions also promote manufacturing and shipping efficiency. The seat pan can be configured to secure with various components of the modular seating assembly (cushions, covers, etc.) and nest within or alongside the seat base during shipping, and components can be secured together via alignment dowels, straps, or interlocking elements. This modular architecture reduces packaging volume and simplifies initial setup.

Turning now to the Figures, FIG. 1 illustrates a perspective view of a seat base 102a, a back member, and a cushion. Cushion provides an end user with a seating surface that can be oriented in various directions to provide an ergonomic or desired level of pitch. The modular seating assembly is configured in a pitched configuration (e.g., where the seating surface is pitched backward toward the back member), as indicated by the sloping of the cushion relative to the seat base 102a. This pitched configuration is a byproduct of a user positioning a seat pan at an angle A relative to the seat base. Angle A can represent a range of angles from 0 degrees relative to the seat base (i.e., a level seating configuration) and up to about 15 degrees relative to the seat base (i.e., a pitched seating configuration). For example, angle A can be a pitched angle ranging from about 1 degree to about 15 degrees, or about 1 degree to about 10 degrees, or about 2 degrees to about 5 degrees, or about 2.5 degrees. To provide a pitched orientation, a user may remove the cushion from the seat base and set it to the side. The user can then lift or move the seat pan away from the seat base 102a and re-engage it with the seat base 102a in a pitched seat orientation. Example views and the corresponding features that provide engagement for pitched seating configurations are described in more detail in the later figures.

Accordingly, the modular seating assemblies of the present disclosure provide an optional ergonomic adjustment without complex mechanical systems or powered components. Instead, the ability to vary the pitch of the seating surface is achieved through simple structural engagement features between the seat pan and the seat base, such as a height difference or distance between a shelf and an upper surface. This allows the user to modify the seating orientation to achieve greater comfort or accommodate different activities while maintaining the overall aesthetic and modular integrity of the furniture.

FIG. 1 illustrates a perspective view of a seat base 102a with the seat pan and cushion removed. The seat base 102a includes four side panels 108a, a central frame 110a, and a corner pillar 112a. The central frame 110a provides a central structural support member that interconnects the various side panels and corner pillars to define the overall geometry of the seat base 102a. In some embodiments, the central frame 110a can be formed from a rigid material such as wood, metal, or a composite structure, and can include mounting or coupling features that facilitate tool-free assembly with adjacent components. The central frame also has an upper surface that can engage with a side, edge, or corner of a seat pan. For example, in a level configuration, a seat pan can rest or engage on the shelves 122a of the corner pillars 112a in each of the four corners of the seat base 102a. However, in a pitched configuration, two corners of the seat pan (or one side or edge) can rest or engage on the upper surface, which is below shelves 122a, while the remaining corners or opposing side or edge of the seat pan can rest on the remaining shelves 122a. This can cause one side of the seat pan to be raised while the opposing side is lowered.

FIG. 1 also illustrates that the four side panels 108a are coupled with at least the central frame 110a. Thus, the side panels 108a define the outer perimeter of the seat base 102a. Side panels 108a include a cover or inner cover. An individual inner cover wraps around an individual side panel 108a to provide a fabric or similarly soft outer layer to each panel. Inner cover can engage with connection components on an inner surface of the side panel. For example, connection components can be hook-and-loop material that engages or couples to the inner cover. Connection components are disposed at or near the upper and lower edges of the inner face of the side panel. The inner face of the side panel is enclosed when the side panel is secured to the central frame, thereby protecting the connection components from external interference and reducing the likelihood of unintended disengagement. In some embodiments, inner cover completely wraps around the side panel, having a slot or cutout to allow for the passage of fasteners, protrusions, etc.

As shown in FIG. 1, each corner pillar 112a can include one or more shelves 122a that define discrete engagement location surfaces for a seat pan to engage. The shelf 122a provides a surface wherein a seat pan may rest or engage to establish either a level configuration or a pitched configuration. Each corner pillar 112a can also include a bottom end that engages with a foot (not shown). The bottom end is positioned at one end of the corner pillar, opposite the shelf 122a. An aperture passes through the bottom end and can selectively receive a post (such as a threaded post) of a foot. In this manner, the corner pillar serves both as a load-bearing support and as an adjustment mechanism, enabling the seat pan to rest securely at multiple elevations or angles relative to the base.

