CA2736687A1 - Structural frames for furniture - Google Patents
Structural frames for furniture Download PDFInfo
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- CA2736687A1 CA2736687A1 CA 2736687 CA2736687A CA2736687A1 CA 2736687 A1 CA2736687 A1 CA 2736687A1 CA 2736687 CA2736687 CA 2736687 CA 2736687 A CA2736687 A CA 2736687A CA 2736687 A1 CA2736687 A1 CA 2736687A1
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- Prior art keywords
- sheet
- rigid
- polygon
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- semi
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Classifications
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47B—TABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
- A47B96/00—Details of cabinets, racks or shelf units not covered by a single one of groups A47B43/00 - A47B95/00; General details of furniture
- A47B96/20—Furniture panels or like furniture elements
- A47B96/205—Composite panels, comprising several elements joined together
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C17/00—Sofas; Couches; Beds
- A47C17/02—Sofas, couches, settees, or the like, without movable parts
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- Health & Medical Sciences (AREA)
- General Health & Medical Sciences (AREA)
- Nursing (AREA)
- Connection Of Plates (AREA)
Abstract
A sheet of semi-rigid material is used in the construction of structural frames. A structural frame comprises a sheet of a semi-rigid material as the body of a structural frame.
A structural frame for a furniture piece selected from a group comprising chairs, arm chairs, sofa back frames, and a wall structures prepared by a process comprising a plurality of 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 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; and (d) wrapping the sheet around the support inserts, preferably completely covering the support inserts with the sheet.
A structural frame for a furniture piece selected from a group comprising chairs, arm chairs, sofa back frames, and a wall structures prepared by a process comprising a plurality of 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 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; and (d) wrapping the sheet around the support inserts, preferably completely covering the support inserts with the sheet.
Description
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.
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:
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.
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:
(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.
(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.
1 i I
[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 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;
I I
(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 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, [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.
[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.
[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.
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.
i 1 i F
[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 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;
I I
(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 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, [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.
[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.
[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.
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.
i 1 i F
Claims (25)
1. A structural frame 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, 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.
(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.
2. The process of claim 1, wherein the sheet is provided with slots adapted to receive the support inserts.
3. The process of claim 1 comprising attaching the plurality of rigid spacers to the sheet with fasteners, the fasteners are selected from a group comprising adhesives, pressure-sensitive adhesive, staples, nails, rivets, metal hog rings, screws, bolts, and nuts.
4. The process of claim 1 comprising coating the sheet 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.
5. The process of claim 1, wherein the sheet is selected from group comprising corrugated sheet, glued sheet, and sheet attached to wood substrates.
6. The process of claim 1, wherein the rigid spacers are selected from group comprising pine wood, plywood, a rigid plastic, cedar, beach and mahogany.
7. The process of claim 1, wherein wrapping the sheet around the support inserts comprises completely covering the support inserts by the sheet.
8. The process of claim 1, wherein the rigid structure is selected from a group comprising a chair box structure; a sofa back frame structure; and a wall structure.
9. A structural frame, comprising:
(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.
(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.
10. The structural frame of claim 9, wherein the polygon ring is made up of a corrugated cellulose based material with fluting, the fluting is selected from a group comprising B
fluting and E
fluting.
fluting and E
fluting.
11. The structural frame of claim 9, wherein the polygon ring is 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.
12. The structural frame of claim 9, wherein the polygon ring is made up of plastic.
13. The structural frame of claim 9, wherein the polygon ring comprises slots adapted to receive the support inserts.
14. The structural frame of claim 9, wherein the rigid spacers are selected from a group comprising pine wood, plywood, a rigid plastic, cedar, beach and mahogany.
15. The structural frame of claim 9 is at least one of: a chair box; a sofa back frame; and a wall structure.
16. A sofa back frame, comprising:
(a) a sheet of semi-rigid material;
(b) a plurality of rigid spacers fixedly attached to the sheet; and (c) a plurality of polygon shaped support inserts, connected to the rigid spacers and standing perpendicularly to the sheet, at distal ends of the sheet and at points in between the distal ends.
(a) a sheet of semi-rigid material;
(b) a plurality of rigid spacers fixedly attached to the sheet; and (c) a plurality of polygon shaped support inserts, connected to the rigid spacers and standing perpendicularly to the sheet, at distal ends of the sheet and at points in between the distal ends.
17. The sofa back frame of claim 16, wherein the sheet is made up of a corrugated cardboard with fluting, the fluting is selected from a group comprising B fluting and E
fluting.
fluting.
18. The sofa back frame of claim 16, wherein the sheet of semi-rigid material is 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.
19. The sofa back frame of claim 16, wherein the sheet is made up of plastic.
20. The sofa back frame of claim 16, wherein the rigid spacers are selected from a group comprising pine wood, plywood, a rigid plastic, cedar, beach and mahogany.
21. The sofa back frame of claim 16, wherein the plurality of polygon shaped support inserts are selected from a group comprising a rigid plastic polygon, a sheet of cardboard folded into a polygon, a wax coated polygon and a rubber coated polygon.
22. A sheet of semi-rigid material is used in the construction of the body of structural frames.
23. A structural frame for a modular wall panel comprising a plurality of support inserts wrapped inside a sheet of semi-rigid material.
24. A support insert, comprising:
a three-dimensional polygon having a profile view adapted to match the profile shape of a desired structural frame having at least one slot to engage with a spacer and position the support insert on a sheet having the spacer, wherein the polygon is selected from a group comprising formed polygons, injection-molded polygons, and folded polygons.
a three-dimensional polygon having a profile view adapted to match the profile shape of a desired structural frame having at least one slot to engage with a spacer and position the support insert on a sheet having the spacer, wherein the polygon is selected from a group comprising formed polygons, injection-molded polygons, and folded polygons.
25. A folded support insert, comprising:
(a) a sheet of semi-rigid material folded into polygon;
(b) wherein the polygon has at least one slot to engage with a spacer and position the polygon on a sheet having the spacer.
(a) a sheet of semi-rigid material folded into polygon;
(b) wherein the polygon has at least one slot to engage with a spacer and position the polygon on a sheet having the spacer.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2736687 CA2736687A1 (en) | 2011-04-05 | 2011-04-05 | Structural frames for furniture |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2736687 CA2736687A1 (en) | 2011-04-05 | 2011-04-05 | Structural frames for furniture |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2736687A1 true CA2736687A1 (en) | 2012-10-05 |
Family
ID=46964775
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2736687 Abandoned CA2736687A1 (en) | 2011-04-05 | 2011-04-05 | Structural frames for furniture |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2736687A1 (en) |
-
2011
- 2011-04-05 CA CA 2736687 patent/CA2736687A1/en not_active Abandoned
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