US20200262696A1 - Molded manufacturing for modular furniture - Google Patents
Molded manufacturing for modular furniture Download PDFInfo
- Publication number
- US20200262696A1 US20200262696A1 US16/707,568 US201916707568A US2020262696A1 US 20200262696 A1 US20200262696 A1 US 20200262696A1 US 201916707568 A US201916707568 A US 201916707568A US 2020262696 A1 US2020262696 A1 US 2020262696A1
- Authority
- US
- United States
- Prior art keywords
- structural frame
- cushioning material
- furniture
- furniture component
- molded
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Images
Classifications
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C23/00—Spring mattresses with rigid frame or forming part of the bedstead, e.g. box springs; Divan bases; Slatted bed bases
- A47C23/06—Spring mattresses with rigid frame or forming part of the bedstead, e.g. box springs; Divan bases; Slatted bed bases using wooden springs, e.g. of slat type ; Slatted bed bases
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C13/00—Convertible chairs, stools or benches
- A47C13/005—Modular seating
-
- 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
- A47C17/04—Seating furniture, e.g. sofas, couches, settees, or the like, with movable parts changeable to beds; Chair beds
-
- 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
- A47C17/86—Parts or details for beds, sofas or couches only not fully covered in a single one of the sub-groups A47C17/02, A47C17/04, A47C17/38, A47C17/52, A47C17/64, or A47C17/84; Drawers in or under beds
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C19/00—Bedsteads
- A47C19/005—Bedsteads dismountable
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/04—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
- A47C27/06—Spring inlays
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
- A47C27/148—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays of different resilience
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C5/00—Chairs of special materials
- A47C5/12—Chairs of special materials of plastics, with or without reinforcement
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C7/00—Parts, details, or accessories of chairs or stools
- A47C7/02—Seat parts
- A47C7/025—Springs not otherwise provided for in A47C7/22 - A47C7/35
- A47C7/028—Springs not otherwise provided for in A47C7/22 - A47C7/35 with wooden springs, e.g. slated type
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C7/00—Parts, details, or accessories of chairs or stools
- A47C7/02—Seat parts
- A47C7/18—Seat parts having foamed material included in cushioning part
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C7/00—Parts, details, or accessories of chairs or stools
- A47C7/02—Seat parts
- A47C7/24—Upholstered seats
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C7/00—Parts, details, or accessories of chairs or stools
- A47C7/02—Seat parts
- A47C7/28—Seat parts with tensioned springs, e.g. of flat type
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C7/00—Parts, details, or accessories of chairs or stools
- A47C7/02—Seat parts
- A47C7/35—Combinations of different types of springs; Adjustable springs; Attachment of springs to other springs or to the base frame ; Springs for seat parts not provided for in other groups of this subclass
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C7/00—Parts, details, or accessories of chairs or stools
- A47C7/62—Accessories for chairs
- A47C7/622—Receptacles, e.g. cup holders, storage containers
- A47C7/626—Receptacles, e.g. cup holders, storage containers directly under the seat
- A47C7/628—Receptacles, e.g. cup holders, storage containers directly under the seat accessible by displacement of seat
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B68—SADDLERY; UPHOLSTERY
- B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
- B68G5/00—Resilient upholstery pads
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B68—SADDLERY; UPHOLSTERY
- B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
- B68G7/00—Making upholstery
- B68G7/05—Covering or enveloping cores of pads
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C7/00—Parts, details, or accessories of chairs or stools
- A47C7/62—Accessories for chairs
- A47C7/622—Receptacles, e.g. cup holders, storage containers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/58—Upholstery or cushions, e.g. vehicle upholstery or interior padding
Definitions
- This invention is in the field of furniture and manufacturing of furniture.
- the present invention relates to apparatus and methods of manufacturing modular furniture components.
- Modular furniture can be used to create customized furniture, such as sectionals, couches, chairs, beds, and other furniture items.
- Modular furniture components are generally manufactured using base members and transverse members that require frames, cushioning, and upholstery. During the manufacturing process of modular furniture components, it is often necessary to manufacture multiple parts and then separately assemble the multiple parts together to form, for example, a frame of a base structure.
- the frame of a modular furniture base structure may include cutting multiple wooden pieces and securing them together via fasteners such as screws, nails, staples, adhesives, and the like. Additional hardware, such as furniture feet, springs, and the like, are then added to the frame separately using more hardware, as noted above. This manufacturing process is time consuming and can be complex and unreliable when a large number of parts are required.
- Additional assembly including securing cushioning and upholstery to the base structure or frame, adds additional complexity that can be time consuming and costly.
- Increased manufacturing and assembly steps increase the likelihood of errors and defects appearing in the finished modular furniture components.
- a large number of assembly steps in the manufacturing process leads to inconsistency and variations between finished components, which further requires additional quality assurance processes. These processes add to the cost and affect efficiency of manufacturing modular furniture components.
- the present invention is in the field of furniture and manufacturing of furniture.
- the present invention relates to apparatus and methods of manufacturing modular furniture components.
- One method for manufacturing modular furniture includes molding a structural frame, securing cushioning around the structural frame, and applying upholstery to the structural frame.
- a method for integrally manufacturing modular furniture components includes molding a structural frame that includes a hollow body with a side or face (e.g., top face) that is at least partially open.
- the structural frame can also include a spring mechanism secured to the body that spans the open side or face of the body.
- an integrally manufactured furniture component includes a structural frame molded to be at least partially hollow.
- springs are molded across an open side or face of the structural frame.
- molded structures can be formed of polymeric (e.g., thermoplastic polymer) materials.
- the furniture component includes a cushioning material secured around at least a portion of the outside of the base structure, so as to cover the base structure (e.g., but not the springs), with upholstery fabric secured thereto.
- a cushioning material is added using fasteners, such as an adhesive or staples.
- the cushioning material may be added by processes like molding, such as a spray foam process.
- the furniture component can include a cushioning material secured around the outside of the structural frame, so as to cover the frame structure (e.g., but not the springs), and upholstery fabric secured thereto.
- a cushioning material secured around the outside of the structural frame, so as to cover the frame structure (e.g., but not the springs), and upholstery fabric secured thereto.
- an upholstery fabric is added by the use of fasteners, such as zippers, hooks, staples or Velcro.
- the various manufactured components may include base members, and/or transverse members, e.g., for use in assembling a chair, couch, or the like, such as disclosed in U.S. Pat. No. 7,213,885 entitled MODULAR FURNITURE ASSEMBLY, herein incorporated by reference in its entirety.
- the modular furniture components and methods disclosed in the present application may be used in connection with numerous furniture assemblies, e.g., such as, but not limited to, any similar to those disclosed in (i) U.S. Pat. No. 9,277,826, entitled MOUNTING PLATFORM FOR MODULAR FURNITURE ASSEMBLY, (ii) U.S. Pat. No.
- the furniture components manufactured according to embodiments described herein can be components of a modular furniture assembly, such as those described in the above referenced patents.
- Such modularity allows the furniture components to be selectively separated from and coupled to one another, for easier transportation and storage.
- Such modularity can also allow various furniture assemblies to be assembled from a small number (e.g., 2) of basic components (e.g., bases and transverse members).
- the modularity can allow a given transverse member to serve interchangeably as a backrest or armrest.
- the length of the base is substantially equal to the sum of the width of the base and the width of the transverse member.
- the transverse member can be conveniently interchangeable as a backrest or armrest in a variety of different furniture configurations.
- Such modularity allows a variety of furniture configurations to be formed from the base and transverse member, or from duplicates of those components, e.g., two bases and four transverse members can be used to form a sofa, for example, or a variety of different furniture configurations such as shown in the above patents.
- FIG. 1A is a perspective view of an exemplary modular furniture assembly in the form of a chair, including a base and a plurality of transverse members.
- FIG. 1B is a perspective view of another modular furniture assembly in the form of a chair, including a base and a transverse member.
- FIG. 1C is an exploded view, illustrating how the transverse member(s) and base are coupled to one another.
- FIGS. 1D-1E further illustrate how the transverse member(s) and base are coupleable to one another.
- FIG. 2 schematically illustrates a process for integrally manufacturing a modular furniture component (e.g., a transverse member or base), according to an implementation of the present disclosure.
- a modular furniture component e.g., a transverse member or base
- FIG. 3A-3C schematically illustrate a process for integrally manufacturing a modular furniture component (e.g., a base or transverse member), according to an implementation of the present disclosure.
- a modular furniture component e.g., a base or transverse member
- FIG. 4 schematically illustrates how coverings (e.g., an outer skin or otherwise) may be provided during manufacture of modular furniture components, according to an implementation of the present disclosure.
- FIG. 5 illustrates an example method for manufacturing a modular furniture component (e.g., base or transverse member), according to an implementation of the present disclosure.
- a modular furniture component e.g., base or transverse member
- FIG. 6 illustrates another example method for manufacturing a modular furniture component (e.g., base or transverse member), according to an implementation of the present disclosure.
- a modular furniture component e.g., base or transverse member
- the apparatus and manufacturing methods disclosed herein provide a streamlined, simplified method of manufacturing modular furniture components.
- the methods described herein require minimal assembly, which lessens manufacturing time and cost.
- manufacturing methods according to the present disclosure reduce the number of components needed to form a modular furniture base or transverse structure, thus reducing the labor associated with assembly thereof, as well as reducing quality assurance and other costly processes.
- FIG. 1A is a perspective view of a modular furniture assembly in the form of a chair 10 , one or more components of which may be manufactured according to the present invention.
- chair 10 includes a base member 12 , and one or more transverse members 14 coupleable to the base 12 , to form such a chair or other modular furniture assembly.
- Furniture assembly 10 e.g., a chair
- Furniture assembly 10 includes a seat cushion 18 positionable over base 12 , as well as a cushion 16 (e.g., for use as a seat back, against one of transverse members 14 ).
- Foot couplers 34 are shown for coupling feet 33 mounted on the bottom portions of transverse members 14 and bases 12 to each other, as described in Applicant's other patents and applications, already incorporated by reference.
- FIG. 1B is a perspective view of a similar modular furniture assembly 10 ′ (e.g., also in the form of a chair), including a base 12 and a transverse member 14 .