The seat base 102a further defines a through cavity 114 that extends vertically or laterally through the central frame 110a (i.e., from the top edge of the side panel 108a to the bottom edge of the side panel 108a). The through cavity 114 can serve multiple purposes, including but not limited to reducing overall material weight, allowing access to a supporting surface (e.g., a floor), and providing an internal space where electronic equipment or other items can be secured or stored. An inner surface of the central frame 110a, the top edge, and the bottom edge thus define the dimensions of the through cavity 114.

FIG. 1 illustrates a view of seat base 102a, showing components such as the side panels 108a, central frame 110a, corner pillars 112a, through cavity 114, shelves 122a, and upper surface. Also shown are panel ends, which, when positioned adjacent to one another, define gaps between neighboring panels at each corner of the seat base. The gap can accommodate inserts or alignment members as part of an outer cover assembly. These gaps can also facilitate dimensional tolerance between adjoining panels, ensuring proper fit, and can receive an insert of a cover to assist in alignment. The upper surface of the central frame provides a planar interface for receiving the seat pan that extends around the entire seat base. By extending around the entire seat base, the upper surface supports a plurality of pitched seat configurations. Side panels also extend along each of the four edges of the central frame, and together form the perimeter structure of the seat base.

FIG. 1 illustrates a view of a seat base 102a, showing the positioning between the central frame 110a, side panels 108a, and corner pillars 112a. As illustrated, Two opposing side panels can have a length of L3, while the remaining two opposing side panels can have a length of L4. L4 is longer than L3, thus providing a seat base that is rectangular in nature. A user will appreciate this feature, as depending on which side panel is oriented as the front, the user can sit in either a deep mode (a longer distance from the front of the seat to the back rest) or a wide mode (a shorter distance from the front of the seat back to the back rest while instead providing a wider seat).

The central frame includes a U-shaped channel configured to receive a protrusion extending from the inner face of each side panel. Thus, the U-shaped channel opens outwards and away from the through cavity. The protrusion can be formed monolithically with the side panel (for example, molded, routed, or machined as part of the side panel body) or it can be an added member that is secured to an inner face of the side panel through fastening, adhesive bonding, or other coupling means.

When assembled, the protrusion is received within the U-shaped channel of the central frame. Once inserted, the manufacturer fastens, adheres, or otherwise secures the protrusion within the channel to create a rigid interlock between the central frame and side panel. The inner face of each side panel also abuts one or more corner pillars, which provides additional structural support and helps prevent flexing, bending, or breakage of the side panels when the seat base is impacted or subjected to dynamic loads.

The protrusion has a length L1 that can be substantially similar to or shorter than a length L2, where L2 represents the distance between two corner pillars positioned along the same edge of the seat base. This proportional relationship provides that the protrusion fits securely between the corner pillars.

There is engagement of a protrusion within the U-shaped channel of the central frame. Protrusion extends outward from the inner face of the side panel and is received within the U-shaped channel, forming a secure connection between these components. A manufacturer can fasten, adhere, and/or otherwise secure the protrusion within the U-shaped channel. The inner face of the side panel is also abutting the corner pillar, providing additional lateral support and reinforcement of the side panel.

A height H represents the vertical distance between the shelf of the corner pillar and the upper surface of the central frame. The height H defines the offset that produces the pitched angle (angle A) when the seat pan is re-engaged with the seat base in a pitched configuration. For example, when one end of a seat pan rests higher on a shelf and the opposing end of the seat pan rests on the upper surface, the seat pan exhibits an angled surface that corresponds to the distance or height H of the upper surface and the shelf. In general, a larger height H results in a greater seating angle, while a smaller height H produces a more subtle pitch. Accordingly, this structural relationship provides a simple geometric means of manually adjusting seat pitch, allowing for multiple ergonomic configurations within the same modular seat assembly.

An aperture is defined by the bottom end of the corner pillar. The aperture is a series of through holes that allow for the passage of a post of a foot or other mountable device/element. In some embodiments, aperture is a single through hole.

The invention includes a seat base 102a and an associated outer cover according to an implementation of the present disclosure. The outer cover is configured to extend around the outer surface of each side panel (including outside of the inner cover) while leaving the through cavity of the central frame unobstructed. In this manner, the outer cover provides an aesthetically pleasing exterior surface for the seat base without obstructing functional openings or structural engagement features. The outer cover is positioned outside of the inner covers, collectively creating a layered covering system that enhances both comfort and visual appearance. Similar to the inner cover, the outer cover can be secured to connection components (such as hook-and-loop fasteners, clips, or adhesive strips) located along the inside face of the side panels. This allows the outer cover to be easily installed, removed, or replaced by an end user while maintaining a taut, finished appearance. Further, this can provide protection to the connection components, as they are on the inner face, as opposed to a top or bottom surface, which may get caught when moving the seat base around.

