U.S. patent application number 10/118540 was filed with the patent office on 2003-08-14 for furniture frame.
Invention is credited to McLarty, Richard H., Medlin, Robert A., Wade, Leslie A..
Application Number | 20030151293 10/118540 |
Document ID | / |
Family ID | 46280469 |
Filed Date | 2003-08-14 |
United States Patent
Application |
20030151293 |
Kind Code |
A1 |
McLarty, Richard H. ; et
al. |
August 14, 2003 |
Furniture frame
Abstract
This invention relates to four part furniture frames having a
seat box portion, a back portion and two arm portions. The unique
tapered side edges on the seat box portions of these frames allows
the seat box portion to be nested with the separate back portion,
thereby forming a substantially flat rectangle. The unique notches
on the back upright supports posts of these frames support the back
spring rail of the seat box portion, allowing the seat stretchers
to be uniquely made of plywood, oriented strand board or plastic
instead of them being required to be made of hardwood such as oak.
The light weight frames of this invention may be incorporated into
both ready-to-assemble furniture and fully assembled upholstered
furniture. These light weight, economical, nestable frames may be
easily stacked, packed and shipped. Additionally, these frames may
be easily assembled, by a furniture manufacturer, a store, a
customer, or anyone else, with only eight easy-to-use connectors
such as bolts and T-nuts.
Inventors: |
McLarty, Richard H.;
(Tupelo, MS) ; Medlin, Robert A.; (Dumas, MS)
; Wade, Leslie A.; (Olive Branch, MS) |
Correspondence
Address: |
Steven Gardner, Esquire
Kilpatrick Stockton LLP
1001 West Fourth Street
Winston-Salem
NC
27101-2400
US
|
Family ID: |
46280469 |
Appl. No.: |
10/118540 |
Filed: |
April 8, 2002 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10118540 |
Apr 8, 2002 |
|
|
|
10073673 |
Feb 11, 2002 |
|
|
|
Current U.S.
Class: |
297/440.15 |
Current CPC
Class: |
A47C 4/028 20130101;
A47C 4/02 20130101 |
Class at
Publication: |
297/440.15 |
International
Class: |
A47C 007/00 |
Claims
What is claimed is:
1. A furniture frame comprising: a seat box portion comprising a
front edge, a back edge, and two side edges disposed proximate the
ends of and between the front edge and the back edge; and a back
portion comprising a top rail, a bottom rail, and two upright end
support posts disposed proximate the ends of and between the top
rail and the bottom rail, wherein each upright support post
comprises a notch for supporting the back edge of the seat box
portion.
2. The furniture frame of claim 1 wherein the two side edges of the
seat box portion are tapered towards the back edge of the seat box
portion so the seat box portion is capable of being nested with the
back portion.
3. The furniture frame of claim 1 wherein the back edge of the seat
box portion comprises a back spring rail, and wherein the seat box
portion further comprises a front spring rail.
4. The furniture frame of claim 3 wherein the seat box portion
further comprises a seat stretcher.
5. The furniture frame of claim 4 wherein the seat stretcher is
interposed between the front spring rail and the back spring
rail.
6. The furniture frame of claim 5 wherein the seat stretcher
comprises at least one of: hardwood, plywood, oriented strand board
and plastic.
7. The furniture frame of claim 1 wherein the seat box portion is
attached to the back portion.
8. The furniture frame of claim 1 wherein the back portion further
comprises an inside gut rail.
9. The furniture frame of claim 8 wherein the back edge of the seat
box portion is attached to the inside gut rail of the back
portion.
10. The furniture frame of claim 9 wherein the back edge of the
seat box comprises a hardwood back spring rail, and wherein the
inside gut rail comprises at least one of: plywood, oriented strand
board and plastic.
11. The furniture frame of claim 1 wherein the seat box portion and
the back portion are nestable.
12. The furniture frame of claim 11 wherein when the seat box
portion and the back portion are nested together, they form a
substantially flat rectangle.
13. A furniture frame comprising: a seat box portion comprising a
front edge, a front spring rail, a back spring rail, two side
edges, and a seat stretcher; and a back portion comprising a top
rail, a bottom rail, and two upright end support posts; wherein the
front edge and the front spring rail are attached together, the
front spring rail and the back spring rail are attached to opposite
ends of the two side edges, and the seat stretcher is interposed
and attached between the front spring rail and the back spring
rail, and wherein the top rail and the bottom rail are attached
proximate opposite ends of the two upright end support posts, and
wherein each upright end support post comprises a notch for
accepting and supporting the back spring rail of the seat box
portion, and wherein the two side edges of the seat box portion are
tapered towards the back spring rail of the seat box portion; and
wherein the seat box portion and the back portion are nestable.