- a seat cushion 18 is shown positioned over base 12 , for seating a user.
- FIG. 1C shows the seat cushion 18 exploded off base 12 , illustrating how U-shaped coupler 15 can be used to couple any given transverse member 14 to base 12 .
- Such coupler 15 can also be used to couple 2 bases 12 to one another, as described in Applicants other patents and applications, already incorporated by reference.
- FIGS. 1D-1E further illustrate the base 12 , transverse member 14 , and how they are coupleable to one another.
- bases 12 and/or transverse members 14 may be manufactured according to methods described herein, by molding. It will be apparent that numerous other furniture components could similarly be manufactured through molding processes as described herein, such that bases 12 and transverse members 14 are merely exemplary of modular furniture components that may be so manufactured. Other furniture components, whether modular or otherwise, may benefit from manufacturing processes as described herein. Further examples of components that are useful in connection with the present invention, or that can be made using the techniques taught herein are shown in U.S. Pat. No. 7,213,885, which is incorporated herein by reference, and Applicant's other patents incorporated herein by reference.
- FIG. 2 illustrates steps of a method for integrally manufacturing modular furniture components, according to one implementation.
- the first step 110 is to mold a structural frame 118 as a single piece using a mold, e.g., with molding form pieces 112 a - 112 b to ensure the frame is molded in a desired shape as a structural frame 118 .
- the structural frame 118 can be molded as a hollow body with a top side or face that is at least partially open.
- FIG. 2 shows an implementation, wherein the structural frame 118 is made by direct injection 116 molding.
- Other implementations of a method for molding the frame structure can include other molding techniques generally known in the art, for example blow molding, compression molding, structural foam molding, gas assist molding and the like.
- one or more furniture support mechanisms are molded as part of the structural frame 118 .
- furniture feet are placed in the mold in appropriate positions so that when the structural frame 118 is molded, the feet are integrally formed with the structural frame 118 .
- a recess such as a threaded recess used to secure feet to the structural frame 118 or a recess used to accommodate a coupler that holds multiple bases 12 (or transverse members 14 ) together, can be integrally molded in with the structural frame 118 .
- the mold cavity itself may include space so that the material filled into the cavity to form structural frame 118 also forms feet, which would be integral with the structural frame, formed as a single piece of material with the structural frame 118 .
- a second step 120 includes the removal of the first form pieces 112 a - 112 b , in favor of applying a second mold, e.g., form pieces 136 a - 136 b , for the purposes of molding the cushioning material 132 .
- a third step 130 of the method includes molding a cushioning material 132 on the structural frame 118 .
- This can be done using form pieces 136 a - 136 b to implement the various methods of molding discussed above to shape the cushioning material 132 .
- the cushioning material 132 may be molded to the structural frame 118 using blow molding, compression molding and/or, as seen in this implementation, injection molding techniques (e.g., through injection molding port 134 ).
- the cushioning material 132 can be molded around the structural frame 118 using heat and pressure, causing the cushioning material 132 to chemically and/or mechanically bond to the structural frame 118 .
- the cushioning material 132 can be formed in such a way that it mechanically secures to the structural frame 118 .
- the cushioning material 132 can comprise a foam material.
- the material 132 may be different from the material from which structural frame 118 is formed (e.g., an injection molded rigid thermoplastic polymer for structural frame 118 versus a soft foam material for cushioning material 132 ).
- the cushioning material 132 is preferably a material comprising flexible, resilient, and durable material that provides a padded layer on top of and/or around the structural frame 118 .
- the structural frame 118 is made of a more rigid material than the cushioning material 132 , including hard plastics and other plastic or polymeric materials that are suitable for molding, as described herein.
- the structural frame 118 comprises expanded polypropylene (EPP).
- EPP expanded polypropylene
- Various other thermoplastic polyolefins and other thermoplastic polymers can be used.
- a fourth step 140 removes the second form pieces 136 a - 136 b .
- the fifth step 150 allows the structural frame 118 and connected cushioning material 132 to be wrapped in upholstery fabric 152 .
- Fifth step 150 includes applying upholstery fabric 152 over the cushioning material 132 which covers structural frame 118 .
- the upholstery fabric 152 is secured over the structural frame 118 and cushioning material 132 using adhesives, hook-and-loop fasteners, sewn thereto with thread, or any other suitable attachment mechanism.
- the upholstery fabric 152 may be secured over the structural frame 118 and/or cushioning 132 via snaps, such as hem snaps that snap into a channel formed in the structural frame 118 , buttons, clips, or via a sliding mechanism such as a zipper mechanism, or the like.
- snaps such as hem snaps that snap into a channel formed in the structural frame 118 , buttons, clips, or via a sliding mechanism such as a zipper mechanism, or the like.
- the upholstery fabric is configured as an upholstery fabric assembly that includes multiple sections or layers including a first fabric layer 152 and a second fabric layer 162 that can be secured separately or secured together and then secured over the cushioning material 132 that covers structural frame 118 .
- the upholstery fabric 152 is formed together as a slipcover and the structural frame 118 and cushioning material 132 is inserted therein.
- the upholstery layer 152 is part of the cushioning material 132 (e.g., a skin layer of the cushioning material 132 ).
- the cushioning material 132 and/or upholstery layer 152 may serve as both cushioning and upholstery or be integrally formed together.
- the upholstery layers ( 152 and 162 ) of the fabric assembly of FIG. 2 can be different types of outer covers made of various materials, e.g., tweed, cotton, synthetic, blend, leather, etc. They may be selected (and exchanged by a user) to cover the foam molded inner cover, for example, as illustrated, for example, in U.S. Pat. No. 10,212,519, entitled ELECTRONIC FURNITURE SYSTEMS WITH INTEGRATED INTERNAL SPEAKERS, which is incorporated herein by reference in its entirety.
- the outer layer may be many different pieces with a variety of different densities.
- the top layer which forms the inner cover, may be relatively firm, for example, so that when a person sits on it they would not feel the underlying rigid (e.g., wood or plastic) layers.
- Other foam portions may be softer.
- foam layers could be over molded over a molded frame, as described herein.
- the structural frame 118 is formed as a single, unitary piece. It can be appreciated that the structural frame can be formed as two or more pieces and subsequently molded, formed, or otherwise secured together, either via heat and pressure, adhesives, fasteners, or the like. Additionally, or alternatively, hardware, such as furniture feet, springs, bolts, threaded holes, clips, recesses, or other hardware can be integrally molded with the structural frame 118 .
- furniture components can be integrally molded into the base structure of the furniture components. Accordingly, two or more furniture components can be joined/secured together to form furniture pieces.
- the size, shape, and configuration of the furniture pieces comprising multiple furniture components can vary depending on the needs or wants of the manufacturer and/or end customer.
- Other furniture components can similarly be molded with the structural frame 118 .
- These embodiments may include, but are not limited to, molded feet for furniture pieces or molded hook Velcro for attaching fabric or cushioning.
- the structural frame 118 may represent a base 12 , transverse member 14 , or other component useful in assembling a furniture assembly, such as chair 10 , 10 ′ of FIGS. 1A-1C .
- the molded structural frame 118 can include webs, venting holes for providing airflow and/or decreasing the weight of the molded component, etc. as desired. Examples of such webbing structures, venting holes, and the like that can be molded as part of the structural frame 118 (e.g., as part of a base 12 or part of a transverse member 14 ) are described in the U.S. Provisional Application No. 62/806,516, to which priority is claimed herein and which is incorporated herein by reference, and/or in Applicant's U.S. patent applications bearing Attorney Docket Nos. 15605.245.2 and 15605.245.6, both filed the same day as the present application, and each of which is herein incorporated by reference in its entirety.
- the molded structural frame 118 can be formed as a monolithic structure where feet, attachment structures, and/or other hardware associated with such structure, can be formed from a single piece of material (e.g., EPP). Alternatively, feet or other associated structures could be separately formed, for later attachment to the structural frame.
- the molded structural frame 118 can include web structures, cross-hatching, patterning, groove formation, or other patterns, venting holes, apertures, etc.
- FIGS. 3A-3C illustrate a furniture component that has been manufactured according to implementations of a manufacturing method described herein.
- the structural frame 118 is molded, as described above.
- the structural frame 118 can take on any number of shapes, dimensions, and sizes.
- the structural frame 118 is a substantially hollow rectangular prism (solid) structure.
- the structural frame 118 has a side or face that is at least partially open to expose the inside of the hollow rectangular prism.
- the top face of the structural frame 118 is open.
- the springs 200 comprise elongated strips of material.
- the material, for springs 200 is the same material as that of the structural frame 118 (EPP).
- the structural frame 118 of FIGS. 3A-3C can be molded as a single unitary piece that includes the springs 200 and the remaining portion of structural frame 118 .
- the springs 200 comprise material that is different from the remainder of the structural frame 118 .
- the spring materials are preferably durable and at least somewhat flexible or elastic so that the springs 200 flex without breaking or permanently deforming when a force is applied from above. Such a force, for example, may result from a person sitting or lying on the structural frame 118 (e.g., on the open end thereof, against springs 200 ).
- the springs 200 comprise elongate strips of material that span the opening in the top face of the structural frame 118 . As seen in FIG. 3A , a plurality of springs 200 span the opening. The number, size, shape, and materials of the springs 200 may vary between embodiments of the furniture component of the present disclosure.
- the springs 200 are integrally molded with the remaining structural frame 118 , all as a single molded piece.
- the springs 200 are formed separately and then secured to the remainder of the structural frame 118 .
- the springs 200 are secured to the structural frame 118 by welding, adhesion, mechanical fit, screws, bolts, or the like.
- FIG. 3B further illustrates a step of securing a cushioning material 132 around the structural frame 118 .
- the cushioning material 132 is secured around the outside perimeter (e.g., bottom face and sides) of the structural frame 118 as well as portions of the top face of the structural frame.
- the cushioning 132 does not extend over the springs 200 .
- the cushioning material 132 may extend at least partially or totally over the springs 200 .
- the cushioning material 132 can be secured to the structural frame 118 in a number of ways.
- the cushioning material 132 is secured to the structural frame 118 using adhesives/glues.
- the cushioning material 132 is secured to the structural frame 118 by mechanically interlocking with the structural frame 118 .