The outer cover includes one or more inserts, which can take the form of dowels, bundled fabric, posts, foam segments, and/or other semi-rigid members positioned to correspond with the gaps defined between adjacent panel ends. The inserts serve as alignment and positioning aids, enabling the user to properly orient and guide the outer cover over and around the seat base during installation. For example, a user aligns the inserts with the gaps at each corner of the seat base. The user can then slide or guide the cover over and around the seat base (i.e., starting at the top edge and guiding towards the bottom edge, or starting at the bottom edge and guiding towards the top edge). This process causes the inserts to fill or engage with the gaps. Once positioned, the inserts can function as cushioned corner elements, smoothing transitions between adjacent side panels and providing a soft edge. The inserts can be formed from semi-rigid or cushioning materials, such as foam or resilient polymer, to provide localized impact absorption while maintaining alignment of the outer cover relative to the seat base. In at least one embodiment, a portion (e.g., a flap) of the cover folds over or around the top edge and/or bottom edge to secure to the inside of the side panels.

A seat base includes one or more end caps that allow for the engagement of an insert of an outer cover. The seat base includes side panels, each having end caps affixed to the ends of the respective side panels. The end caps are coupled to the side panels after the side panels have been wrapped with an inner cover. This configuration allows the inner cover to be applied around each side panel in a manner similar to wrapping a present, where the panel ends may include folds, seams, or multiple layers of the inner cover. The end caps conceal the panel end, thereby providing a clean and aesthetically pleasing outer appearance to the remainder of the side panel. Together, the end caps can partially fill the gap and define a slot configured to receive an insert of an outer cover. The slot is curved, though in other implementations, the slot may be angled or sloped to correspond to the shape of the insert or desired aesthetic profile.

End caps are secured to the ends of side panels. Each end cap includes one or more tabs that extend inwardly toward the back or inner surface of the respective side panel, and over any applied inner cover. The tabs can serve as anchors or attachment features that assist in fastening the end caps to the side panels, such as by adhesive, fasteners, or press-fit engagement. The end caps extend across and conceal the entire panel end of each side panel, providing a clean finished edge and continuous interface with adjacent structural components. The slot, defined between the end caps, is continuous and extends the full height of the side panels. The slot is configured to receive an insert of an outer cover, and may have a curved, angled, or sloped profile to correspond to the desired contour or shape of the cover insert.

A continuous slot is formed between the end caps along the height of each side panel. The slot extends uniformly from the upper to the lower edges of the side panels, providing a consistent channel for receiving the insert of an outer cover. The end caps fully enclose the panel end of the side panels, concealing any seams, folds, or material layers of the inner cover to maintain a smooth and visually continuous edge appearance.

Another embodiment of the modular seat base, which is similar to and adaptable with the features of seat base 102a shown in FIG. 1 includes a different central frame structure made from one or more L-shaped brackets secured between corner pillars.

Similar to seat base 102a of FIG. 1, the seat base includes a central frame, side panels, and corner pillars. The central frame is defined by a plurality of L-shaped brackets joined at their ends to a plurality of corner pillars. A through cavity is still provided, panels still include an inner cover, and connection components are also included. Additionally, the seat base includes an upper surface (of the L-shaped brackets) and a shelf, which provides for either level or pitched engagement with a seat pan. The bottom end of the corner pillars engages with a foot. Thus, while the embodiment demonstrates an alternative arrangement of internal bracing, the features provided are similar and interchangeable with those of another embodiment of the seat bases disclosed herein.

L-shaped brackets extend between and couple to the corner pillars, thereby defining the central frame. The arrangement of the brackets provides structural rigidity while still maintaining the open through cavity, which reduces weight and allows access to a supporting surface whereon the seat base is mounted (e.g., the floor). The corner pillars each include the shelf for engagement with a seat pan, and the upper surfaces of the L-shaped brackets form continuous support interfaces that extend between the pillars. Thus, even though the L-shaped brackets are not a continuous or monolithic structure, the upper surface is still provided along each side of the seat base. Gaps between adjacent panel ends remain present to receive inserts or alignment members when an outer cover is installed.