14. The furniture frame of claim 13 wherein the seat stretcher
comprises at least one of: hardwood, plywood, oriented strand board
and plastic.
15. The furniture frame of claim 13 wherein the seat box portion is
attached to the back portion.
16. The furniture frame of claim 13 wherein the back portion
further comprises an inside gut rail and wherein the back spring
rail of the seat box portion is attached to the inside gut rail of
the back portion.
17. The furniture frame of claim 16 wherein the inside gut rail
comprises at least one of: plywood, oriented strand board and
plastic.
18. The furniture frame of claim 17 wherein the back spring rail of
the seat box portion is attached to the inside gut rail of the back
portion via two bolts and T-nuts.
19. The furniture frame of claim 13 wherein when the seat box
portion and the back portion are nested together, they form a
substantially flat rectangle.
20. The furniture frame of claim 13 further comprising two arm
portions, wherein one arm portion is attached to one of the side
edges of the seat box portion and to one of the upright end support
posts at an edge of the back portion, while the other arm portion
is attached to the other side edge of the seat box portion and to
another upright end support post at an opposite edge of the back
portion.
21. The furniture frame of claim 20 wherein one arm portion is
attached to one of the side edges of the seat box portion with one
bolt and T-nut and to one of the upright end support posts at an
edge of the back portion with two bolts and T-nuts, while the other
arm portion is attached to the other side edge of the seat box
portion with one bolt and T-nut and to another upright end support
post at an opposite edge of the back portion with two bolts and
T-nuts.
22. The furniture frame of claim 13 wherein the frame is made
substantially all of at least one of the following: oriented strand
board and plywood.
23. The furniture frame of claim 13 wherein the top rail, the back
spring rail and the front spring rail comprise oak, and the two
side edges, the bottom rail, the front edge and the two upright end
support posts comprise at least one of: plywood and oriented strand
board.
24. The furniture frame of claim 13 wherein the seat box portion
and the back portion are separate pieces that are nested
together.
25. A method of assembling a four part furniture frame, comprising
the steps of: providing a seat box portion, a back portion and two
arm portions, wherein two side edges of the seat box portion are
tapered towards a back spring rail of the seat box portion so that
the seat box portion and the back portion may be nested together
into a substantially flat rectangle, at least two upright support
posts in the back portion each having notches for supporting the
back spring rail of the seat box portion, attaching the back spring
rail of the seat box portion to an inside gut rail of the back
portion using at least two connectors to form a partial frame;
attaching one arm portion to a first side of the partial frame
using at least three connectors; and attaching the other arm
portion to a second side of the partial frame using at least three
connectors.
26. The method of claim 25 wherein the connectors are bolts and
T-nuts.
27. A method of assembling a four part furniture frame, comprising
the steps of: providing a seat box portion, a back portion, two arm
portions and cushions, wherein two side edges of the seat box
portion are tapered towards a back spring rail of the seat box
portion so that the seat box portion and the back portion may be
nested together into a substantially flat rectangle, at least two
upright support posts in the back portion each having notches for
supporting the back spring rail of the seat box portion; shipping
the seat box portion nested together with the back portion in a
substantially flat rectangle; attaching the back spring rail of the
seat box portion to an inside gut rail of the back portion using at
least two connectors to form a partial frame; attaching one arm
portion to a first side of the partial frame using at least three
connectors; and attaching the other arm portion to a second side of
the partial frame using at least three connectors.
28. The method of claim 27, the shipping step further comprising
shipping the nested seat box portion and back portion in a single
box to one of the following: a warehouse, a furniture manufacturer,
a store, and a customer.
29. The method of claim 27 wherein the attaching steps are
performed by one of the following: an employee in a warehouse, an
employee in a furniture manufacturing company, an employee in a
store, and a customer.
30. The method of claim 27 further comprising placing the two arm
portions and the cushions on top of the nested seat box portion and
back portion prior to shipping.
31. The method of claim 30, the shipping step further comprising
shipping the nested seat box portion and back portion, the two arm
portion and the cushions in a single box to one of the following: a
warehouse, a furniture manufacturer, a store, and a customer.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to Applicants' co-pending
non-provisional application, entitled "Furniture Frame", U.S. Ser.
No. 10/073,673, filed Feb. 11, 2002, which is hereby incorporated
in full by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to furniture frames, and more
specifically, to an economical, lightweight furniture frame having
unique angled side rails on the seat box portion, a unique seat
stretcher, and a unique notch on the back upright posts to accept
and support the seat box portion of the frame.