- the cushioning material 132 is molded to the structural frame 118 (e.g., a 2-step molding process, where the cushioning material 132 is molded over the more rigid structural frame 118 ).
- heat and/or pressure can be applied to the cushioning material 132 and the structural frame 118 to bond the cushioning material 132 to the material of the structural frame 118 , either chemically or mechanically.
- dedicated attachment mechanisms e.g., adhesives/glue and/or clips such as J-clips
- the molding of cushioning material 132 to the structural frame 118 may substantially eliminate the need to cut cushioning material 132 , for subsequent attachment to a furniture component. Instead, a precise registration of cushioning material 132 , such as flexible foam, can be molded to the structural frame 118 . In such a method, no cutting is necessary, which reduces material waste and saves time during the manufacturing process.
- FIG. 3C illustrates a third step for integrally manufacturing a modular furniture component.
- upholstery fabric 152 is secured to the furniture component over the cushioning material 132 which covers structural frame 118 .
- Various fabrics or other materials can be used for the upholstery material 152 .
- twill fabric is used as the upholstery material 152 .
- Other embodiments may use upholstery fabric comprising fabrics other than twill.
- such an upholstery material e.g., twill
- an inner liner which covers the underlying frame components of the base, transverse member, or other furniture component.
- An outer cover e.g., layer 162
- the upholstery fabric 152 is secured to the cushioning material 132 and/or structural frame 118 materials using an adhesive. In one or more other embodiments, other methods may be used to secure the upholstery 152 to the furniture component.
- the upholstery 152 is sewn to the furniture component.
- the upholstery material 152 is formed together as a slipcover and the furniture component is inserted therein.
- hook-and-loop fastening methods such as Velcro, can be used to secure the upholstery fabric 152 together and on/around the furniture component.
- more than one type of fabric, as well as multiple independent sections of said fabric can be used to cover the furniture component.
- one or more embodiments include upholstery material 152 that is secured to an inner side of the structural frame 118 .
- one embodiment of the structural frame 118 is hollow so that the structural frame 118 possesses inner surfaces. In one embodiment, at least a portion of the inner surfaces of such a structural frame 118 are also covered in upholstery fabric 152 .
- Upholstery fabric 152 is secured to the inner surfaces of the structural frame 118 in the same way upholstery fabric 152 is secured to the outer surfaces around the base structure 118 , as described above, such as by chemical or mechanical means, including glue, adhesives, Velcro, snaps, or clips such as J-clips.
- the upholstery fabric secured to the inner surfaces of the structural frame 118 may comprise the same or different materials as the upholstery fabric secured around the outside of the structural frame 118 .
- FIG. 4 illustrates an embodiment showing molding examples to make transverse members 314 , using methods of the present invention, e.g., to make transverse members similar to transverse member 14 of FIGS. 1A-1E .
- Parts or all of the transverse members 314 of the present invention can be molded in a variety of different manners.
- foam 330 may be molded onto frame portions 332 of the transverse members, such as using a molding technique as shown in the perspective sectional view at 340 .
- FIG. 4 shows an exemplary foam 330 that may be molded integrally or otherwise attached onto a transverse member frame 332 to form the transverse member 314 shown.
- the foam may include an outer “skin” layer 320 (serving as an upholstery layer, such as inner liner layer 152 ) that is integrally formed as the outer surface of the underlying cushioning material 330 .
- a skin layer 320 may be substantially smooth, while the underlying cushioning material 330 may have a cushioned foamed (e.g., open or closed cells) structure.
- some polyurethane materials are capable of forming such an exterior smooth “skin layer” over the remainder of the polyurethane material, which assumes a cushioned foamed, cellular configuration.
- Other skin forming foam molding materials will be apparent to those of skill in the art.
- the manufacturing process can cut down on time that would normally be required to perform the tasks of applying a fabric cover (e.g., upholstery inner liner 152 , where an outer layer 162 may eventually also be provided) and the foam cushioning material 330 individually.
- a fabric cover e.g., upholstery inner liner 152 , where an outer layer 162 may eventually also be provided
- a liner material e.g., a fabric cover, which can eventually serve as an inner cover
- a liner material could be positioned within the mold, as the foam layer of the cushioning material is being formed about the structural frame.
- Such a liner material can bond to the cushioning material as the cushioning material is molded about the frame “core” of the furniture component.
- Such a method can also result in a structure where the furniture component includes a desired liner (e.g., inner cover) as it is removed from the mold.
- FIG. 5 shows a flowchart of steps associated with exemplary methods, such as method 400 .
- a first molding process is used to create a single piece structural frame (a transverse member frame) for the modular furniture component.
- the molding process can be as previously described. That is, the molding process can implement methods such as injection molding or blow molding or other techniques known in the art.
- a second molding process is used to create flexible foam cushioning in designated locations around the structural frame of the base or transverse member.
- this foam can be created through various suitable molding techniques.
- the cushioning material can be molded directly over the structural frame, e.g., formed integrally thereto, such as in a 2-step molding process, or can be attached via fasteners such as nails, screws, or staples, or with a glue or other adhesive.
- upholstery is attached around the flexible foam that covers the structural frame.
- the upholstery as described herein, can be applied to the frame and foam via fasteners such as nails, screws, or staples or with a glue or adhesive.
- the upholstery could also be applied as a slipcover and closed with zippers or the like.
- the upholstery layer could be an integrally formed “skin layer” that forms during molding or other formation of the foam layer.
- a second upholstery layer can also be provided (e.g., an inner liner, and an outer cover).
- FIG. 6 illustrates such a method 400 ′ where at 410 the first molding process creates the structural frame of the modular furniture component in one piece.
- a second molding process results in creation of a flexible foam cushioning material in designated locations around the structural frame, and at 430 ′, such second molding process is configured to also provide an integral outer “skin” layer, e.g., automatically, during such molding process.
- Such outer skin layer can serve as a liner layer about the modular furniture component.
- an outer covering upholstery layer e.g., outer cover
- the end user could select an outer cover of a desired material, color, etc. according to their own personal tastes, which provides the actual outer upholstery material seen by end users of the furniture assembly.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Health & Medical Sciences (AREA)
- General Health & Medical Sciences (AREA)
- Nursing (AREA)
- Manufacturing & Machinery (AREA)
- Mattresses And Other Support Structures For Chairs And Beds (AREA)
- Combinations Of Kitchen Furniture (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
Abstract
Description
- The present application claims priority to and the benefit of U.S. Provisional Application No. 62/806,516, under 35 U.S.C. 119(e), filed Feb. 15, 2019, entitled INTEGRATED MANUFACTURING FOR MODULAR FURNITURE, which is herein incorporated by reference in its entirety.
- This invention is in the field of furniture and manufacturing of furniture. In particular, the present invention relates to apparatus and methods of manufacturing modular furniture components.
- Modular furniture can be used to create customized furniture, such as sectionals, couches, chairs, beds, and other furniture items. Modular furniture components are generally manufactured using base members and transverse members that require frames, cushioning, and upholstery. During the manufacturing process of modular furniture components, it is often necessary to manufacture multiple parts and then separately assemble the multiple parts together to form, for example, a frame of a base structure.
- For example, the frame of a modular furniture base structure may include cutting multiple wooden pieces and securing them together via fasteners such as screws, nails, staples, adhesives, and the like. Additional hardware, such as furniture feet, springs, and the like, are then added to the frame separately using more hardware, as noted above. This manufacturing process is time consuming and can be complex and unreliable when a large number of parts are required.
- Additional assembly, including securing cushioning and upholstery to the base structure or frame, adds additional complexity that can be time consuming and costly. Increased manufacturing and assembly steps increase the likelihood of errors and defects appearing in the finished modular furniture components. Also, a large number of assembly steps in the manufacturing process leads to inconsistency and variations between finished components, which further requires additional quality assurance processes. These processes add to the cost and affect efficiency of manufacturing modular furniture components.
- Accordingly, there is a need for apparatus and methods of manufacturing modular furniture components that solve these and other problems.
- During the manufacturing process of modular furniture components, it is often necessary to manufacture multiple parts and then separately assemble the multiple parts together to form furniture pieces. This method of manufacturing can be costly, labor intensive, and can lead to errors in production.
- The present invention is in the field of furniture and manufacturing of furniture. In particular, the present invention relates to apparatus and methods of manufacturing modular furniture components.
- One method for manufacturing modular furniture includes molding a structural frame, securing cushioning around the structural frame, and applying upholstery to the structural frame.
- In one or more embodiments, a method for integrally manufacturing modular furniture components includes molding a structural frame that includes a hollow body with a side or face (e.g., top face) that is at least partially open. The structural frame can also include a spring mechanism secured to the body that spans the open side or face of the body. In one embodiment, an integrally manufactured furniture component includes a structural frame molded to be at least partially hollow. In one or more embodiments, there is a spring mechanism created in a separate process, or as part of another process. Such processes could include creating a molded structure, e.g., of metal or a polymeric or other suitable material. After the completion of the creation of the spring mechanism, it is attached to the molded frame and is secured to the frame by means of a fastener, such as screws, nails, etc.
- Alternatively, in one or more embodiments, springs are molded across an open side or face of the structural frame. Such molded structures can be formed of polymeric (e.g., thermoplastic polymer) materials. In addition, the furniture component includes a cushioning material secured around at least a portion of the outside of the base structure, so as to cover the base structure (e.g., but not the springs), with upholstery fabric secured thereto.
- In one embodiment, a cushioning material is added using fasteners, such as an adhesive or staples. In one or more embodiments, the cushioning material may be added by processes like molding, such as a spray foam process.
- In addition, the furniture component can include a cushioning material secured around the outside of the structural frame, so as to cover the frame structure (e.g., but not the springs), and upholstery fabric secured thereto. In one embodiment, an upholstery fabric is added by the use of fasteners, such as zippers, hooks, staples or Velcro.
