Note: Descriptions are shown in the official language in which they were submitted.
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STRUCTURAL FRAMES FOR FURNITURE
FIELD OF INVENTION
[0011 The subject matter disclosed herein relates generally to structural
frames, and
more specifically to furniture frames and a process for making durable and
relatively
light-weight structural frames.
BACKGROUND
[0021 Most furniture structures are tested for load bearing capacity on the
finished
composite furniture structures; after additional comfort and aesthetic
cladding have
been added. The strength and durability of the furniture structures are tested
with
various static and dynamic loads on seat, back, seat front, foot and leg
rests, arm rests,
wings and legs, impact test on seat, impact test on back, strike test on arms,
drop test,
leg support.
10031 Although several conventional techniques have been employed for
furniture
frame construction, most techniques suffer from high assembly and material
costs,
and excessive weight of structural frame members, among other disadvantages.
[0041 For example, existing designs of furniture frames for padded sofas and
padded
chairs use relatively heavy materials such as melamine board or ply-wood
sheets, all-
wood support inserts, and they require 100's or 1000's of nails in their
assembly, and
their manufacture is difficult to automate. Existing furniture frame designs
are costly
and labor intensive to manufacture, assemble, and transport.
[005] Accordingly, a need exists for an improved process for efficiently
making
durable and relatively light-weight rigid furniture frames and furniture
structures in
general.
[006] Accordingly, a need exists for furniture frames designed with lighter-
weight
materials, materials that do not require the extensive use of nails, materials
that lend
themselves to automation in the manufacturing process, and materials that are
semi-
rigid.
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SUMMARY
[007] In the invention, sheets of semi-rigid materials are used in the
construction of
structural frames.
[008] A structural frame comprises a sheet of a semi-rigid material as the
body of a
structural frame.
[009] A structural frame for a modular wall panel comprising a plurality of
support
inserts wrapped inside a sheet of semi-rigid material.
[0010] A furniture frame comprising a plurality of support inserts wrapped
inside a
sheet of semi-rigid material.
[0011] In an embodiment of the present invention, a furniture frame, which is
preferably later covered with padding, cloth, or other cladding, is
constructed by a
process comprising the following steps:
(a) providing a sheet of semi-rigid material;
(b) fixedly attaching a plurality of rigid spacers to the sheet;
(c) placing a plurality of polygon shaped support inserts on the sheet,
connecting the
inserts to the rigid spacers and standing the inserts perpendicularly to the
sheet, at
distal ends of the sheet and at points in between the distal ends; and
(d) wrapping the sheet around the support inserts.
[0012] In an embodiment, a structural frame comprises:
(a) an elongated polygon ring of semi-rigid material;
(b) a plurality of rigid spacers fixedly attached to the interior annulus of
the ring; and
(c) a plurality of polygon shaped support inserts are connected to the rigid
spacers and
stand perpendicularly to the annulus of the ring, at distal ends of the ring
and at points
in between.
[0013] In an embodiment, a furniture frame comprises:
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(a) an elongated polygon ring of semi-rigid material;
(b) a plurality of rigid spacers fixedly attached to the interior annulus of
the ring; and
(c) a plurality of polygon shaped support inserts are connected to the rigid
spacers and
stand perpendicularly to the annulus of the ring, at distal ends of the ring
and at points
in between.
[00141 In an embodiment, a wall panel frame is constructed by a process,
comprising
the steps of:
(a) providing a sheet of semi-rigid material;
(b) fixedly attaching a plurality of rigid spacers to the sheet;
(c) placing a plurality of polygon shaped support inserts on the sheet,
connecting the
inserts to the rigid spacers and standing the inserts perpendicularly to the
sheet, at
distal ends of the sheet and at points in between the distal ends; and
(d) wrapping the sheet around the support inserts.
DRAWINGS
[0015] These and other features, aspects, and advantages of the present
invention will
become better understood when the following detailed description is read with
reference to the accompanying drawings in which like characters represent like
parts
throughout the drawings, wherein:
[00161 FIG. 1 shows a set of views of a furniture frame of a single seat sofa
assembly
according to an embodiment of the invention, showing perspective view 104,
side
view 102, front view 106, and top view 108.
[00171 FIG. 2 is a top view illustrating an unfolded frame for the single seat
sofa
embodiment shown in FIG. 1.