BACKGROUND OF THE INVENTION
[0003] Historically, furniture has been manufactured and sold to
consumers fully assembled and upholstered. Such furniture tends to
be heavy and bulky, making it difficult to lift and maneuver, both
during manufacture and transport of the furniture. Such furniture
is also often difficult to store in a warehouse because it takes up
so much space. Furthermore, it can be difficult to deliver to
customers, and may even be impossible to deliver to some customers
due to the dimensional constraints of their doorways, hallways,
stairways, etc. Finally, the shipping costs associated with such
furniture tends to be quite expensive because the furniture is so
large and cumbersome.
[0004] New ergonomic standards were recently proposed, wherein
employees would not be allowed to lift more than 50 pounds more
than one time in 8 hours. These proposed standards prompted the
furniture industry to consider lighter weight sofas, chairs,
loveseats, and other pieces. Although these proposed ergonomic
standards were not instituted, some kept pursuing lighter-weight
furniture for other reasons.
[0005] Many different solutions were attempted. However, such
solutions provided many disadvantages. For example, metal seat
frames are too heavy and too expensive. Wood seat boxes with a
metal seating structure were also constructed, but they too are too
heavy, too hard to manufacture, and too expensive in their current
form.
[0006] Four part sofa frames were another one of the solutions
attempted. Four part frames themselves, comprising a seat box
portion, a back portion and two arm portions, are well-known in the
industry, as evidenced by such furniture frames currently being
manufactured by several foreign and domestic companies.
[0007] Various Italian furniture manufacturers have utilized
conventional four part furniture frame construction for years.
However, such construction does not lend itself to being
lightweight, or to being broken down into smaller sizes that can
nest together and fit into smaller shipping containers. Such
conventional frame construction has no hardwood or plywood in it;
it uses European fiberboard instead. Furthermore, it does not use
metal seat springs; it uses webbing material. This conventional
construction results in furniture that cannot be shipped in
relatively small, flat containers because it cannot be easily
broken down. Even broken down as much as possible, furniture made
using such conventional frame construction cannot generally be
shipped in a single box via a common carrier such as UPS or FedEx
because it exceeds their maximum ground shipping weight and size
limits.
[0008] Stanton International of Tualatin, Oreg. uses a frame very
similar to the four part frame described above in its line of
stationary sofas. However, Stanton uses plywood and oak rails in
its frames instead of fiberboard. The Stanton frame is not
conducive to being lightweight, or to being broken down into
smaller sizes that can nest together and fit into smaller shipping
containers. Furthermore, the Stanton-style seat box is essentially
a big square--four rectangles that have been stapled together to
form a seat box. These sofas cannot be shipped economically via a
common carrier broken down in a single box.
[0009] Benchcraft, Inc. of Blue Mountain, Mass. also uses a four
part frame in its Quasar line of sofas. However, the Benchcraft
frame includes a metal seat box, which is much more expensive than
using a wooden seat box. Additionally, metal adds undesirable
weight to the frame and finished piece of furniture. Like the
frames discussed above, the Benchcraft frame is not conducive to
being broken down into smaller sizes that can nest together and fit
into smaller shipping containers.
[0010] Simply Together of High Point, N.C. is yet another furniture
company utilizing four part frame construction in all of its
upholstered furniture. This company breaks its furniture down and
ships it directly to customers, who then assemble the furniture
themselves. However, these frames contain a lot of metal, which
makes them heavy. This, in turn, leads to three separate shipping
containers being needed to ship one single sofa in, thereby
increasing the cost of this furniture. Additionally, the seating
suspension in these frames is basically just four pieces of wood
with webbing strung between them. See, for example, Simply
Together's U.S. Pat. No. 5,263,764, No. 5,338,095, No. 5,394,573,
No. 5,423,596, and No. 5,551,757. The problem with this seating
suspension is that it is not attached anywhere to the frame itself,
so it is prone to wobbling, creaking, and warping.
[0011] The conventional four part frames all have similar problems.
The side rails used in the seat box portions of these frames are
all generally rectangular in shape, and therefore are not easily
nested together with the back portions of the frames to form a
relatively flat rectangle that can be easily packaged, stacked and
transported. Additionally, the seat and back portions of these
frames are generally built together as one piece, instead of two
separate, lighter weight pieces. Furthermore, the seat stretchers
in existing four part frames have generally always been made of
hardwood such as oak, not plywood, oriented strand board ("OSB") or
plastic. Finally, the back upright posts of existing furniture
frames have never included a notch for accepting and supporting the
seat box portion of the frame and the weight of anyone sitting on
the sofa or chair.
[0012] There is a need for durable furniture frames that are
lighter-weight than conventional frames, but that do not sacrifice
strength and/or sturdiness as a result of being lighter weight.
There is also a need for furniture frames comprised of a minimal
number of pieces that can be easily assembled. There is yet a
further need for lighter weight furniture frames to facilitate
easier and more ergonomic manufacturing and transport, to help
improve productivity, and to help reduce injury and shipping
costs.