- The various manufactured components may include base members, and/or transverse members, e.g., for use in assembling a chair, couch, or the like, such as disclosed in U.S. Pat. No. 7,213,885 entitled MODULAR FURNITURE ASSEMBLY, herein incorporated by reference in its entirety. The modular furniture components and methods disclosed in the present application may be used in connection with numerous furniture assemblies, e.g., such as, but not limited to, any similar to those disclosed in (i) U.S. Pat. No. 9,277,826, entitled MOUNTING PLATFORM FOR MODULAR FURNITURE ASSEMBLY, (ii) U.S. Pat. No. 8,783,778, entitled MOUNTING PLATFORM FOR MODULAR FURNITURE ASSEMBLY, (iii) U.S. Pat. No. 7,963,612 entitled MODULAR FURNITURE ASSEMBLY, (iv) U.S. Pat. No. 7,547,073, entitled MODULAR FURNITURE ASSEMBLY, (v) U.S. Pat. No. 7,213,885 entitled MODULAR FURNITURE ASSEMBLY, (vi) U.S. Publication No. 2017/0367486 entitled MODULAR FURNITURE ASSEMBLY CORNER SEATING SYSTEM, (vii) U.S. Pat. No. 10,212,519 entitled ELECTRONIC FURNITURE SYSTEMS WITH INTEGRATED INTERNAL SPEAKERS, (viii) U.S. Pat. No. 10,236,643 entitled ELECTRICAL HUB FOR FURNITURE ASSEMBLIES, (ix) U.S. Pat. No. 10,143,307 entitled FURNITURE SYSTEM WITH RECLINER ASSEMBLY, and (x) U.S. Pat. No. 10,123,621 entitled FURNITURE SYSTEM RECLINER ASSEMBLY WITH SLED RAILS, each of which is herein incorporated by reference in its entirety.
- By way of example, the furniture components manufactured according to embodiments described herein can be components of a modular furniture assembly, such as those described in the above referenced patents. Such modularity allows the furniture components to be selectively separated from and coupled to one another, for easier transportation and storage. Such modularity can also allow various furniture assemblies to be assembled from a small number (e.g., 2) of basic components (e.g., bases and transverse members). The modularity can allow a given transverse member to serve interchangeably as a backrest or armrest. In one embodiment, the length of the base is substantially equal to the sum of the width of the base and the width of the transverse member. The transverse member can be conveniently interchangeable as a backrest or armrest in a variety of different furniture configurations. Such modularity allows a variety of furniture configurations to be formed from the base and transverse member, or from duplicates of those components, e.g., two bases and four transverse members can be used to form a sofa, for example, or a variety of different furniture configurations such as shown in the above patents.
- These and other objects and features of the present invention will become more fully apparent from the following description and appended claims or may be learned by the practice of the invention as set forth hereinafter.
- To further clarify the above and other advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only illustrated embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings.
-
FIG. 1A is a perspective view of an exemplary modular furniture assembly in the form of a chair, including a base and a plurality of transverse members. -
FIG. 1B is a perspective view of another modular furniture assembly in the form of a chair, including a base and a transverse member. -
FIG. 1C is an exploded view, illustrating how the transverse member(s) and base are coupled to one another. -
FIGS. 1D-1E further illustrate how the transverse member(s) and base are coupleable to one another. -
FIG. 2 schematically illustrates a process for integrally manufacturing a modular furniture component (e.g., a transverse member or base), according to an implementation of the present disclosure. -
FIG. 3A-3C schematically illustrate a process for integrally manufacturing a modular furniture component (e.g., a base or transverse member), according to an implementation of the present disclosure. -
FIG. 4 schematically illustrates how coverings (e.g., an outer skin or otherwise) may be provided during manufacture of modular furniture components, according to an implementation of the present disclosure. -
FIG. 5 illustrates an example method for manufacturing a modular furniture component (e.g., base or transverse member), according to an implementation of the present disclosure. -
FIG. 6 illustrates another example method for manufacturing a modular furniture component (e.g., base or transverse member), according to an implementation of the present disclosure. - The manufacturing process of modular furniture can be time consuming complex and unreliable when a large number of parts are required. When many pieces need to be combined, a significant number of man hours must be spent assembling the furniture piece and checking quality to ensure proper assembly.
- The apparatus and manufacturing methods disclosed herein provide a streamlined, simplified method of manufacturing modular furniture components. In particular, the methods described herein require minimal assembly, which lessens manufacturing time and cost. For example, manufacturing methods according to the present disclosure reduce the number of components needed to form a modular furniture base or transverse structure, thus reducing the labor associated with assembly thereof, as well as reducing quality assurance and other costly processes.
-
FIG. 1A is a perspective view of a modular furniture assembly in the form of achair 10, one or more components of which may be manufactured according to the present invention. For example,chair 10 includes abase member 12, and one or moretransverse members 14 coupleable to thebase 12, to form such a chair or other modular furniture assembly. Furniture assembly 10 (e.g., a chair) includes aseat cushion 18 positionable overbase 12, as well as a cushion 16 (e.g., for use as a seat back, against one of transverse members 14).Foot couplers 34 are shown forcoupling feet 33 mounted on the bottom portions oftransverse members 14 andbases 12 to each other, as described in Applicant's other patents and applications, already incorporated by reference. -
FIG. 1B is a perspective view of a similarmodular furniture assembly 10′ (e.g., also in the form of a chair), including abase 12 and atransverse member 14. Aseat cushion 18 is shown positioned overbase 12, for seating a user.FIG. 1C shows theseat cushion 18 exploded offbase 12, illustrating howU-shaped coupler 15 can be used to couple any giventransverse member 14 tobase 12.Such coupler 15 can also be used to couple 2bases 12 to one another, as described in Applicants other patents and applications, already incorporated by reference.FIGS. 1D-1E further illustrate thebase 12,transverse member 14, and how they are coupleable to one another. As will be further described herein, bases 12 and/ortransverse members 14 may be manufactured according to methods described herein, by molding. It will be apparent that numerous other furniture components could similarly be manufactured through molding processes as described herein, such thatbases 12 andtransverse members 14 are merely exemplary of modular furniture components that may be so manufactured. Other furniture components, whether modular or otherwise, may benefit from manufacturing processes as described herein. Further examples of components that are useful in connection with the present invention, or that can be made using the techniques taught herein are shown in U.S. Pat. No. 7,213,885, which is incorporated herein by reference, and Applicant's other patents incorporated herein by reference. -
FIG. 2 illustrates steps of a method for integrally manufacturing modular furniture components, according to one implementation. In this implementation, thefirst step 110 is to mold astructural frame 118 as a single piece using a mold, e.g., with molding form pieces 112 a-112 b to ensure the frame is molded in a desired shape as astructural frame 118. Thestructural frame 118 can be molded as a hollow body with a top side or face that is at least partially open.FIG. 2 shows an implementation, wherein thestructural frame 118 is made bydirect injection 116 molding. Other implementations of a method for molding the frame structure can include other molding techniques generally known in the art, for example blow molding, compression molding, structural foam molding, gas assist molding and the like. - In one embodiment, one or more furniture support mechanisms are molded as part of the
structural frame 118. For example, furniture feet are placed in the mold in appropriate positions so that when thestructural frame 118 is molded, the feet are integrally formed with thestructural frame 118. Also, for example, a recess, such as a threaded recess used to secure feet to thestructural frame 118 or a recess used to accommodate a coupler that holds multiple bases 12 (or transverse members 14) together, can be integrally molded in with thestructural frame 118. In an embodiment, the mold cavity itself may include space so that the material filled into the cavity to formstructural frame 118 also forms feet, which would be integral with the structural frame, formed as a single piece of material with thestructural frame 118. - In the illustrated embodiment, a
second step 120 includes the removal of the first form pieces 112 a-112 b, in favor of applying a second mold, e.g., form pieces 136 a-136 b, for the purposes of molding thecushioning material 132. - A
third step 130 of the method, according to the illustrated implementation ofFIG. 2 , includes molding acushioning material 132 on thestructural frame 118. This can be done using form pieces 136 a-136 b to implement the various methods of molding discussed above to shape thecushioning material 132. That is, thecushioning material 132 may be molded to thestructural frame 118 using blow molding, compression molding and/or, as seen in this implementation, injection molding techniques (e.g., through injection molding port 134). For example, in one implementation, thecushioning material 132 can be molded around thestructural frame 118 using heat and pressure, causing thecushioning material 132 to chemically and/or mechanically bond to thestructural frame 118. In another implementation, thecushioning material 132 can be formed in such a way that it mechanically secures to thestructural frame 118. - In one implementation, the
cushioning material 132 can comprise a foam material. Thematerial 132 may be different from the material from whichstructural frame 118 is formed (e.g., an injection molded rigid thermoplastic polymer forstructural frame 118 versus a soft foam material for cushioning material 132). Thecushioning material 132 is preferably a material comprising flexible, resilient, and durable material that provides a padded layer on top of and/or around thestructural frame 118. Thestructural frame 118 is made of a more rigid material than thecushioning material 132, including hard plastics and other plastic or polymeric materials that are suitable for molding, as described herein. For example, in one implementation, thestructural frame 118 comprises expanded polypropylene (EPP). Various other thermoplastic polyolefins and other thermoplastic polymers can be used. - In the illustrated embodiment, a
fourth step 140 removes the second form pieces 136 a-136 b. Thefifth step 150 allows thestructural frame 118 and connectedcushioning material 132 to be wrapped inupholstery fabric 152.Fifth step 150 includes applyingupholstery fabric 152 over thecushioning material 132 which coversstructural frame 118. In one implementation, theupholstery fabric 152 is secured over thestructural frame 118 andcushioning material 132 using adhesives, hook-and-loop fasteners, sewn thereto with thread, or any other suitable attachment mechanism. In one or more implementations, theupholstery fabric 152 may be secured over thestructural frame 118 and/or cushioning 132 via snaps, such as hem snaps that snap into a channel formed in thestructural frame 118, buttons, clips, or via a sliding mechanism such as a zipper mechanism, or the like. - In one implementation, as shown at
step 160, the upholstery fabric is configured as an upholstery fabric assembly that includes multiple sections or layers including afirst fabric layer 152 and asecond fabric layer 162 that can be secured separately or secured together and then secured over thecushioning material 132 that coversstructural frame 118. In another implementation, theupholstery fabric 152 is formed together as a slipcover and thestructural frame 118 andcushioning material 132 is inserted therein. In yet another implementation, theupholstery layer 152 is part of the cushioning material 132 (e.g., a skin layer of the cushioning material 132). In such an implementation, thecushioning material 132 and/orupholstery layer 152 may serve as both cushioning and upholstery or be integrally formed together. - The upholstery layers (152 and 162) of the fabric assembly of
FIG. 2 can be different types of outer covers made of various materials, e.g., tweed, cotton, synthetic, blend, leather, etc. They may be selected (and exchanged by a user) to cover the foam molded inner cover, for example, as illustrated, for example, in U.S. Pat. No. 10,212,519, entitled ELECTRONIC FURNITURE SYSTEMS WITH INTEGRATED INTERNAL SPEAKERS, which is incorporated herein by reference in its entirety. The outer layer may be many different pieces with a variety of different densities. The top layer, which forms the inner cover, may be relatively firm, for example, so that when a person sits on it they would not feel the underlying rigid (e.g., wood or plastic) layers. Other foam portions may be softer. Such foam layers could be over molded over a molded frame, as described herein. - In the illustrated implementation of