Each L-shaped bracket provides an outer engagement surface along which the side panels are secured. Each side panel can include a recess configured to align the side panel with the L-shaped brackets and the corner pillars. The recess is a cutout or gap in the inner cover to allow for direct contact of the panel to the central frame. In at least one embodiment, no recess is provided by panels; instead, the inner face of panels is substantially planar and fastens directly to engagement surface. The side panels are fastened, bonded, or otherwise coupled to the brackets and/or corner pillars to form a rigid and lightweight structure. Two opposing panels may have a first length L3, and the remaining two may have a second length L4, thereby enabling the seat base to be oriented in either a deep or wide configuration, depending on user preference or assembly orientation.

A seat base illustrates the structural relationship between the L-shaped bracket, the corner pillar, and the side panel, as well as the vertical offset between the shelf and the upper surface that defines a height H. The height H determines the pitched angle achieved when a seat pan is re-engaged with the base in a pitched configuration. Thus, rather than a protrusion-channel engagement, the inner face of panel can directly engage with engagement surface of the central frame. This can allow a manufacturer to provide a simplified cover that does not include a slot or opening where a protrusion resides. A manufacturer can also secure each side panel to one or more corner pillars to provide additional support.

Similar to seat base 102a, the seat base includes a through cavity, side panels, and corner pillars positioned at each corner of the assembly. In this embodiment, each corner pillar includes two shelves, which define engagement surfaces for a seat pan, providing both a level configuration and a pitched configuration. This differs from the embodiment where a single shelf and the upper surface of the central frame were used to define the two engagement levels. In this embodiment, the height difference or distance between the shelves can define the pitched angle provided by the seat base.

The central frame is positioned at or near a lower edge of the side panels, as opposed to the central frame which is positioned closer to the top edge. The central frame is directly fastened to the side panels using fasteners, adhesives, or interlocking joints (i.e., without a protrusion and channel engagement). This is similar to the way in which engagement surface engages with panels. The side panels can likewise be fastened to both the corner pillar and the central frame, forming a rigid, integrated structure. The seat base further includes corner plates, each positioned near the lower edge. Each corner plate defines one or more apertures configured to receive a foot, a mounting post, or other accessory components such as electronic modules, a mount/bracket, and/or storage attachments. In some embodiments, the corner plate may be formed integrally with the corner pillar, while in other implementations it may be a separate member fastened to the pillar or frame.

The seat base includes side panels, a central frame, and a through cavity that extends through the seat base to reduce weight and provide a usable inner volume. The seat base also includes one or more corner members, which are similar in form and function to the previously described corner pillars, but differ in that the corner members do not extend downward to the bottom edge of the base and do not connect directly or engage with the central frame. Instead, each corner member is secured to one or more of the side panels and provides shelves for receiving and supporting a seat pan in either a level or pitched configuration.

In this embodiment, the manufacturer assembles the seat base by sliding a protrusion of the side panel into a T-shaped channel of the central frame in a first direction. Once properly seated within the channel, another side panel is slid into engagement with the same or an opposing T-shaped channel of the central frame in a second direction. This sequential engagement process allows the manufacturer to lock the panels in place, as the edges of one adjacent side panel can prevent another side panel from sliding out once fully inserted. After the side panels are engaged with the central frame, the corner members can be installed or fastened along the adjoining panel edges to complete the strengthening of the corners of the seat base. Thus, corner members not only provide shelves but also reinforce the corner joints between side panels, improving stability and preventing separation under load.

Various embodiments of central frames and their corresponding configurations for coupling with side panels of the modular seating assemblies. Each central frame defines a unique engagement geometry that allows the manufacturer to select an assembly method best suited to the desired production process, material set, or performance requirements.

In an embodiment, a central frame has a U-shaped channel configured to receive a corresponding protrusion from a side panel. The central frame can be formed as a monolithic member, for example, through extrusion, molding, or machining, or it can be assembled from multiple components (e.g., each edge of the channel can be welded, fastened, or otherwise secured together). In an embodiment, a central frame includes a T-shaped channel. The T-shaped channel is configured to allow side panels to slide into engagement with the central frame along the direction of the channel rather than simply being inserted or dropped into place. The sliding engagement provides retention of the side panels during assembly.