[0013] Additionally, there is a need for furniture frames that have
separate seat box and back portions. There is also a need for
furniture frames that have angled, curved or tapered side rails on
their seat box portions so that the separate seat box portion and
back portion can be nested together to form a relatively flat
rectangle, to help reduce the shipping container size and the
amount of storage space needed. There is yet a further need for
furniture that can be shipped via a common carrier in a single slim
container without exceeding the maximum shipping weight and size
limits, to help reduce shipping costs.
[0014] Furthermore, there is a need for furniture frames that have
seat stretchers made of plywood or OSB to help reduce the cost of
the frames. There is also a need for furniture frames that have a
notch in the back upright posts to accept and help support the seat
box portion and the weight of a person, or persons, sitting on the
sofa or chair.
[0015] Also, there is a need to provide ready-to-assemble
furniture--such as sofas, loveseats, and chairs--that is
inexpensive and that customers can buy and assemble themselves.
Many other types of ready-to-assemble furniture--such as bookcases,
cabinets, entertainment centers, tables, etc.--can already be
bought from various places such as Home Depot, Lowe's, Wal-Mart,
etc. Therefore, it would be very beneficial to have sofas,
loveseats, chairs, etc. that customers can buy and assemble
themselves, purchased either through mail order, via the Internet,
or in stores.
SUMMARY OF THE INVENTION
[0016] Accordingly, the above identified shortcomings of existing
furniture frames are overcome by embodiments of the present
invention. The present invention relates to furniture frames that
can be more simply and inexpensively manufactured, assembled, and
transported. Embodiments of a furniture frame according to the
present invention include one or more unique aspects. The preferred
embodiment comprises a four piece furniture frame. In one
embodiment, the side rails of the seat box portion are angled,
curved or tapered so the seat box portion of the frame can be
nested with the separate back portion of the frame, thereby forming
a substantially flat, rectangular shape that is much smaller than
the fully assembled frame. In an embodiment, the seat stretchers in
the frames of the present invention are made of either plywood, OSB
or plastic, which has never been done before. However, hardwood may
still be used for the seat stretchers if it is desirable and/or
economical to do so. In an embodiment, the back upright posts
include a notch proximate their bottom edge to accept the seat box
portion of the frame, to support the seat box portion and the
weight of a person(s) sitting on the couch or chair. Moreover, the
seat box portion and back portion of the frames of the present
invention may be made as two separate pieces that can be easily
nested together for storage and shipping, and that may be easily
assembled at its destination, i.e., either at the store or at the
customer's home. Embodiments of the present invention preferably
include all of the above-mentioned aspects, but other embodiments
may include less than all of the above-mentioned aspects.
[0017] Embodiments of the present invention provide many
advantages. The frames of the present invention are lighter weight,
and are made up of fewer pieces, than existing frames. As such,
they are easier to assemble. This results in less training time,
generally less than one day, being required to teach new furniture
manufacturing employees how to make furniture using the frames of
the present invention. Cutting down on training time can be
especially important in an industry, such as the furniture
industry, that sees as much as 15-20% employee turnover per month.
The frames of the present invention can be used to make sofas,
loveseats, chairs, and the like. The side rails of the seat box of
the present invention are curved, angled or tapered towards the
back of the frame, to facilitate compact nesting and stacking of
the frames. The ability of the frames of the present invention to
be nested allows greater quantities of work-in-process to be stored
in a given area, which in turn leads to greater output for a given
floor space. Additionally, since the frames of the present
invention are lighter, they are more ergonomic, which benefits the
framebuilding, assembly and upholstery stages of production.
Furthermore, because these frames are lighter and more ergonomic,
less injury is likely to occur during production, transportation,
and/or assembly of the frames.
[0018] When the separate seat box and back portions of the frames
of the present invention are nested together, they can easily be
fit into a relatively flat, rectangular shipping carton.
Thereafter, the frames can be easily stacked for storage or
transport. This is especially important if one desires to have the
four individual parts of these frames manufactured offshore, such
as in China or Brazil, and then shipped to the USA to be assembled
and/or sold. Ideally, these frames are designed and manufactured so
that the finished product can be fit into a single shipping carton
without exceeding common carrier's maximum ground shipping
limits.
[0019] The notches on the back upright support posts of the frames
of the present invention accept the seat box portion of the frame,
and also support the seat box portion and the weight of anyone
sitting on the sofa or chair. This helps distribute the
load-bearing weight across the entire width of the frame, instead
of placing it all on a few connecting bolts, as is traditionally
done in four part frames.
[0020] Generally, the seat stretchers in furniture frames are made
of hardwood such as oak, but the notches in the back upright posts
allow the seat stretchers in the present invention to be uniquely
made of plywood, OSB, or plastic. This helps reduce costs and
weight. However, hardwood may still be used for the seat stretchers
if it is desirable and/or economical to do so.