FIG. 2 , thestructural frame 118 is formed as a single, unitary piece. It can be appreciated that the structural frame can be formed as two or more pieces and subsequently molded, formed, or otherwise secured together, either via heat and pressure, adhesives, fasteners, or the like. Additionally, or alternatively, hardware, such as furniture feet, springs, bolts, threaded holes, clips, recesses, or other hardware can be integrally molded with thestructural frame 118. - As noted above, in one or more embodiments, hardware necessary to secure multiple furniture components together, such as recesses, J-clips and/or other clips, latches, and the like, can be integrally molded into the base structure of the furniture components. Accordingly, two or more furniture components can be joined/secured together to form furniture pieces. The size, shape, and configuration of the furniture pieces comprising multiple furniture components can vary depending on the needs or wants of the manufacturer and/or end customer. Other furniture components can similarly be molded with the
structural frame 118. These embodiments may include, but are not limited to, molded feet for furniture pieces or molded hook Velcro for attaching fabric or cushioning. Thestructural frame 118 may represent a base 12,transverse member 14, or other component useful in assembling a furniture assembly, such aschair FIGS. 1A-1C . - The molded
structural frame 118 can include webs, venting holes for providing airflow and/or decreasing the weight of the molded component, etc. as desired. Examples of such webbing structures, venting holes, and the like that can be molded as part of the structural frame 118 (e.g., as part of a base 12 or part of a transverse member 14) are described in the U.S. Provisional Application No. 62/806,516, to which priority is claimed herein and which is incorporated herein by reference, and/or in Applicant's U.S. patent applications bearing Attorney Docket Nos. 15605.245.2 and 15605.245.6, both filed the same day as the present application, and each of which is herein incorporated by reference in its entirety. By way of example, the moldedstructural frame 118 can be formed as a monolithic structure where feet, attachment structures, and/or other hardware associated with such structure, can be formed from a single piece of material (e.g., EPP). Alternatively, feet or other associated structures could be separately formed, for later attachment to the structural frame. The moldedstructural frame 118 can include web structures, cross-hatching, patterning, groove formation, or other patterns, venting holes, apertures, etc. - Attention is now directed to the embodiment of
FIGS. 3A-3C which illustrate a furniture component that has been manufactured according to implementations of a manufacturing method described herein. First, as shown inFIG. 3A , thestructural frame 118 is molded, as described above. As previously indicated, thestructural frame 118 can take on any number of shapes, dimensions, and sizes. In the illustrated embodiment ofFIG. 3A , thestructural frame 118 is a substantially hollow rectangular prism (solid) structure. Thestructural frame 118 has a side or face that is at least partially open to expose the inside of the hollow rectangular prism. In the illustrated embodiment, the top face of thestructural frame 118 is open. - Also illustrated in
FIG. 3A are a number ofsprings 200 that span the opening in the top face of thestructural frame 118. In one implementation, thesprings 200 comprise elongated strips of material. In one embodiment, the material, forsprings 200 is the same material as that of the structural frame 118 (EPP). For example, thestructural frame 118 ofFIGS. 3A-3C can be molded as a single unitary piece that includes thesprings 200 and the remaining portion ofstructural frame 118. In one or more other implementations, thesprings 200 comprise material that is different from the remainder of thestructural frame 118. The spring materials are preferably durable and at least somewhat flexible or elastic so that thesprings 200 flex without breaking or permanently deforming when a force is applied from above. Such a force, for example, may result from a person sitting or lying on the structural frame 118 (e.g., on the open end thereof, against springs 200). - In one embodiment, the
springs 200 comprise elongate strips of material that span the opening in the top face of thestructural frame 118. As seen inFIG. 3A , a plurality ofsprings 200 span the opening. The number, size, shape, and materials of thesprings 200 may vary between embodiments of the furniture component of the present disclosure. - As mentioned, in one embodiment, such as shown in
FIG. 3A , thesprings 200 are integrally molded with the remainingstructural frame 118, all as a single molded piece. Alternatively, in one or more other embodiments, thesprings 200 are formed separately and then secured to the remainder of thestructural frame 118. In such an embodiment, thesprings 200 are secured to thestructural frame 118 by welding, adhesion, mechanical fit, screws, bolts, or the like. -
FIG. 3B further illustrates a step of securing acushioning material 132 around thestructural frame 118. As shown, thecushioning material 132 is secured around the outside perimeter (e.g., bottom face and sides) of thestructural frame 118 as well as portions of the top face of the structural frame. In the illustrated embodiment, the cushioning 132 does not extend over thesprings 200. In one or more other embodiments, thecushioning material 132 may extend at least partially or totally over thesprings 200. Thecushioning material 132 can be secured to thestructural frame 118 in a number of ways. For example, in one embodiment, thecushioning material 132 is secured to thestructural frame 118 using adhesives/glues. - Additionally, or alternatively, the
cushioning material 132 is secured to thestructural frame 118 by mechanically interlocking with thestructural frame 118. Also, in one embodiment, thecushioning material 132 is molded to the structural frame 118 (e.g., a 2-step molding process, where thecushioning material 132 is molded over the more rigid structural frame 118). For example, heat and/or pressure can be applied to thecushioning material 132 and thestructural frame 118 to bond thecushioning material 132 to the material of thestructural frame 118, either chemically or mechanically. In an embodiment, dedicated attachment mechanisms (e.g., adhesives/glue and/or clips such as J-clips) can be used, e.g., positioned between the two, to achieve the attachment. - The molding of
cushioning material 132 to thestructural frame 118 may substantially eliminate the need to cutcushioning material 132, for subsequent attachment to a furniture component. Instead, a precise registration ofcushioning material 132, such as flexible foam, can be molded to thestructural frame 118. In such a method, no cutting is necessary, which reduces material waste and saves time during the manufacturing process. - Additionally,
FIG. 3C illustrates a third step for integrally manufacturing a modular furniture component. In the third step,upholstery fabric 152 is secured to the furniture component over thecushioning material 132 which coversstructural frame 118. One or more sections or layers of fabric, as seen inFIG. 2 , at 152 and 162, can be used to cover the furniture component so that thecushioning material 132 is not exposed. Various fabrics or other materials can be used for theupholstery material 152. For example, in one embodiment, twill fabric is used as theupholstery material 152. Other embodiments may use upholstery fabric comprising fabrics other than twill. In an embodiment, such an upholstery material (e.g., twill) may be provided as an inner liner, which covers the underlying frame components of the base, transverse member, or other furniture component. An outer cover (e.g., layer 162) may be selected based on the preference of the end user, for positioning thereover, providing esthetics desired by the end user. - In one embodiment, the
upholstery fabric 152 is secured to thecushioning material 132 and/orstructural frame 118 materials using an adhesive. In one or more other embodiments, other methods may be used to secure theupholstery 152 to the furniture component. For example, in one embodiment, theupholstery 152 is sewn to the furniture component. Also, for example, in one embodiment, theupholstery material 152 is formed together as a slipcover and the furniture component is inserted therein. In yet another embodiment, hook-and-loop fastening methods, such as Velcro, can be used to secure theupholstery fabric 152 together and on/around the furniture component. Also, more than one type of fabric, as well as multiple independent sections of said fabric, can be used to cover the furniture component. - In addition to securing
upholstery material 152 around the outside of thestructural frame 118, one or more embodiments includeupholstery material 152 that is secured to an inner side of thestructural frame 118. For example, as noted above, one embodiment of thestructural frame 118 is hollow so that thestructural frame 118 possesses inner surfaces. In one embodiment, at least a portion of the inner surfaces of such astructural frame 118 are also covered inupholstery fabric 152.Upholstery fabric 152 is secured to the inner surfaces of thestructural frame 118 in the sameway upholstery fabric 152 is secured to the outer surfaces around thebase structure 118, as described above, such as by chemical or mechanical means, including glue, adhesives, Velcro, snaps, or clips such as J-clips. The upholstery fabric secured to the inner surfaces of thestructural frame 118 may comprise the same or different materials as the upholstery fabric secured around the outside of thestructural frame 118. -
FIG. 4 illustrates an embodiment showing molding examples to maketransverse members 314, using methods of the present invention, e.g., to make transverse members similar totransverse member 14 ofFIGS. 1A-1E . Parts or all of thetransverse members 314 of the present invention can be molded in a variety of different manners. In some embodiments,foam 330 may be molded ontoframe portions 332 of the transverse members, such as using a molding technique as shown in the perspective sectional view at 340.FIG. 4 shows anexemplary foam 330 that may be molded integrally or otherwise attached onto atransverse member frame 332 to form thetransverse member 314 shown. The foam may include an outer “skin” layer 320 (serving as an upholstery layer, such as inner liner layer 152) that is integrally formed as the outer surface of theunderlying cushioning material 330. Such askin layer 320 may be substantially smooth, while theunderlying cushioning material 330 may have a cushioned foamed (e.g., open or closed cells) structure. For example, some polyurethane materials are capable of forming such an exterior smooth “skin layer” over the remainder of the polyurethane material, which assumes a cushioned foamed, cellular configuration. Other skin forming foam molding materials will be apparent to those of skill in the art. By integrating theskin 320 andcushioning foam 330 that make up the exterior surface and cushioning portion ofmember 314, the manufacturing process can cut down on time that would normally be required to perform the tasks of applying a fabric cover (e.g., upholsteryinner liner 152, where anouter layer 162 may eventually also be provided) and thefoam cushioning material 330 individually. - In another embodiment, rather than automatically forming such an
integral skin layer 320, a liner material (e.g., a fabric cover, which can eventually serve as an inner cover) could be positioned within the mold, as the foam layer of the cushioning material is being formed about the structural frame. Such a liner material can bond to the cushioning material as the cushioning material is molded about the frame “core” of the furniture component. Such a method can also result in a structure where the furniture component includes a desired liner (e.g., inner cover) as it is removed from the mold. - Attention is now directed to
FIG. 5 , which shows a flowchart of steps associated with exemplary methods, such asmethod 400. For example, at 410, a first molding process is used to create a single piece structural frame (a transverse member frame) for the modular furniture component. The molding process can be as previously described. That is, the molding process can implement methods such as injection molding or blow molding or other techniques known in the art. - At 420, a second molding process is used to create flexible foam cushioning in designated locations around the structural frame of the base or transverse member. As described herein, this foam can be created through various suitable molding techniques. The cushioning material can be molded directly over the structural frame, e.g., formed integrally thereto, such as in a 2-step molding process, or can be attached via fasteners such as nails, screws, or staples, or with a glue or other adhesive.