In another embodiment a central frame includes a series of L-shaped brackets defining outer engagement surfaces (or first edge). The L-shaped brackets are secured at their ends to the corner pillars, thereby forming a rigid interconnected frame. In this configuration, the central frame functions as a hybrid structural system, combining brackets with corner pillars (as opposed to embodiments where the central frame forms a continuous ring-like member, which is then secured to a corner pillar). A foot is threadingly engaged with one of the corner pillars.

In still another embodiment of a central frame, the central frame includes one or more geometric members extending between corner pillars. The geometric members are similar to the L-shaped members described and provide structural connection and rigidity across the central frame. Each geometric member includes a series of apertures configured to receive fasteners for securing side panels or other modular components to the frame. Additional apertures are provided along the members (such as along the lower edge of the geometric member) to allow a manufacturer or end user to attach various accessories or attachments, such as storage trays, electronics housings, power outlets, brackets, or other components.

Various embodiments of seat pan constructions according to implementations of the present disclosure are illustrated. Each embodiment demonstrates an approach to achieving structural support and user comfort, while maintaining compatibility with the modular seat bases described above (i.e., having the structural support and configuration to allow for pitched seating). The seat pans can be manufactured from a variety of materials, including but not limited to wood, metal, or composite structures, and can incorporate suspension means to provide a suspended seating surface

FIGS. 7 and 8 illustrate an embodiment of a seat pan 200b, the seat pan is constructed from one or more side members that are secured together to define the perimeter of the seat pan 200b. At each corner, the seat pan 200b includes corner members, which provide reinforcement and structural stability at the junctions between adjoining side members. The inclusion of corner members helps distribute load evenly across the seat pan and enhances resistance to twisting or flexing during use. Seat pan 200b also includes two forms of suspension means, designated as 202a and 202b, which extend perpendicular to one another between opposing side members. The first suspension means 202a comprises fabric straps that may be elastic or tensioned to provide a soft, resilient support surface for a seat cushion or occupant. The second suspension means 202b includes metal S-springs, which provide a complementary form of suspension with higher load capacity and responsive rebound. Together, suspension means 202a and 202b create a bi-directional suspension network that distributes weight evenly across the seat pan 200a.

A seat pan, is formed as a monolithic metal, wood, or composite frame providing both structural support and an integrated seating surface. The monolithic construction can be achieved through stamping, molding, or casting processes, resulting in a rigid yet lightweight structure suitable for high-strength applications. The seat pan further includes multiple suspension means arranged to provide bi-directional suspension across the seating surface. Some suspension means are springs while other suspension means are rods connected thereto. The suspension means extends laterally across the seat pan and serves as a connection element between springs and additional suspension means. These additional suspension means include flexible (or non-flexible) strands or cables, which extend in a direction generally perpendicular to the rods they are coupled directly to. A plurality of suspension means are used to create a bi-directional support network. Together, the springs, rods, and strands form a dynamic suspension system that distributes the load evenly across the seating surface.

The seat pan also includes corner structures positioned at each corner of the frame. These corner structures are shaped and configured to engage with the shelves or upper surfaces of the seat bases described elsewhere in the present disclosure. Each corner structure includes an engagement tab, which is sized to fit securely into a corresponding shelf on a seat base.

A seat pan provides a seating surface and is designed as a lightweight modular construction. The seat pan comprises multiple beams, corner couplers, and a suspension means extending between the beams. The suspension means can be formed from a fabric or mesh material that possesses elastic or tensioned suspension qualities, allowing it to flex and conform under load while maintaining a seating surface whereon a seat cushion is supported. The suspension means includes a series of sleeves positioned along its perimeter. During assembly, a manufacturer or user can insert each beam through a corresponding sleeve and then secure a corner coupler at each end of the beam. This process can be performed for each edge of the suspension mean, or for each individual sleeve section. The process of securing all the beam into the corner couplers results in the suspension means being pulled tight, creating a uniformly tensioned seating surface. This configuration offers a lightweight yet durable solution that minimizes the amount of rigid material (i.e., corner and beams) while maintaining sufficient structural integrity to support the user's weight during normal use.

A seat pan according to an implementation of the present disclosure is configured to provide a flat or level ride, meaning a user does not sink or bunch toward the center of the seat pan when seated. The seat pan includes a non-stretching central region and a plurality of stretching regions arranged around the periphery of the central region. The seat pan also includes corner couplers at each corner of the beam frame, which are two-part components that clamp around both the suspension material and the beam to secure the seat pan under tension. Together, the central region and stretching regions define a suspension assembly that is tensioned across an underlying beam frame.