[0021] Embodiments of the present invention comprise a four part
furniture frame that can be nested and packed in a substantially
flat rectangular shape. One embodiment of the frame of the present
invention has a seat box portion and a back portion, where the seat
box portion has at least a front edge, a back edge, and two side
edges and the back portion has at least a top rail, a bottom rail,
and two notched upright end support posts. The two side edges of
the seat box portion are preferably tapered, curved or angled back
towards the back edge of the seat box portion so the seat box
portion may be nested with the back portion. The back edge of the
seat box portion may be a back spring rail, and there is also
preferably a front spring rail present in the seat box portion of
the frame. Both the front and back spring rails may have spring
attachment mechanisms attached to them so that springs may be
attached thereto to form the seating suspension of the frame.
Additionally, there is preferably at least one seat stretcher
interposed between the front and back spring rails to hold them
apart, if anything larger than a chair is being made with this
frame. Furthermore, there is preferably an inside gut rail, and
also at least one upright center support post, included in the back
portion of the frame.
[0022] Ideally, the seat box portion and the back portion are
separate pieces that can be assembled by either the furniture
manufacturer, the store, the customer, or anyone else capable of
making the necessary connections. However, the seat box portion and
the back portion may be attached together. These frames may be
included in both ready-to-assemble furniture and fully assembled
furniture.
[0023] Further, ideally, the frames of the present invention are
made substantially all of plywood or OSB, with only a few critical
pieces being made of something else, such as hardwood like oak. For
example, the top rail, the front spring rail, and the back spring
rail are ideally made of oak because superior strength is required
for these pieces. All the remaining pieces may easily and
economically be made of plywood, OSB or plastic, without
sacrificing the overall strength of the frames. Even the seat
stretchers and the inside gut rails in these frames may be made of
plywood, OSB or plastic because the notches in the upright back
support posts provide superior strength and support to the seat box
portion of these frames. However, hardwood may still be used for
the seat stretchers if it is desirable and/or economical to do
so.
[0024] Other embodiments of the frames of the present invention
also include two arm portions. Each arm portion is preferably
attached to one side edge of the seat box portion and to one of the
upright back support posts. Ideally, only three bolts and T-nut
connectors are needed to attach each arm portion to the seat box
and back portions so that the arms may be easily attached by
anyone, including the furniture manufacturer, the store, the
customer, or anyone else.
[0025] In some embodiments of the frames of the present invention,
the seat box portion and the back portion are nested together into
a substantially flat rectangle, which is then stacked and shipped
to either a warehouse, a furniture manufacturer, a store, or a
customer. In this embodiment, the arm portions and the cushions may
be packed and shipped separately. In other embodiments of the
present invention, two arm portions and cushions may be arranged,
preferably as flat as possible, on top of the nested seat box and
back portions, and the entire package may then be shipped to either
a warehouse, a furniture manufacturer, a store, or a customer in a
single container. This makes it easier to get sofas into inner city
apartments with narrow stairways and doors, and also into other
buildings and homes that will not accommodate conventional
furniture or other four part frame configurations.
[0026] In some embodiments of the present invention, the frame is
fully assembled by one or more employees of a furniture
manufacturer. In others, the furniture manufacturer employee(s) may
only assemble the four individual parts (the seat box portion, the
back portion and the two arm portions), and then employee(s) of a
store may assemble the four parts together in the store. In other
embodiments, the four individual parts may be assembled by one or
more people in a warehouse. In still other embodiments, the four
individual parts may be sent directly to the customer for them to
assemble the four parts together.
[0027] Further aspects and advantages of the present invention will
be more readily apparent to those skilled in the art during the
course of the following description, wherein references are made to
the accompanying drawings which illustrate some preferred forms of
the present invention and wherein like characters of reference
designate like parts throughout the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a perspective side view of a furniture frame of
the prior art showing the rectangular side rails on the seat box,
the oak seat stretchers, and the notchless back upright posts;
[0029] FIG. 2 is a side view of the furniture frame of the prior
art shown in FIG. 1;
[0030] FIG. 3 is an exploded perspective side view of the frame
shown in FIGS. 3 and 4 showing the unique angled side rails of the
seat box, the unique seat stretchers, and the unique notches on the
back upright posts;
[0031] FIG. 4 is a side view of the furniture frame shown in FIG.