- At 430, upholstery is attached around the flexible foam that covers the structural frame. The upholstery, as described herein, can be applied to the frame and foam via fasteners such as nails, screws, or staples or with a glue or adhesive. The upholstery could also be applied as a slipcover and closed with zippers or the like. As described herein, the upholstery layer could be an integrally formed “skin layer” that forms during molding or other formation of the foam layer. Where desired, a second upholstery layer can also be provided (e.g., an inner liner, and an outer cover).
- For example,
FIG. 6 illustrates such amethod 400′ where at 410 the first molding process creates the structural frame of the modular furniture component in one piece. At 420, a second molding process results in creation of a flexible foam cushioning material in designated locations around the structural frame, and at 430′, such second molding process is configured to also provide an integral outer “skin” layer, e.g., automatically, during such molding process. Such outer skin layer can serve as a liner layer about the modular furniture component. At 440, an outer covering upholstery layer (e.g., outer cover) can be selected or provided for positioning over the liner layer provided by the integral skin layer. For example, the end user could select an outer cover of a desired material, color, etc. according to their own personal tastes, which provides the actual outer upholstery material seen by end users of the furniture assembly. - The present invention may be embodied in other specific forms without departing from its spirit or characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
Claims (35)
Priority Applications (9)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US16/707,568 US20200262696A1 (en) | 2019-02-15 | 2019-12-09 | Molded manufacturing for modular furniture |
US16/788,026 US11659936B2 (en) | 2019-02-15 | 2020-02-11 | Modular furniture support systems |
EP20755033.6A EP3923768A4 (en) | 2019-02-15 | 2020-02-13 | Modular furniture support systems |
AU2020221266A AU2020221266A1 (en) | 2019-02-15 | 2020-02-13 | Modular furniture support systems |
PCT/US2020/018102 WO2020168070A1 (en) | 2019-02-15 | 2020-02-13 | Modular furniture support systems |
CN202080012121.1A CN113395918A (en) | 2019-02-15 | 2020-02-13 | Modular furniture support system |
CA3124853A CA3124853A1 (en) | 2019-02-15 | 2020-02-13 | Modular furniture support systems |
US18/137,629 US20230255358A1 (en) | 2019-02-15 | 2023-04-21 | Modular Furniture Support Systems |
US18/456,284 US20230404270A1 (en) | 2019-02-15 | 2023-08-25 | Modular mattress systems |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201962806516P | 2019-02-15 | 2019-02-15 | |
US16/707,568 US20200262696A1 (en) | 2019-02-15 | 2019-12-09 | Molded manufacturing for modular furniture |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/707,571 Continuation-In-Part US11191364B2 (en) | 2019-02-15 | 2019-12-09 | Furniture storage base |
Related Child Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/707,574 Continuation-In-Part US11178973B2 (en) | 2019-02-15 | 2019-12-09 | Furniture spring system |
US16/788,026 Continuation-In-Part US11659936B2 (en) | 2019-02-15 | 2020-02-11 | Modular furniture support systems |
Publications (1)
Publication Number | Publication Date |
---|---|
US20200262696A1 true US20200262696A1 (en) | 2020-08-20 |
Family
ID=72041001
Family Applications (4)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/707,568 Abandoned US20200262696A1 (en) | 2019-02-15 | 2019-12-09 | Molded manufacturing for modular furniture |
US16/707,574 Active US11178973B2 (en) | 2019-02-15 | 2019-12-09 | Furniture spring system |
US16/707,571 Active US11191364B2 (en) | 2019-02-15 | 2019-12-09 | Furniture storage base |
US17/532,536 Active US11659933B2 (en) | 2019-02-15 | 2021-11-22 | Furniture spring system |
Family Applications After (3)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/707,574 Active US11178973B2 (en) | 2019-02-15 | 2019-12-09 | Furniture spring system |
US16/707,571 Active US11191364B2 (en) | 2019-02-15 | 2019-12-09 | Furniture storage base |
US17/532,536 Active US11659933B2 (en) | 2019-02-15 | 2021-11-22 | Furniture spring system |
Country Status (1)
Country | Link |
---|---|
US (4) | US20200262696A1 (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
USD965332S1 (en) * | 2019-11-18 | 2022-10-04 | Oliver Bladek | Sofa |
US11633046B2 (en) | 2021-08-30 | 2023-04-25 | Raad Altemimei | Sectional seating system |
US11839305B2 (en) | 2021-08-30 | 2023-12-12 | Raad Altemimei | Sectional seating with connectors and suction holding |
Families Citing this family (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20160174715A1 (en) | 2005-06-10 | 2016-06-23 | Sac Acquisition Llc | Modular furniture assembly with dual coupling mechanisms |
US11696644B2 (en) | 2018-07-27 | 2023-07-11 | Ashley Furniture Industries, Llc | Upholstered furniture including molded furniture components |
DE202019100110U1 (en) * | 2019-01-10 | 2020-04-16 | Innotec Motion GmbH | Seating chassis |
US20200262696A1 (en) | 2019-02-15 | 2020-08-20 | The Lovesac Company | Molded manufacturing for modular furniture |
US11659936B2 (en) | 2019-02-15 | 2023-05-30 | The Lovesac Company | Modular furniture support systems |
US11350754B2 (en) * | 2019-09-11 | 2022-06-07 | MiEN Company | Modular furniture with replaceable panels |
MX2022006117A (en) * | 2019-11-20 | 2022-06-14 | Vetsak Gmbh | Modular furniture system. |
CN115334940A (en) * | 2020-03-16 | 2022-11-11 | 阿希礼家具工业有限公司 | Soft package furniture comprising a moulded furniture part |
US11612248B2 (en) * | 2020-06-11 | 2023-03-28 | Fomcore, Llc | Foam seat with removable nesting insert |
US11412847B2 (en) * | 2021-01-04 | 2022-08-16 | Plusmofa International Ltd. | Combination table |
USD989685S1 (en) * | 2021-04-26 | 2023-06-20 | Brunswick Corporation | Furniture for marine vessel |
USD989505S1 (en) * | 2021-04-26 | 2023-06-20 | Brunswick Corporation | Furniture for marine vessel |
USD988968S1 (en) * | 2021-05-06 | 2023-06-13 | Brunswick Corporation | Furniture for marine vessel |
Family Cites Families (145)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US371091A (en) * | 1887-10-04 | Extensible seat | ||
US132350A (en) * | 1872-10-22 | Improvement in spring-seats for furniture or cars | ||
US1318569A (en) * | 1919-10-14 | Planodraph co | ||
US746211A (en) | 1903-04-17 | 1903-12-08 | Arthur N Webb | Bed-slat fastener. |
US954594A (en) * | 1909-04-01 | 1910-04-12 | Alvoni G Shaw | Convertible chair. |
US956837A (en) * | 1909-06-25 | 1910-05-03 | Emil Guenther | Convertible chair and couch. |
US1459540A (en) | 1922-03-20 | 1923-06-19 | Labenz Ernst | Sectional mattress |
US1915674A (en) | 1932-01-16 | 1933-06-27 | Barber Mfg Co | Spring construction |
GB416620A (en) | 1933-11-24 | 1934-09-18 | Mueller Ludwig | Improvements relating to resilient supporting surfaces for seats, beds and the like |
DE676218C (en) | 1935-04-08 | 1939-05-30 | Anton Lorenz | Device for fastening the ends of the slats of a floor of seating or reclining furniture to their frame |
US2249266A (en) | 1938-04-16 | 1941-07-15 | Joseph D Bell | Combined chair and bed |
US2216991A (en) | 1939-01-19 | 1940-10-08 | Sallie D Trovillo | Mattress |
US2316628A (en) * | 1942-05-16 | 1943-04-13 | Kroehler Mfg Co | Laminated flexwood spring for chair seats |
US2358437A (en) * | 1942-09-15 | 1944-09-19 | Beachley Reichard Furniture Co | Upholstered chair |
US2371825A (en) * | 1942-09-28 | 1945-03-20 | Percy Solotoy | Furniture spring construction |
US2375289A (en) * | 1942-10-12 | 1945-05-08 | Julius Deutsch | Spring unit for use in furniture, autos, etc. |
US2358438A (en) * | 1942-10-23 | 1944-09-19 | Beachley Reichard Furniture Co | Upholstered chair |
US2446775A (en) | 1944-01-12 | 1948-08-10 | Marsack Patents Corp | Innerspring mattress construction |
US2466204A (en) * | 1944-12-26 | 1949-04-05 | William F Brown | Combination furniture |
US2547840A (en) | 1949-04-01 | 1951-04-03 | William B Smith | Sectional mattress |
US2793685A (en) * | 1953-04-24 | 1957-05-28 | Raymond F Spitz | Snap on sectional furniture |
US2886832A (en) * | 1957-02-28 | 1959-05-19 | Mitchell Tony | Adjustable bed slat |
US3030146A (en) * | 1958-08-18 | 1962-04-17 | Faxon Morris | Separable furniture construction |
US3117775A (en) * | 1961-07-26 | 1964-01-14 | Hamilton Cosco Inc | Slat for an article of furniture |