[0018] FIG. 3 is a perspective view of a polygon shaped support insert
according to
an embodiment of the invention.
[0019] FIG. 4 is a perspective view of an arm rest of a furniture frame
according to an
embodiment of the present invention.
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[0020] FIG. 5 is a perspective view of a sofa back frame according to an
embodiment
of the present invention, illustrating a partially exposed view of a polygon
shaped
support insert wrapped with a cardboard sheet.
[0021] FIG. 6 is an unwrapped perspective view of the sofa back frame shown in
Fig.
5, according to an embodiment of the invention.
[0022] FIG. 7 is a flowchart illustrating a process for making a furniture
structure
according to an embodiment of the invention.
[0023] FIG. 8 is a perspective view of a corrugated wall panel, in an
embodiment of
the invention, illustrating a partially exposed view of polygon shaped support
inserts
wrapped inside a cardboard sheet.
[0024] FIG. 9 is a perspective view of a corrugated sofa end, in an embodiment
of the
invention, illustrating a partially exposed view of a load bearing support
insert
wrapped inside a cardboard sheet..
[0025] FIG. 10 is a perspective view of a chair box structure, in an
embodiment of the
invention, illustrating a partially exposed view of a load bearing support
insert.
DETAILED DESCRIPTION
[0026] Durability of furniture frame structures may be enhanced by using
materials
able to withstand fatigue of repetitive loads. Relatively light-weight energy
absorbing
cushions and cladding reduce the need to over-design furniture frame
structures.
[0027] Accordingly, it is unnecessary to use relatively heavy materials such
as
melamine board or ply-wood sheets, and all-wood support inserts, which
generally
require 100's or 1000's of nails in their assembly.
[0028] Composite construction of furniture frame structures may instead be
created
with the use of predominately cardboard construction, when the surfaces are
later
covered with additional comfort and aesthetic cladding, reducing the need for
all
wood and Masonite board frame structures. Masonite is a manufactured product
made
from wood that is broken down to its basic fibers and then rearranged to form
hard
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panels, namely, fiber board, composite board, and construction board,
collectively
herein after referred to as Masonite. Masonite boards typically have a single
tempered
side that are a harder, paint-able surface, greater strength and more
resistance to liquid
and water than the flip side of the boards. Masonite boards are typically 3mm
(2/16")
thick.
[0029] References to "an embodiment" of the claimed invention should not be
interpreted as excluding the existence of additional embodiments that also
incorporate
the recited features.
[0030] In an embodiment of the invention, a structural frame is prepared by a
process
comprising the steps of:
(a) providing a sheet of semi-rigid material;
(b) fixedly attaching a plurality of rigid spacers to the sheet;
(c) placing a plurality of polygon shaped support inserts on the sheet and
engaging the
support inserts to the rigid spacers while standing the support inserts
perpendicularly
to the sheet, at distal ends of the sheet and at points in between the distal
ends;
(d) wrapping the sheet around the support inserts, preferably completely
covering the
support inserts with the sheet.
[0031] Preferably, the structural frame is selected from a group comprising
chairs,
arm chairs, sofa back frames, and wall structures.
[0032] Preferably, the process is automated on an assembly line using
machines.
[0033] In an embodiment, a furniture frame for a sofa back frame is prepared
by a
process comprising the steps of.
(a) providing a sheet of semi-rigid material;
(b) fixedly attaching a plurality of rigid spacers to the sheet;
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(c) placing a plurality of polygon shaped support inserts on the sheet and
engaging the
support inserts to the rigid spacers while standing the support inserts
perpendicularly
to the sheet, at distal ends of the sheet and at points in between the distal
ends;
(d) wrapping the sheet around the support inserts, preferably completely
covering the
support inserts with the sheet.
100341 In some embodiments, steps are added to the process to secure the
plurality of
rigid spacers to the sheet with fasteners; the fasteners are selected from a
group
comprising adhesive glues, pressure-sensitive adhesive strips, staples, nails,
rivets,
metal hog rings, screws, bolts, and nuts. The rigid spacers are selected from
a group
comprising strips of a rigid plastic or a wood, preferably, pine wood,
plywood, cedar,
beach, and mahogany.