3;
[0032] FIG. 5 is an exploded side view of the furniture frame shown
in FIGS. 3 and 4 showing the notch on a back upright post;
[0033] FIG. 6 is a perspective side view of one embodiment of the
frame of the present invention showing the unique angled side rails
of the seat box, the unique seat stretchers, and the unique notches
on the back upright posts;
[0034] FIG. 7 is a perspective side view of the frame shown in
FIGS. 3-6 showing the seat box and back portions nested together
for easy packing, stacking, and/or shipping; and
[0035] FIG. 8 is a perspective side view of the frame shown in
FIGS. 3-7 showing four seat box and back portions nested together
and stacked.
DETAILED DESCRIPTION
[0036] For the purposes of promoting an understanding of the
invention, reference will now be made to the preferred embodiment
of the present invention as illustrated in FIGS. 3-8, and specific
language used to describe the same. For illustrative purposes only,
the invention is primarily shown and described as applied to a
sofa, but as will be readily apparent, the invention can be easily
adapted for any similar type of furniture such as a loveseat or
chair, either ready-to-assemble or fully assembled. Therefore, it
should be understood that no limitation of the scope of the
invention is hereby intended. The terminology used herein is for
the purpose of description, not limitation. Any modifications or
variations in the depicted frames and the methods of making and
assembling the same, and such further applications of the
principles of the invention as illustrated herein, as would
normally occur to one skilled in the art, are considered to be
within the spirit of this invention.
[0037] Referring now to FIGS. 1 and 2, there are shown two views of
a prior art furniture frame 10 showing the rectangular side rails
22 on the seat box portion 20, the oak seat stretchers 30, and the
notchless back upright support posts 48. As can be seen from FIGS.
1 and 2, the seat box portion 20 and the back portion 40 of the
prior art frame are integrally made as a single piece. As such, the
seat box 20 and back 40 portions of the prior art frames are not
suitable for easy nesting and stacking. The side rails 22 on this
prior art seat box 20 are substantially rectangular, with the
bottom edges of the side rails being substantially flush with the
floor and the bottoms of the back upright support posts 48. The
longer seat stretchers 30 and the inside gut rail 46 in this prior
art frame are made of oak, which is much heavier and more expensive
than plywood, OSB or plastic. Furthermore, in this prior art frame
design, there are no back upright support posts with notches in
them for accepting and supporting the seat box portion 20 of the
frame 10. This seat box portion 20 is merely integrated with the
back portion 40, but is not supported by back portion 40.
[0038] Referring now to FIGS. 3-8, different views of an embodiment
of the present invention are shown. In embodiments of the present
invention, the seat box portion 20 and the back portion 40 may be
made as separate pieces, as shown in FIG. 3.
[0039] In embodiments of the present invention, the seat box
portion 20 has two spaced-apart side panels or side edges 22 that
are uniquely angled, curved or tapered (i.e., narrowing from the
front towards the back of the frame) so the seat box portion 20 may
nest together with the back portion 40, forming a substantially
flat rectangle once nested, as seen in FIG. 7. Once nested, the two
unupholstered portions form a rectangle approximately 60-78"
long.times.25-29" wide.times.7-11" high, depending on wheather a
sofa, loveseat or chair is being made from the frame. If fully
upholstered before being nested together, the two portions form a
rectangle approximately 60-78" long.times.25-29" wide.times.17-28"
high. These nested portions can be easily stacked, as shown in FIG.
8, and can also be easily stored and transported. Each of the two
side panels 22 is attached to a back spring rail 26 and a front
rail or front edge 28. A front spring rail 24 is also attached to
the front rail 28 and to the two side panels 22. Front spring rail
24 and back spring rail 26 form the seating suspension of these
frames once springs 36 are strung between them. Therefore,
preferably front rail 28 and the seating suspension are attached
together to impart strength to the frame. Additionally, there is a
bottom front rail 34 attached to the bottom of the front rail 28
for attaching the upholstery to. Preferably, the individual pieces
that make up the seat box portion (the side panels 22, the front
spring rail 24, the back spring rail 26, the front rail 28, the
seat stretchers 30, and the bottom front rail 34) are attached
together with a frame stapler, but other suitable attachment
mechanisms may be used.
[0040] If a chair is being made from this frame, there is really no
need for seat stretchers, but one or more seat stretchers 30 may be
interposed between the back spring rail 26 and the front rail 28.
However, preferably no seat stretchers are used if a chair is being
made with this frame. But, if a loveseat or sofa or larger piece of
furniture is being made with this frame, then at least one seat
stretcher 30 is interposed between the back spring rail 26 and the
front rail 28. For loveseats, one seat stretcher is preferably
included, and for sofas, two seat stretchers are preferably
included. Spring attachment mechanisms 32 may be attached to the
spring rails 24, 26, and springs 36 may then be secured or anchored
to these spring rail attachment mechanisms 32. The seat box portion
20 of the frames of the present invention may be pitched downwards
towards the rear of the sofa to provide the desired seating surface
for the finished furniture. The pitch of the seating surface is
determined by the difference in height or elevation between front
spring rail 24 and back spring rail 26.
[0041] Side panels 22, front rail 28, and bottom front rail 34 may
be made of any suitable material, preferably either mill grade
plywood, OSB or plastic. Front spring rail 24 and back spring rail
26 may also be made of any suitable material, preferably oak. Seat
stretchers 30 may likewise be made of any suitable material capable
of holding spring rails 24, 26 apart, but are preferably made of
mill grade plywood, OSB or plastic instead of the oak typically
used in the prior art frames. In the prior art frames the seat
stretchers 30 support the spring rails 24, 26, and also provide
support to back portion 40. Now, however, since notches 50 provide
so much support in the frames of the present invention, the seat
stretchers 30 no longer need to be made of oak. However, hardwood
may still be used for the seat stretchers if it is desirable and/or
economical to do so. Using the preferred materials specified herein
helps reduce the material costs, as well as the weight, of these
frames. Also, using mill grade plywood, OSB or plastic makes it
possible to use a router to cut many of these parts out. This too
helps reduce the costs associated with the frames of the present
invention.
[0042] In some embodiments of the present invention, the back
portion 40 of frame 10 has at least two spaced-apart back upright
support posts 48. The two back upright support posts 48 are
attached together with a top rail 42 and an outside back bottom
rail 44. Additionally, an inside gut rail 46 is interposed between
the two back upright support posts 48. If a chair is being made
from this frame, there is really no need for center back upright
support posts 48. However, if a loveseat or sofa or larger piece of
furniture is being made with this frame, then one or more center
back upright support posts 48 may be interposed between the top
rail 42 and the outside back bottom rail 44. Preferably, a loveseat
will have at least one center back upright support post 48, and a
sofa will have at least two center back upright support posts 48.
Preferably, the individual pieces that make up the back portion
(the top rail 42, the outside bottom rail 44, the inside gut rail
46, and the back upright support posts 48) are attached together
with a frame stapler, but other suitable attachment mechanisms may
be used.
[0043] The back upright support posts 48 include a notch 50, which
is designed to accept and support the back spring rail 26 of seat
box portion 20. The inside gut rail 46 also fits within notch 50 in
the back upright support posts 48. This notch 50 provides support
to the seat box portion 20 of frame 10, and to anyone sitting on
the finished piece of furniture. The design of the present
invention is superior to the prior art design because these notches
50 bear and distribute the weight-bearing load over the entire
width of frame 10, whereas in the past, the weight-bearing load was
all borne by one or two connection mechanisms between the back
portion 40 and the seat box portion 20. In the frames of the
present invention, very little, if any, weight or stress is borne
by the connectors connecting seat box portion 20 and back portion
40 together at connections 14. Instead, these connectors,
preferably bolts and T-nuts, merely attach these parts together at
14; they do not help support the load on these parts. This makes
the frames of the present invention sturdier than those of the
prior art. It should be obvious to those skilled in the art that
connectors other than bolts and T-nuts may be used to connect these
parts together. Therefore, all such easy to use connectors are
deemed to be within the scope of the present invention.
[0044] Back upright support posts 48 and outside back bottom rail
44 may be made of any suitable material, preferably either mill
grade plywood, OSB or plastic. Top rail 42 may also be made of any
suitable material, preferably a hardwood such as oak. Since notches
50 provide so much support in the frames of the present invention,
the inside gut rail 46 no longer needs to be made of oak; instead
it is preferably made of mill grade plywood, OSB or plastic, all of
which are much cheaper and lighter than oak. However, other
suitable, economical materials may also be utilized for inside gut
rail 46. As previously discussed with respect to the seat box
portion 20, using the preferred materials specified herein helps
reduce the material costs, as well as the weight, of these frames.
Also, using mill grade plywood, OSB or plastic makes it possible to
use a router to cut many of these parts out. This too helps reduce
the costs associated with the frames of the present invention.
[0045] In many embodiments of the present invention, arm portions
are also attached to the seat box portion 20 and back portion 40 of
the present invention.
[0046] Separate seat box portion 20 and back portion 40 may be
easily nested together for stacking, storing or shipping, as shown
in FIG. 7. Additionally, seat box portion 20 and back portion 40
may be upholstered before being nested together. When fully
upholstered and nested, with the two arm portions and cushions
stacked as flat as possible on top of the nested seat box and back
portions, one sofa incorporating a frame of the present invention
measures approximately 69"L.times.35"W.times.32"H. That means many
more sofas incorporating frames of the present invention may be fit
within a given area than was possible with the prior art frames.
For example, a typical forty foot high cubed tractor trailer will
hold approximately thirty nine (39) prior art sofas, as compared to
fifty-eight (58) sofas incorporating the frames of the present
invention, which helps reduce shipping costs, as well as reducing
the amount of warehouse and production space that is needed. The
seat box 20 and back 40 portions may be nested and packed in a box,
with the arm portions 60 and cushions being packed and shipped in a
separate box. Preferably, however, the seat box 20 and back 40
portions are nested, then the arm portions 60 and cushions are
arranged as flat as possible on top of the nested portions 20, 40,
and everything is packed and shipped in a single box. If only the
seat box portion 20 and back portion 40 are packed together and
shipped, with the arm portions 60 and cushions packed and shipped
separately, then even more sofas with these new frames can be fit
on the tractor trailer.
[0047] As previously stated, separate seat box portion 20 and back
portion 40 may be easily nested together for stacking, storing or
shipping, as shown in FIG. 7. These substantially rectangular
nested portions may then be easily stacked one upon another, as
shown in FIG. 8.
[0048] Seat box portion 20 and back portion 40 may be easily
attached to one another at 14 via two easy to use connectors, such
as bolts and T-nuts or the like. These two connectors connect the
back spring rail 26 on the seat box portion 20 to the inside gut
rail 46 on the back portion 40, preferably with one being located
near each end back upright support post 48, as shown in FIGS. 3
& 5. Assembly of the seat box portion 20 with the back portion
40 may occur in the furniture manufacturing facility, in a
warehouse, in the store that sells the furniture, in a customer's
home, or anywhere else suitable for assembling furniture. Employees
of any of these afore-mentioned places can be easily trained to
assemble these frames. Even customers can be provided with
easy-to-follow instructions so that they may assemble these frames
by themselves. Each of the two arm portions 60 (not shown) may be
easily attached to the assembled seat and back portions preferably
via three connectors, and preferably with bolts and T-nuts, at
14--two through each end back upright support post 48 and one
through each side panel 22 of seat box 10 portion 20, as shown in
FIGS. 3 & 5. As just described, assembling this frame together
is simple, requiring only eight (8) easy to use connectors, such as
bolts and T-nuts, once the individual seat box 20, back 40, and arm
60 portions are manufactured by the furniture manufacturing
company. Preferably, all the bolts and T-nuts are 3/4" to provide
the desired stability to the frame. Additionally, to help ensure
that the arm portions do not move once attached, two additional
screws may be used to anchor the arm portions 60 in place.
Preferably, one of these screws 16 is located towards the bottom
front corner of each side edge 22, and is preferably a 1/4"
screw.
[0049] Since seat box portion 20 and back portion 40 are made as
separate pieces, they may be nested together to form a
substantially flat rectangle, as previously discussed. To
facilitate the best possible packing arrangements on a truck, the
back and seat box portions of these frames may be shipped
separately from the arm portions of the frames. Doing that would
make the boxes even flatter, and would allow more of the boxes to
be stacked in a trailer of a given height.
[0050] Since the frames of the present invention are so easily
assembled, customers may purchase unassembled sofas, chairs or
loveseats incorporating these frames, and then assemble them by
themselves. For example, customers may purchase such furniture at a
store, via mail order, or via the Internet. The furniture may then
be taken home by the customer, or it may be shipped directly to the
customer's home. The customer may then easily assemble the
furniture preferably using only eight (8) easy-to-use connectors,
like bolts and T-nuts, and two (2) screws. The seat box portion 20
is preferably attached to the back portion 40 using two (2) bolts
and T-nuts 14, as shown in FIGS. 3 and 6. An arm portion 60 is then
preferably attached to one upright end support post 48, using two
(2) bolts and T-nuts 14, and to the side edge 22 proximate the
upright end support post 48 using one (1) bolt and T-nut 14. The
other arm portion may then be similarly attached to the other
upright end support post 48 and side edge 22. To secure these arm
portions in place, a screw 16 may be used to anchor each arm
portion 60 in place with respect to each side edge 16 and upright
end support post 48.
[0051] While the figures and description herein generally depict a
frame for a sofa, it is contemplated that the frames of the present
invention may be utilized in variations other types of furniture,
that will be obvious to one skilled in the art, without deviating
from the spirit of this invention. It is contemplated that the
frames of the present invention may be designed in various sizes,
shapes, designs and styles for sofas, loveseats, chairs and the
like. Furthermore, it is contemplated that the frames of the
present invention may be incorporated into either ready-to-assemble
or fully assembled furniture such as sofas, loveseats and/or
chairs. Finally, it is contemplated that the frames of the present
invention may be assembled by the manufacturer, the seller, the end
consumer, or anyone else capable of assembling these frames. Thus,
it is intended that the present invention cover such modifications
and variations as come within the scope of the appended claims and
their equivalents.
* * * * *