US3114578A (en) * | 1962-09-27 | 1963-12-17 | Hamilton Cosco Inc | Back rest |
US3588930A (en) * | 1967-03-30 | 1971-06-29 | Erik Hjalmar Frisell | Resilient bottom for furniture |
US3527499A (en) * | 1968-12-04 | 1970-09-08 | Alan E Rathbun | Spring seat front edge construction |
US3761970A (en) * | 1971-12-29 | 1973-10-02 | H Fredman | Adjustable bed carriage with adapter unit |
US4032188A (en) * | 1974-12-30 | 1977-06-28 | Jones Ferris E | Modular bench seat |
US4062584A (en) | 1976-09-08 | 1977-12-13 | Warren Pinkham | Combination seat and carrying case |
US4077666A (en) * | 1977-02-28 | 1978-03-07 | Metropolitan Furniture Manufacturing Co. | Modular seating arrangement and method |
US4523787A (en) * | 1982-03-08 | 1985-06-18 | Robinson Wilfred R | Furniture construction |
US4602817A (en) * | 1983-05-13 | 1986-07-29 | Steelcase Inc. | Modular furniture system |
CA1237204A (en) * | 1984-12-14 | 1988-05-24 | Max Magder | Upholstered furniture |
CN2040337U (en) | 1988-09-18 | 1989-07-05 | 王晓廷 | Combined foldable sofa bed |
US4868941A (en) | 1988-10-26 | 1989-09-26 | Tai Hsin Fen | Assembled mattress having bellows for jacketing spring therein |
US4932720A (en) * | 1988-11-14 | 1990-06-12 | Sherman Ronald K | Modular furniture system |
US4956884A (en) | 1988-11-18 | 1990-09-18 | Hwang Dye Shuh | Modular box spring mattress |
US5040255A (en) | 1990-06-06 | 1991-08-20 | Barber Manufacturing Company, Inc. | Cushion or mattress structure |
US5214809A (en) | 1992-06-29 | 1993-06-01 | Paul Stuart | Articulated mattress for adjustable bed |
US5316371A (en) * | 1993-03-25 | 1994-05-31 | Mccord Winn Textron | Adjustable vehicle seat |
US5471688A (en) | 1994-02-28 | 1995-12-05 | Cavazos; Frank G. | Modular innerspring and box spring assemblies |
US5485639A (en) | 1994-02-28 | 1996-01-23 | Cavazos; Frank G. | Modular innerspring and box spring assemblies |
US5435026A (en) | 1994-02-28 | 1995-07-25 | Cavazos; Frank G. | Mattress clip and mattress |
US5660436A (en) * | 1995-11-17 | 1997-08-26 | Wilson; Michael | Laterally extendable furniture |
US5700060A (en) * | 1996-08-07 | 1997-12-23 | Leggett And Platt, Inc. | Seating suspension assembly |
US5815860A (en) * | 1997-03-31 | 1998-10-06 | Mitchell; Herbert L. | Telescoping bed slat |
US5970547A (en) | 1997-04-07 | 1999-10-26 | Cavazos; Frank G. | Modular mattress and innerspring |
US6267446B1 (en) | 1997-05-14 | 2001-07-31 | Home Reserve, Inc. | Compressed upholstered furniture assembly kit and method of manufacture |
US5890767A (en) * | 1997-10-14 | 1999-04-06 | Chang; Yuan-Feng | Modular sofa |
US6338172B1 (en) * | 1997-10-15 | 2002-01-15 | Harry A. Taylor, et al. | Polymeric length and width adjustable bed frame system |
ID27521A (en) * | 1998-03-11 | 2001-04-12 | Sleep Tec Inc | SOFA SLEEP WITH AIR CASSES |
WO2000018275A1 (en) | 1998-09-25 | 2000-04-06 | Isaac Fogel | Multiple module mattress system |
US6050638A (en) * | 1998-11-02 | 2000-04-18 | West, Iii; David T | Article of furniture with secured compartment |
US6082825A (en) * | 1999-02-02 | 2000-07-04 | L&P Property Management Company | Seating suspension assembly |
US6116694A (en) * | 1999-02-03 | 2000-09-12 | L&P Property Management Company | Seating product with sinuous spring assemblies |
US6595592B1 (en) * | 1999-08-23 | 2003-07-22 | Wieland Furniture Company, Inc. | Article of furniture |
US6367880B1 (en) * | 1999-11-05 | 2002-04-09 | Alfred G. Niederman | Modular upholstered furniture construction |
US6758450B2 (en) * | 1999-11-05 | 2004-07-06 | Alfred G. Niederman | Modular furniture including interchangeable upholstery |
EP1106112A1 (en) * | 1999-11-30 | 2001-06-13 | Jimmy Wu | Modular chair construction |
ES2294021T3 (en) | 2000-08-23 | 2008-04-01 | Mario Piraino | IMPROVED BED MATTRESS. |
US7066548B2 (en) * | 2002-02-07 | 2006-06-27 | Moeller Marine Products | Take-down seating |
US20030151295A1 (en) | 2002-02-11 | 2003-08-14 | Shawn Nelson | Packaged furniture assembly and method thereof for compressible furniture |
US7066553B2 (en) | 2002-05-01 | 2006-06-27 | Fincastle County Chairworks, Llc | Furniture structure |
DE20207959U1 (en) | 2002-05-17 | 2002-11-28 | Frey Wolfgang | slatted |
US20040021359A1 (en) * | 2002-08-02 | 2004-02-05 | Yuan-Feng Chang | Modular sofa |
US6942298B2 (en) * | 2003-01-17 | 2005-09-13 | Larry W. Harrison | Five-part furniture frame and method of assembly |
US7181783B2 (en) | 2003-03-06 | 2007-02-27 | O'reilly Erin M | Multi-function room furnishing system having articulating separable components |
US7028859B2 (en) * | 2003-04-08 | 2006-04-18 | Suncast Corporation | Deck storage box |
US7770965B2 (en) | 2003-04-09 | 2010-08-10 | Shane Zwezdaryk | Chair |
US6796614B1 (en) * | 2003-04-23 | 2004-09-28 | James Robert Paul | Modular furniture unit |
US7252339B2 (en) * | 2003-09-15 | 2007-08-07 | Larry Owens | Bracket furniture components |
US20050067876A1 (en) * | 2003-09-26 | 2005-03-31 | Dortch John Patrick | Knockdown furniture assembly and method for making same |
ITMI20040037U1 (en) * | 2004-02-04 | 2004-05-04 | Gruppo Ind Styling Meccanis | ARMREST FOR SOFA INCLUDING MEANS OF FIXING TO THE FRAME OF THE SOFA |
CN2693098Y (en) * | 2004-04-02 | 2005-04-20 | 东莞南亚家具有限公司 | Combined sofa with adjustable backrest obliquity |
US7494182B2 (en) * | 2005-04-11 | 2009-02-24 | West & Knowles Design & Engineering, L.L.C. | Access and support system for convertible furniture |
US10070725B2 (en) | 2010-11-12 | 2018-09-11 | The Lovesac Company | Modular furniture assembly with dual coupling mechanisms |
US7213885B2 (en) | 2005-06-10 | 2007-05-08 | Sac Acquistion Llc | Modular furniture assembly |
US9277813B2 (en) | 2010-11-12 | 2016-03-08 | Sac Acquisition Llc | Modular furniture assembly and display kit with magnetic coupling assembly |
US20160174715A1 (en) | 2005-06-10 | 2016-06-23 | Sac Acquisition Llc | Modular furniture assembly with dual coupling mechanisms |
US8783778B2 (en) | 2005-06-10 | 2014-07-22 | Sac Acquistion Llc | Mounting platform for modular furniture assembly |
US20070001494A1 (en) | 2005-06-29 | 2007-01-04 | Randy Hoover | Method and apparatus for simultaneously simulating an environment while participating in an activity |
US6990701B1 (en) * | 2005-08-05 | 2006-01-31 | Vera Litvak | Sectional non-slip mattress |
RU2335223C2 (en) | 2005-09-27 | 2008-10-10 | Алексей Александрович Молоденов | Mattress, mattress module |
US8408653B2 (en) * | 2005-10-13 | 2013-04-02 | Billy Joe Griggs, Jr. | Ready to assemble sofa and method for packaging same |
US7744162B2 (en) * | 2005-10-13 | 2010-06-29 | Griggs Jr Billy Joe | Ready to assemble sofa and method for packaging same |
US8480179B2 (en) * | 2005-10-13 | 2013-07-09 | Billy Joe Griggs, Jr. | Ready to assemble sofa and method for packaging same |
US7322642B2 (en) * | 2006-04-12 | 2008-01-29 | Bojack Nancy L | Furniture system |
US20080098533A1 (en) | 2006-10-25 | 2008-05-01 | Erdman Thomas C | Modular mattress system |
US7568767B2 (en) * | 2006-12-28 | 2009-08-04 | Suncast Corporation | Snap-together patio bench |
US7861333B2 (en) | 2007-07-27 | 2011-01-04 | Night And Day Furniture Llc | Frames for futon sofa beds and methods of securing slats therein |
US8375483B2 (en) | 2007-07-27 | 2013-02-19 | Night And Day Furniture Llc | Daybeds and methods for converting daybeds |
KR100881350B1 (en) | 2007-10-09 | 2009-02-02 | 안정호 | A mattress |
US20090235451A1 (en) * | 2008-03-21 | 2009-09-24 | Markus Gorkin | Interchangeable upholstered furniture frame system |
US20100093257A1 (en) * | 2008-10-14 | 2010-04-15 | Elliott Joseph T | Ready to assemble structural system |
US7581786B1 (en) * | 2008-12-15 | 2009-09-01 | Wen-Tsan Wang | Combination chair |
WO2010113152A1 (en) * | 2009-04-02 | 2010-10-07 | Babyroo Ltd. | Dual hinged ovoid leave spring package for a seat |
US8689992B2 (en) * | 2011-02-03 | 2014-04-08 | Suncast Technologies, Llc | Wood and resin deck box |
US8777319B2 (en) * | 2011-03-30 | 2014-07-15 | Ashley Furniture Industries, Inc. | Furniture assembly system |
US8764114B1 (en) * | 2011-04-18 | 2014-07-01 | Simplicity Sofas, Inc | Ready to assemble sectional sofa and method |
KR101228569B1 (en) * | 2011-05-19 | 2013-02-07 | 한경희 | a health assembly chair |
AU2012325748B2 (en) | 2011-10-20 | 2017-07-20 | Dreamwell, Ltd. | Multi-piece mattress supporting foundation |
US8621685B2 (en) | 2011-11-11 | 2014-01-07 | Ki Ho Jin | Extendable folding bed frame |