[0035] In an embodiment, a furniture frame structure comprises:
(a) an elongated polygon ring of semi-rigid material;
(b) a plurality of rigid spacers fixedly attached to the interior annulus of
the ring; and
(c) a plurality of polygon shaped support inserts are connected to the rigid
spacers and
stand perpendicularly to the annulus of the ring, at distal ends of the ring
and at points
in between.
[0036] In an embodiment, a sofa back frame comprises
(a) an elongated polygon ring of semi-rigid material;
(b) a plurality of rigid spacers fixedly attached to the interior annulus of
the ring; and
(c) a plurality of polygon shaped support inserts are connected to the rigid
spacers and
stand perpendicularly to the annulus of the ring, at distal ends of the ring
and at points
in between.
[0037] Preferably, the sheet of semi-rigid material is selected from group
comprising
cellulose based sheets and semi-rigid plastics. Preferably, the cellulose
based sheets
are selected from a group comprising corrugated cardboard sheet, pulp and
paper
sheet, sheet attached to semi-rigid wood substrates. In some embodiments,
additional
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steps are added to the process to coat the sheet with a substrate, where the
substrate is
selected from a group comprising wax, a flexible polymer vinyl wrap sheet, a
pressure
activated adhesive polymer vinyl wrap, and rubber.
[0038] More preferably, the sheet provided has slots adapted to receive and
secure a
plurality of support inserts at each of the distal ends and points in between
the distal
ends of the sheet.
[0039] Preferably, the sheets have fluting that is selected from a group
comprising B
fluting and E fluting.
[0040] A support insert comprises a three-dimensional polygon having a profile
view
adapted to match the profile shape of a desired structural frame.
[0041] Preferably, the support inserts are selected from a group comprising
formed
polygons, injection-molded polygons, and folded polygons.
[0042] In the folded polygon embodiment, a support insert comprises: a sheet
of
semi-rigid material folded into a polygon.
[0043] Preferably, the support insert has a corner adapted to position the
support
insert on a sheet having the spacer. More preferably, the support insert has a
slot to
operatively engage with a spacer and position the support insert on a sheet
having the
spacer.
[0044] Preferably, the support inserts are are coated with a reinforcing and
water
resistant substrate selected from the group comprising, a wax, a flexible
polymer vinyl
wrap sheet, a pressure activated adhesive polymer vinyl wrap, and rubber.
[0045] FIG. I shows a set of views of a furniture structure 100 for a frame of
single
seat sofa assembly according to an embodiment of the invention, showing
perspective
view 104, side view 102, front view 106, and a top view 108, comprising a
sheet of
semi-rigid material folded in to chair without legs, having a back portion 110
and a
plurality of load bearing support inserts 112, 114,
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[0046] FIG. 2 is a top view of an unfolded frame 200 for the single seat sofa
embodiment shown in FIG.1.
[0047] The frame 200 comprises a sheet of semi-rigid material 202 and a
plurality of
load bearing support inserts 206.
[0048] FIG. 3 is a perspective view of a polygon shaped support insert 300
according
to an embodiment of the invention, comprising, a sheet of semi-rigid material
folded
into polygon; wherein the polygon as has a corner to rest on a spacer and
position the
polygon on a sheet having the spacer.
[0049] In a preferred embodiment, the polygon shaped support insert 300
comprises a
multi-wall sheet of semi-rigid material folded into polygon, adapted to
connect and
engage with a plurality of rigid spacers 206. Preferably, the support insert
300 is
placed on the sheet 202, connecting the support insert 300 to the rigid
spacers 206
while the support insert 300 stands perpendicularly to the sheet 202 at distal
ends of
the sheet 202 and points in between the distal ends.
[0050] FIG. 4 is a perspective view of an embodiment of an arm rest structural
frame
400 of a furniture structure, having a leg rail 402, a side panel 404 and a
sheet of
semi-rigid material 406 folded into a box. The leg rail 402 may be made of
plywood
material.
[0051] FIG. 5 is a perspective view of an embodiment of a sofa back frame 500
and
illustrates a partially exposed view of a support insert wrapped with a sheet
of semi-
rigid material.
[0052] The sofa back frame 500 comprises a sheet of semi-rigid material 504
wrapped around support inserts 502, and a rigid spacer 506 adapted for
positioning
the support insert 502.
[0053] Preferably, support inserts 502, when constructed from a sheet
cellulose based
material, such as corrugated cardboard, it has a triple wall.
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[0054] FIG. 6 is an unwrapped perspective view 600 of the sofa back frame
shown in
FIG.5, in an embodiment of the invention.
[0055] The perspective view 600 comprises sheet of semi-rigid material 604,
having a
plurality of apertures 606 and an appendage 602 to provide a side panel, and a
plurality of polygon shaped support inserts 608.
[0056] In an embodiment, the sheet of semi-rigid material 604 is a cellulose
based
material and preferably is a corrugated cardboard sheet coated with a
substrate, the
substrate is selected from a group comprising wax, a flexible polymer vinyl
wrap
sheet, a pressure activated adhesive polymer vinyl wrap, and rubber.
[0057] In an embodiment, the sheet of semi-rigid material 604 is be made of
plastic.
Preferably, the plurality of apertures 606 is adapted to receive the support
inserts 608.
The support inserts 608 are connected to the rigid spacers and standing
perpendicularly to the ring, at distal ends of the ring and at points in
between.
[0058] FIG. 7 illustrates a product-by-process flowchart 700 for making a
structural
frame, in an embodiment of the invention, comprising the steps of:
(a) providing 702 a sheet of semi-rigid material;
(b) attaching 704 a plurality of rigid spacers to the sheet;
(c) placing 706 a plurality of polygon shaped support inserts on the sheet,
connecting
the inserts to the rigid spacers and standing the inserts perpendicularly to
the sheet, at
distal ends of the sheet and at points in between the distal ends;
(d) wrapping 708 the sheet around the support inserts.
[0059] The structural frame preferably include at least one of a furniture
frame, a sofa
back frame, an arm rest, and a wall structure.
[0060] FIG. 8 is a perspective view of a structural frame for a wall panel
800, in an
embodiment of the invention, illustrating a partially exposed view of a
polygon
shaped support insert wrapped inside a semi-rigid sheet material.
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[00611 The wall panel 800 comprises a semi-rigid sheet 802, a support insert
804,
and perimeter rails 806 and 808. The support insert 804 is adapted to provide
support
and strength to the semi-rigid sheet 802.
[00621 FIG. 9 is a perspective view of a corrugated sofa end 900, according to
an
embodiment of the invention, illustrating a partially exposed view of a load
bearing
support insert wrapped inside a cardboard sheet. The sofa end 900 may comprise
a
corrugated board 902, a leg rail 904, and an inside arm panel 906.
[00631 The corrugated board 902 may be made up of a sheet of semi-rigid
material
Preferably made up of a corrugated cardboard with fluting that is selected
from a
group comprising B fluting and E fluting.
[00641 In an embodiment, the sheet of semi-rigid material is coated with a
substrate
that is selected from a group comprising wax, a flexible polymer vinyl wrap
sheet, a
pressure activated adhesive polymer vinyl wrap, and rubber. In an embodiment,
the
corrugated board 902 may be made up of a plastic material. The leg rail 904
and the
inside arm panel 906 may be configured to provide support and strength for the
sofa
end 900.
[00651 FIG. 10 is a perspective view of a structural frame for a chair 1000,
in an
embodiment of the invention, comprising a sheet of semi-rigid material folded
in to
chair without legs, having a back portion 1002 and a plurality of load bearing
support
inserts placed within the folds of the lower side walls of the seat 1004 of
the chair
1000.
[00661 Unless defined otherwise, technical and scientific terms used herein
have the
same meaning as is commonly understood by one of skill in the art to which
this
invention belongs. The terms "a" and "an" do not denote a limitation of
quantity, but
rather denote the presence of at least one of the referenced item, and the
terms "front",
"back", "bottom", "perspective" and/or "top", unless otherwise noted, are
merely used
for convenience of description, and are not limited to any one position or
spatial
orientation.
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100671 In the foregoing description preferred embodiments of the invention
have been
presented for the purpose of illustration and description. They are not
intended to be
exhaustive or to limit the invention to the precise form disclosed. Obvious
modifications or variations are possible in light of the above teachings. The
embodiments were chosen and described to provide the best illustration of the
principles and the invention and its practical application, and to enable one
of
ordinary skill in the art to utilize the invention in various embodiments and
with
various modifications as are suited to the particular use contemplated. All
such
modifications and variations are within the scope of the invention as
determined by
the appended claims when interpreted in accordance with the breadth they are
fairly,
legally, and equitably entitled.
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