The central region is formed from a non-stretch or low-stretch material, such as a woven fabric or reinforced textile, while stretching regions are composed of materials configured to elongate in a specific direction (such as directions D3, D4, D5, and D6). Thus, each stretching region is designed to stretch only in a direction that is perpendicular to the adjacent edge of the seat pan. The outer circumference of the central region is shaped (curved) to counteract the deflection caused by the stretching regions, such that when a user sits within the central region, the surrounding various stretching regions deflect to maintain a generally level seating plane rather than forming a deep depression or divot right below the user's posterior.

The seat pan includes a central region and stretching regions as described previously. The seat pan further includes a set of panels that together form the peripheral connection structure for tensioning the suspension means to the beam frame. Some panels are longer than other panels, and each longer panel connects at its ends to a corresponding shorter panel. Each of the panels includes a J-clip or similar connector along its edge. During assembly, the longer panels wrap around the underside of the seat pan and couple to the shorter panels via the connectors (i.e., elastically deforming or stretching the panels around the central frame). This coupling process draws the stretching regions taut, thereby tensioning the suspension material and enabling the seat pan to act as a stretched suspension surface when secured to the underlying beam frame. Additionally, corner coupler is a two-part component wherein a first part and a second part are on opposite sides of the seat pan. Together, the two parts clamp around both the suspension material and the beam to secure the seat pan under tension.

Various pitched configurations or pitched orientations include altering which side of the seat pan engages with the upper surface or the shelf of the seat base. A level orientation or level configuration includes a seat pan engaging with either only the selves at each corner (of the seat pan) or only the upper surface at each edge (of the seat pan). Though the terms “front face” and “left face” are used to describe the following orientation, these are merely illustrative, as any side of the seat bases disclosed herein can act as a front face or left face, depending on how a user orients the seat base.

A forward pitched orientation of the seat pan relative to the seat base is a seat pan pitched toward the front face. The front side of the seat pan (i.e., the side adjacent to the front face) is positioned on the shelves of the upper surface of the central frame, while the rear side of the seat pan (i.e., the side opposite front face) rests on the shelves. This configuration positions the seating surface at a forward slope, providing an active seating angle.

FIG. 3 illustrates a rearward pitched orientation of the seat pan 200a relative to the seat base 102a. In this configuration, the seat pan 200a is pitched toward the back face (i.e., opposite front face). The front side of the seat pan 200a (i.e., the side adjacent to the front face) is positioned on the shelves of the corner pillars, while the rear side of the seat pan 200a (i.e., the side opposite front face) rests on the upper surface of the central frame. This configuration positions the seating surface at a rearward slope, providing a reclined seating angle that can enhance comfort and relaxation for lounging or casual seating applications.

In a rightward pitched orientation of the seat pan relative to the seat base, the seat pan is pitched toward the right side (i.e., the side opposite the left face) of the seat base. The left side of the seat pan (i.e., the side nearest the left face) is supported by the shelves of the corner pillars, while the right side (i.e., the side opposite the left face) rests on the upper surface of the central frame. This orientation produces a lateral slope across the seating surface from left (high) to right (low), enabling ergonomic adjustment for asymmetrical seating positions or for use in modular arrangements where adjoining seats are angled differently. As previously described with respect to the wide and deep seating modes, when the left face is oriented as the front face of the seat base, this same configuration instead allows for a rearward pitched orientation in that alternate orientation, further demonstrating the versatility and adaptability of the disclosed seating assemblies.

In a leftward pitched orientation of the seat pan relative to the seat base, the seat pan is pitched toward the left side (i.e., the side nearest the left face) of the seat base. The right side of the seat pan (i.e., the side opposite the left face) is supported by the shelves of the corner pillars, while the left side (i.e., the side nearest the left face) rests on the upper surface of the central frame. This arrangement produces a lateral slope across the seating surface from right (high) to left (low), thereby complementing the rightward pitched configuration. Similar to the previously described relationship between the wide and deep modes, if the left face of the seat base is oriented as the front face, the configuration can provide a forward pitched orientation in that orientation, further demonstrating the multi-directional ergonomic adjustability and modular versatility of the present disclosure.

The front side of the seat pan (i.e., the side nearest the front face of the seat base) is resting on the upper surface of an L-shaped bracket. Conversely, the rear side of the seat pan (i.e., the side nearest the rear face, which is opposite the front face) is supported by the shelf of the corner pillar. This differential in support height between the upper surface and the shelf establishes the forward pitched angle of the seating surface. The front of the seat pan is positioned lower than the rear, producing a forward-leaning ergonomic posture that encourages active sitting while maintaining stable engagement between the seat pan and the base.

FIG. 4 illustrates an embodiment of a seat base 102b having a soft edge mechanism. The seat base 102b includes side panels, a seat pan, corner members, and a suspension member. The corner members are formed as block-like structures that are fastened between two adjacent side panels, thereby reinforcing the corners of the base and providing a shelf for the seat pan to engage. In the embodiment, the seat pan is in a pitched configuration, demonstrating the same variable seating orientation capability described.

Each side panel includes a recess formed along its top edge. In this example, recess has a curved profile; however, in other embodiments, the recess may be angular, squared, or faceted, depending on design preference or material selection. At either end of the recess are notches, each configured to receive a prong of the suspension member. The suspension member is an elongated, linear element having elastic or spring-like properties that bias it toward a straight or neutral state. When both prongs are engaged within their respective notches, the suspension member is positioned across or over the recess, allowing it to flex into the recess when weight is applied. This configuration allows the suspension member to function as a soft-edge feature for the upper perimeter of the seat base. A rigid upper edge of a side panel can sometimes be felt sharply by a user when seated near the edge of the furniture, creating a perceptible pressure point. By contrast, the spring-like nature of the suspension member allows the top edge to flex slightly under localized load, softening the tactile feel and reducing edge perception when a user sits near or leans against that region. This creates a more comfortable and forgiving seating experience while preserving the clean structural form of the modular base. The soft-edge feature, therefore, enhances the overall ergonomic performance and perceived quality of the seating assembly without adding bulk or mechanical complexity.

In at least one embodiment, suspension member is not an elongated and linear member but is instead a coil, S-shaped, or similar style spring member that spans across the recess. Similarly, a woven or fabric elastic member may also be used.

A seat base is configured to accommodate mounting components and internal devices within the through cavity. This demonstrates how the modular seating assemblies of the present disclosure can integrate functional features, such as electronics, speakers, storage compartments, or other accessories, while still retaining the features previously discussed.

FIG. 9 illustrates a view of the seat base 102b, showing the through cavity housing a device 282. The device 282 may represent any accessory or functional component suitable for integration within the furniture base, such as an electronic control unit, a speaker, a lighting module, or a personal storage compartment. The device 282 is supported by mounts, which are configured to engage with one or more bottom ends of the corner pillars. Once positioned, the mounts can be secured to the device 282 using fasteners or thumb screws, allowing for installation or removal by either the manufacturer or the end user. This configuration offers a modular approach to incorporating optional features without modifying the core seat base structure. In at least one embodiment, a single mount that engages all four of the bottom ends is used.

The seat base has two side panels and associated L-shaped brackets. A foot includes an upwardly extending post that passes through the apertures (e.g., aperture) defined by the bottom ends of the corner pillars and the mount. A top nut or fastener can then be applied to secure all components together in a stacked assembly, coupling the foot, mount, and corner pillar into a unified structure. This arrangement not only provides support and stability for the seating assembly but also enables convenient installation and removal of functional devices positioned within the through cavity. Additionally, post can include a spring-loaded detent that allows a user to couple the foot to the bottom end by simply pushing the post into the aperture. This advantageously provides a quick connect-and-release mechanism that does not require screwing or twisting of the foot or post, which can take a longer period of time to complete. The detent can engage with a connection component of the bottom end, for example, the edge of aperture to prevent foot from falling out.

Rotatable shoes are configured for use with the modular seating assemblies of the present disclosure. These components allow multiple seat bases to be mechanically coupled or decoupled from one another in a simple and repeatable manner, allowing users or manufacturers to connect seating modules into larger assemblies such as couches or sectionals. A seat base is equipped with rotatable shoes. Each rotatable shoe is mounted to a support positioned near a corner of the seat base. In some embodiments, the support is formed as part of the bottom end of the seat base or the corner pillar,. Each rotatable shoe pivots about a pivot point, allowing the shoe to rotate between various deployed and stowed configurations. Support (or, in some embodiments, the rotatable shoe) also includes a spring-loaded detent, which exerts a resistive force on the rotatable shoe to prevent unintended movement and maintain the shoe in a selected position during use. Each shoe is a solid block or section of material wherein the cups are through holes or cut out into the block or section of material.

The shoe is rotated outward such that three cups extend from beneath the seat base, ready to receive feet from a foot from an adjacent seat base for coupling. Shoes are in an intermediate position, where two cups project outward, while the remaining cup is retained beneath the seat base base. Shoes are rotated fully inward, storing all cups beneath the seat base for situations where interconnection is not required or when the furniture is used as a standalone unit. The cups are sized and shaped to receive and retain a corresponding foot or post from an adjacent seat base, thereby enabling multiple units to be aligned, stabilized, and joined together in a secure yet reversible fashion. This configuration provides users with a flexible connection mechanism that maintains the modularity and adaptability central to the present seating system.

In another embodiment of the rotatable shoe system, rotatable shoes function similarly to the rotatable shoes, but utilize a different coupling interface. Each rotatable shoe is mounted to a support near a corner of the seat base and is configured to rotate about a pivot point. As in the previous embodiment, the support may form part of a bottom end or structural member of the seat base and can include a spring-loaded detent that provides a resistive force to maintain the rotatable shoe in a desired position and prevent unwanted rotation during use. In this embodiment, however, each rotatable shoe includes one or more rings instead of cups. The rings (each defining an aperture) are designed to receive and retain a post or dowel extending from the foot of an adjacent seat base. Shoes have a fully deployed position, an intermediate configuration (i.e., where two of the rings extend outward), and a fully stowed position (i.e., where all rings are positioned beneath the seat base).

A process includes acts of unpacking a shipped modular furniture assembly according to an implementation of the present disclosure. The modular furniture assembly can be efficiently packaged, shipped, and unpacked while minimizing waste, reducing the number of boxes required, and protecting all components during transport by utilizing the through cavity of the seat base as a storage compartment, a manufacturer can consolidate multiple furniture components (such as seat pans, panels, and accessories) into a single, compact package, simplifying logistics and reducing shipping costs.

In an act, in which a user unboxes the seat base and the seat pan that has been secured to the seat base, the seat pan is wrapped with one or more straps, which hold the seat pan and associated components together during shipment. The straps maintain the assembly in a compact and stable arrangement, protecting the parts from shifting or damage while in transit. In an act in which the user lifts and flips the seat pan to access the components secured beneath it by the straps, the components may include, without limitation, side panels, corner members, fasteners, tools, cushions, covers, or other accessories used for assembling or customizing the modular seating system. The straps maintain all components together as a single package, simplifying inventory and reducing the risk of lost parts during unpacking.

In an act in which the user rests the seat base and the components on a surface such that the seat pan is below the components, the various components are accessible and can be removed or organized as desired. In an act in which the user removes a rod from its engagement with the straps, in the packaged configuration, the straps are looped around the seat pan and components and locked in place by the rod, which prevents the straps from loosening during shipment. Upon removal of the rod, the straps are released, thereby freeing the seat pan and all stored components. This packaging method allows the manufacturer to store many, if not all, of the necessary accessories and assembly parts within the through cavity of the seat base, enabling the entire furniture system to be shipped in a single, consolidated package. This approach reduces packaging material, minimizes the number of boxes required, and provides effective cost savings in shipping and handling while maintaining a compact and user-friendly unboxing experience.

It will also be appreciated that embodiments described herein can also include properties and/or features (e.g., ingredients, components, members, elements, parts, and/or portions) described in one or more separate embodiments and are not necessarily limited strictly to the features expressly described for that particular embodiment. Accordingly, the various features of a given embodiment can be combined with and/or incorporated into other embodiments of the present disclosure. Thus, disclosure of certain features relative to a specific embodiment of the present disclosure should not be construed as limiting the application or inclusion of said features to the specific embodiment. Rather, it will be appreciated that other embodiments can also include such features.

A user having ordinary skill in the art should realize, in view of the present disclosure, that equivalent constructions do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and alterations can be made to embodiments disclosed herein without departing from the spirit and scope of the present disclosure. Equivalent constructions, including functional “means-plus-function” clauses are intended to cover the structures described herein as performing the recited function, including both structural equivalents that operate in the same manner, and equivalent structures that provide the same function. It is the express intention of the applicant not to invoke means-plus-function or other functional claiming for any claim except for those in which the words ‘means for’ appear together with an associated function. Each addition, deletion, and modification to the embodiments that falls within the meaning and scope of the claims is to be embraced by the claims.