TWI578937B (en) * | 2011-11-23 | 2017-04-21 | 雅詩立傢俱工業公司 | Ready to assembly furniture system |
US20130269114A1 (en) | 2012-04-16 | 2013-10-17 | Bridge Robin Wu | Modular Mattress Assembly |
US9247823B2 (en) * | 2012-09-28 | 2016-02-02 | Flexsteel Industries, Inc. | Seating unit with improved structure |
US9016794B2 (en) * | 2012-11-20 | 2015-04-28 | Ogg Design, Inc. | Modular chair and method of assembly |
US9603448B2 (en) | 2013-03-08 | 2017-03-28 | Sac Acquisition Llc | Modular shelving assembly with universal design ratio |
MX2015016420A (en) * | 2013-05-31 | 2016-07-05 | Ashley Furniture Ind Inc | Seat box with drop-in webbing assembly. |
GB201311073D0 (en) * | 2013-06-21 | 2013-08-07 | Cohen Martin | A seat core |
CA2930407C (en) * | 2013-11-11 | 2017-05-30 | Suncast Technologies, Llc | Blow molded resin furniture having a stabilizing box structure |
DE202013105757U1 (en) | 2013-12-18 | 2015-03-19 | Rummel Matratzen Gmbh & Co. Kg | Cushion core, in particular for a mattress, with connecting elements in the butt joints of the upholstery core parts, as well as a mattress with a cushion core |
TW201609024A (en) * | 2014-04-24 | 2016-03-16 | 雅詩立傢俱工業公司 | Drop in seat deck for furniture assemblies |
US9131782B1 (en) | 2014-05-01 | 2015-09-15 | Roger Baker | Modular pod mattress |
DE202014104327U1 (en) | 2014-09-12 | 2014-10-08 | Bali Schaumstoff Gmbh | Combinable seat reclining furniture |
US9668581B1 (en) * | 2014-10-15 | 2017-06-06 | Prominence Furniture & Finishing, Inc. | Knockdown sofa |
CH710418A2 (en) | 2014-11-28 | 2016-05-31 | Smartassist Gmbh | Multipart mattress assembly. |
US9888781B2 (en) * | 2014-12-01 | 2018-02-13 | Flexsteel Industries, Inc. | Extendible sofa |
CN205321855U (en) | 2015-06-30 | 2016-06-22 | 乐瑞亚洲有限公司 | Convertible bed |
CN204908714U (en) | 2015-07-09 | 2015-12-30 | 史磊 | Removable formula mattress core of inner core with shoulder recess |
US9936800B2 (en) | 2015-07-28 | 2018-04-10 | The Lovesac Company | Leisure seating workstation |
CA3035790A1 (en) * | 2015-09-08 | 2017-03-16 | Daniel CHIRIAC | Expandable seating furniture |
US20170119168A1 (en) | 2015-10-30 | 2017-05-04 | Intercoil International Co, LLC | Mattresses with mutilple customizable and replaceable levels and sections and methods thereof |
US10979241B2 (en) | 2015-11-19 | 2021-04-13 | The Lovesac Company | Electronic furniture systems with integrated artificial intelligence |
US11689856B2 (en) * | 2015-11-19 | 2023-06-27 | The Lovesac Company | Electronic furniture systems with integrated induction charger |
US10212519B2 (en) | 2015-11-19 | 2019-02-19 | The Lovesac Company | Electronic furniture systems with integrated internal speakers |
US10236643B2 (en) | 2015-11-19 | 2019-03-19 | The Lovesac Company | Electrical hub for furniture assemblies |
US11178486B2 (en) | 2015-11-19 | 2021-11-16 | The Lovesac Company | Modular furniture speaker assembly with reconfigurable transverse members |
US10123621B2 (en) | 2015-11-19 | 2018-11-13 | The Lovesac Company | Furniture system recliner assembly with sled rails |
US10143307B2 (en) | 2015-11-19 | 2018-12-04 | The Lovesac Company | Furniture system with recliner assembly |
US9950653B1 (en) * | 2016-03-17 | 2018-04-24 | Peter J. Burer | Seat suspension system |
US20170319938A1 (en) * | 2016-05-09 | 2017-11-09 | Samuel Chen | Spring Enclosed Trampoline |
US10188888B2 (en) * | 2016-05-09 | 2019-01-29 | Samuel Chen | Spring enclosed trampoline |
DE102016006237B4 (en) | 2016-05-23 | 2020-07-30 | Oke Group Gmbh | Cap arrangement for holding at least one female connector of a spring base for furniture or a frame and associated female connector |
US20170367486A1 (en) | 2016-06-24 | 2017-12-28 | Sac Acquisition Llc | Modular Furniture Assembly Corner Seating System |
US10470582B2 (en) | 2016-08-30 | 2019-11-12 | 4Rmiture & Co | Adjustable furniture frame system |
CN207011997U (en) | 2017-01-24 | 2018-02-16 | 杭州呼吧网络科技股份有限公司 | The mattress of Multi-stage module |
US10512338B1 (en) * | 2017-06-01 | 2019-12-24 | Ashley Furniture Industries, Inc. | Furniture assembly with metal seat stretcher |
CN108324004A (en) | 2018-03-19 | 2018-07-27 | 浙江农林大学 | A kind of customization mattress and production method |
US10506883B2 (en) * | 2018-05-17 | 2019-12-17 | Bruce Hirschhaut Designs, Inc. | Seating unit |
WO2020040064A1 (en) * | 2018-08-18 | 2020-02-27 | 株式会社マーベルコーポレーション | Outdoor structure |
US11160381B2 (en) * | 2019-01-29 | 2021-11-02 | Vanco Products LLC | Removable cushion for a chair, mold for making a cushion and a chair having a removable cushion |
US20200262696A1 (en) | 2019-02-15 | 2020-08-20 | The Lovesac Company | Molded manufacturing for modular furniture |
US11659936B2 (en) | 2019-02-15 | 2023-05-30 | The Lovesac Company | Modular furniture support systems |
US20210093087A1 (en) * | 2019-09-27 | 2021-04-01 | Albany Industries | Furniture Systems and Furniture System Components |
-
2019
- 2019-12-09 US US16/707,568 patent/US20200262696A1/en not_active Abandoned
- 2019-12-09 US US16/707,574 patent/US11178973B2/en active Active
- 2019-12-09 US US16/707,571 patent/US11191364B2/en active Active
-
2021
- 2021-11-22 US US17/532,536 patent/US11659933B2/en active Active
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
USD965332S1 (en) * | 2019-11-18 | 2022-10-04 | Oliver Bladek | Sofa |
US11633046B2 (en) | 2021-08-30 | 2023-04-25 | Raad Altemimei | Sectional seating system |
US11839305B2 (en) | 2021-08-30 | 2023-12-12 | Raad Altemimei | Sectional seating with connectors and suction holding |
Also Published As
Publication number | Publication date |
---|---|
US11178973B2 (en) | 2021-11-23 |
US20200260875A1 (en) | 2020-08-20 |
US11191364B2 (en) | 2021-12-07 |
US20200260879A1 (en) | 2020-08-20 |
US20220079347A1 (en) | 2022-03-17 |
US11659933B2 (en) | 2023-05-30 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US20200262696A1 (en) | Molded manufacturing for modular furniture | |
US11122907B2 (en) | Upholstered furniture including molded furniture components | |
US5951110A (en) | Contoured plastic seat back | |
CA1098815A (en) | Bonded chair construction | |
KR101073748B1 (en) | modular furniture assembly | |
US3669499A (en) | Chair | |
US4152023A (en) | Chairs and method for making same | |
CN108289550B (en) | Upholstery furniture with integrated back rib support | |
US6305750B1 (en) | Clamshell backrest components | |
US4230365A (en) | Article of furniture and method of manufacture | |
US7040700B2 (en) | Sofa and method of manufacturing same | |
US4880276A (en) | Seat assembly | |
CA1082091A (en) | Furniture subframe | |
US5655812A (en) | Upholstery system for chairs | |
US11464337B1 (en) | Chair with molded panel | |
US20050151409A1 (en) | Chair with readily removable and replaceable components | |
US20050099052A1 (en) | Stackable chair with modular slide-on seat back | |
US5090769A (en) | Cushioned rocking chair | |
US3797885A (en) | Seat type article of furniture and method of manufacturing | |
US6039404A (en) | Structure for suspension in articles of furniture or the like and method for the assembly of said structure | |
CN116249465A (en) | Method for manufacturing a piece of furniture | |
KR20110088576A (en) | Modular furniture assembly | |
US20060192420A1 (en) | Furniture item and a method for attaching webbing thereto | |
KR100933918B1 (en) | Chair | |
JP3561827B2 (en) | Seat body |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: THE LOVESAC COMPANY, CONNECTICUT Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:NELSON, SHAWN D.;UNDERWOOD, DAVID M.;KUCHLER, BRIAN;AND OTHERS;SIGNING DATES FROM 20200106 TO 20200114;REEL/FRAME:051814/0766 Owner name: THE LOVESAC COMPANY, CONNECTICUT Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:RAEYMAEKERS, BART;INNOVEXUS;REEL/FRAME:051814/0599 Effective date: 20200113 |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: RESPONSE TO NON-FINAL OFFICE ACTION ENTERED AND FORWARDED TO EXAMINER |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: NON FINAL ACTION MAILED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: RESPONSE TO NON-FINAL OFFICE ACTION ENTERED AND FORWARDED TO EXAMINER |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: NON FINAL ACTION MAILED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: RESPONSE TO NON-FINAL OFFICE ACTION ENTERED AND FORWARDED TO EXAMINER |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: FINAL REJECTION MAILED |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |