U.S. patent application number 10/643448 was filed with the patent office on 2004-02-19 for furniture with molded frame.
Invention is credited to Stipek, Grant.
Application Number | 20040032156 10/643448 |
Document ID | / |
Family ID | 23882988 |
Filed Date | 2004-02-19 |
United States Patent
Application |
20040032156 |
Kind Code |
A1 |
Stipek, Grant |
February 19, 2004 |
Furniture with molded frame
Abstract
Furniture having a frame made of a molded article in which the
molded article is a shell-structure is described. Preferably the
molded article describes a lattice structure in the form of a space
frame. The molded article is preferably scaled and contoured
providing significant structural integration and torsional
strength.
Inventors: |
Stipek, Grant; (Hansville,
WA) |
Correspondence
Address: |
SHERIDAN ROSS PC
1560 BROADWAY
SUITE 1200
DENVER
CO
80202
|
Family ID: |
23882988 |
Appl. No.: |
10/643448 |
Filed: |
August 18, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10643448 |
Aug 18, 2003 |
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08474314 |
Jun 7, 1995 |
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Current U.S.
Class: |
297/452.18 |
Current CPC
Class: |
A47C 31/11 20130101;
A47C 5/12 20130101 |
Class at
Publication: |
297/452.18 |
International
Class: |
A47C 007/02 |
Claims
What is claimed is:
1. A substantially internal frame for upholstered furniture
comprising: a weight-bearing frame for supporting one or more users
for seating above a support surface, the weight-bearing frame
having a main loading area adapted to receive compressive load
forces from the weight of the one or more users and defining at
least one span across a part of the main loading area, wherein the
larger part of the weight bearing frame is one or more molded
components, and wherein the main loading area is substantially a
lattice form that is defined by the one or more molded components
and that is positioned substantially around all sides of a recessed
or open area within the main loading area of the weight bearing
frame.
2. A frame for upholstered furniture, as claimed in claim 1,
wherein at least the larger part of the one or more molded
components is structural to support the weight of one or more
users.
3. A frame for upholstered furniture, as claimed in claim 2,
wherein the one or more molded components structural to support the
weight of one or more users is substantially scaled.
4. A frame for upholstered furniture, as claimed in claim 2,
wherein the one or more molded components structural to support the
weight of one or more users is substantially contoured.
5. A frame for upholstered furniture, as claimed in claim 2,
wherein the one or more molded components structural to support the
weight of one or more users provide means for substantial
structural integration.
6. A frame for upholstered furniture, as claimed in claim 1,
wherein substantially all of the one or more molded components is
structural to support the weight of one or more users.
7. A frame for upholstered furniture, as claimed in claim 6,
wherein one or more molded components structural to support the
weight of one or more users is substantially scaled.
8. A frame for upholstered furniture, as claimed in claim 6,
wherein the one or more molded components structural to support the
weight of one or more users is substantially contoured.
9. A frame for upholstered furniture, as claimed in claim 6,
wherein one or more molded components structural to support the
weight of one or more users provide means for substantial
structural integration.
10. A frame for upholstered furniture, as claimed in claim 1,
wherein the one or more molded components provide the substantial
structural integration.
11. A frame for upholstered furniture, as claimed in claim 1,
wherein the one or more molded components provide means for
substantial torsional strength.
12. A frame for upholstered furniture, as claimed in claim 11,
wherein the one or more molded components are shell-structure.
13. A frame for upholstered furniture, as claimed in claim 1,
wherein the one or more molded components provide the substantial
torsional strength.
14. A frame for upholstered furniture, as claimed in claim 13,
wherein the one or more molded components are shell-structure.
15. A frame for upholstered furniture, as claimed in claim 1,
wherein the lattice form defined is plural.
16. A frame for upholstered furniture, as claimed in claim 1,
wherein the one or more molded components define an efficient
structure.
17. A frame for upholstered furniture, as claimed in claim 1,
wherein the one or more molded components define an optimized
structure.
18. A frame for upholstered furniture, as claimed in claim 1,
wherein at least a portion of the one or more molded components is
substantially flexible.
19. A frame for upholstered furniture, as claimed in claim 1,
wherein at least a portion of the one or more molded components is
closed shell construction shell-structure.
20. A frame for upholstered furniture, as claimed in claim 1,
wherein at least a portion of the frame is an openwork.
21. A frame for upholstered furniture, as claimed in claim 1,
wherein substantially all of the frame comprises one or more molded
components and substantially all of the one or more molded
components is structural to support the weight of one or more
users.
22. A frame for upholstered furniture, as claimed in claim 1,
wherein substantially all weight bearing portions of the frame are
molded components.
23. A frame for upholstered furniture, as claimed in claim 1,
wherein the one or more molded components define a first depth
orientated to provide strength for assuming compressive load forces
greater than the strength obtained from at least some other
orientation of depth.
24. A frame for upholstered furniture, as claimed in claim 1,
wherein at least a first portion of the frame defines a
load-bearing span having a first shell-structure molded component
with a first depth substantially near the center of the span which
is greater than a depth of the shell-structure molded component
spaced from the center of the span.
25. A frame for upholstered furniture, as claimed in claim 1,
wherein the one or more molded component is shaped to transfer
loads to regions of load distribution.
26. A frame for upholstered furniture, as claimed in claim 1,
wherein the frame comprises a plurality of dissassemblable
sections.
27. A frame for upholstered furniture, as claimed in claim 26,
wherein at least some of the disassemble sections are configured to
accommodate stacking and/or internesting.
28. A frame for upholstered furniture, as claimed in claim 26,
wherein at least some of the dissassemblable sections are
configured to be interchangeable.
29. A frame for upholstered furniture, as claimed in claim 1,
wherein the frame is contoured to accommodate stacking and/or
internesting with similar frames.
30. A frame for upholstered furniture, as claimed in claim 1,
wherein at least a portion of the frame is custom fit and/or scaled
to a user.
31. A frame for upholstered furniture, as claimed in claim 1,
wherein the frame includes means for providing a therapeutic
service selected from the group consisting of massage, pneumatic
variable body support and heating.
32. A frame for upholstered furniture, as claimed in claim 1,
wherein at least two sections of the frame are configured so as to
be movable with respect to one another during normal use.
33. A frame for upholstered furniture, as claimed in claim 32,
wherein the frame further comprises means for controlling the
relative movement.
34. A frame for upholstered furniture, as claimed in claim 1,
wherein the frame includes at least a first joint providing
relative movement of portions of the frame, the first joint being
integral to the one or more molded components.
35. A frame for upholstered furniture, as claimed in claim 1,
wherein the frame includes at least a first joint providing
relative movement of portions of the frame, the first joint being
non-integral with the coupled to the one or more molded
components.
36. A frame for upholstered furniture, as claimed in claim 1,
further comprising strapping coupled to the frame.
37. A frame for upholstered furniture, as claimed in claim 1,
further comprising strapping coupled to the frame, wherein the
strapping provides a function selected from the group consisting of
motion control and stress distribution.
38. A frame for upholstered furniture, as claimed in claim 1,
wherein at least one of the one or more molded components is
produced by a molding process which is intrinsically descriptive of
shell-structures.
39. A frame for upholstered furniture, as claimed in claim 1,
wherein at least one of the one or more molded components is
produced by a low pressure molding process.
40. A frame for upholstered furniture, as claimed in claim 1,
wherein at least one of the one or more molded components is
produced by a molding process which uses supplemental inflatable
forms.
41. A frame for upholstered furniture, as claimed in claim 1,
wherein at least one of the one or more molded components is
produced by a molding process which uses inflatable molds.
42. A frame for upholstered furniture, as claimed in claim 1,
wherein at least one of the one or more molded components is
produced by a molding process selected from the group consisting of
blow-molding, rotational molding and foam-molding.
43. A frame for upholstered furniture, as claimed in claim 1,
wherein the frame is at least partially upholstered or is
substantially upholstered.
44. A frame for upholstered furniture, as claimed in claim 1,
further comprising a suspension material coupled to the frame.
45. A frame for upholstered furniture, as claimed in claim 44,
wherein the suspension material passes through an opening defined
in an inner region of the frame.
46. A frame for upholstered furniture, as claimed in claim 44,
wherein the tension of the suspension material is adjustable.
47. A frame for upholstered furniture, as claimed in claim 44,
wherein the suspension material is a fabric.
48. A frame for upholstered furniture, as claimed in claim 1,
further comprising a first material with padding properties coupled
to the frame.
49. A frame for upholstered furniture, as claimed in claim 48,
wherein the first material is produced in individual molds.
50. A frame for upholstered furniture, as claimed in claim 48,
wherein a first material with padding properties is coupled to the
frame using a fabric material extending over at least a first side
of the first material.
51. A frame for upholstered furniture, as claimed in claim 50,
wherein the fabric material is joined to the first material in a
molding process.
52. A frame for upholstered furniture, as claimed in claim 1,
further comprising at least one component of an upholstered
furniture unit configured to be manipulated to perform a function
selected from the group consisting of assembly, disassembly,
adjustment and interchange.
53. A frame for upholstered furniture, as claimed in claim 1,
wherein the frame is adapted for supporting more than one user.
54. A frame for upholstered furniture, as claimed in claim 1,
wherein the lattice form defines a skeletal framework.
55. A frame for upholstered furniture, as claimed in claim 1,
wherein the lattice form defines a lattice structure.
56. A frame for upholstered furniture, as claimed in claim 1,
wherein the lattice form defines a lattice structure that is a
space-frame.
57. A substantially internal frame for upholstered furniture
comprising: a weight-bearing frame for supporting one or more users
for seating above a support surface, the weight-bearing frame
having a main loading area adapted to receive compressive load
forces from the weight of the one or more users and defining at
least one span across a part of the main loading area, wherein the
larger part of the frame is one or more molded components that are
largely shell structure, which are substantially closed
shell-construction shell structure, the main loading area is
largely a lattice form that is defined by the one or more molded
components, defines a space-frame and is positioned largely around
all sides of a recessed or open area within the main loading area
of the weight bearing frame, and the frame is substantially an
openwork.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application is a continuation of U.S. patent
application Ser. No. 08/474,314, filed Jun. 7, 1995, entitled
"Furniture With Molded Frame," which is incorporated herein by this
reference.
[0002] The present invention relates to furniture for seating
having a frame, the larger portion of which is made with a molding
process. In particular, the invention relates to a frame having
molded components which are largely shell-structure, in which a
lattice form is defined by the molded components around a recessed
or open area e.g., within the seat portion of the seat frame, and
which may optionally be upholstered.
[0003] Furniture for seating is typically made by providing a
weight-bearing frame and, in many cases, a suspension and foam or
other padding and upholstery.
[0004] A significant portion of seat frames are of conventional
construction. The overwhelming majority of upholstered seat frames
are of conventional construction. The conventional construction of
seat frames is the familiar frame construction seen in most
furniture, and especially in most upholstered furniture. In it,
conventional materials such as hardwood, softwood, plywood,
chipboard, and extruded steel members, are processed by
conventional means such as sawing, milling, planing, etc., and
joined using conventional material and methods such as screw and
glue joinery, staple gun joinery, welding, rabbeting, and the like.
The conventional construction of seat frames is limited as a
process of manufacture. The conventional construction of seat
frames is limited as regard to the intended use, and potentially
desired capabilities for use, of the seat frame. The limitations of
conventional construction are particularly significant for seat
frames that are upholstered.
[0005] Seat frames of conventional construction are poorly equipped
to provide higher quality and greater value at modest or reduced
cost. The materials and processes of the conventional construction
severely limit the range of properties that can be provided in a
seat frame, particularly at modest cost. Seat frames of
conventional construction are not efficiently produced. Extensive
pre-processing of materials is usually required, and assembly
processes are usually cumbersome and labor-intensive, leading to
poor cost-efficiency. Labor in many cases accounts for nearly 50%
of value-added cost of manufacture. The conventional construction
can result in inconsistencies in product quality. The high labor
content in the manufacturing process is a contributing factor, as
are conventional frame materials, particularly wood-based
materials, which are often idiosyncratic and inconsistent.
[0006] The engineering capabilities in seat frames of conventional
construction are limited. The properties, structural and otherwise,
that can be engineered into the seat frame, especially at modest
cost, are limited. Conventional seat frames are often governed by
strict perpendicularity at places of intersection where the
component parts join, and the nature of the joinery often provides
for non-optimal strength and durability. The design capabilities in
seat frames of conventional construction are limited. It is not
feasible to produce a generous range of forms, especially at modest
cost. Conventional seat frame designs incline to a rigid,
rectilinear format. Ergonomic features such as lumbar support, are
poorly accommodated. Seat frames of conventional construction are
often difficult to recycle, since the hardware used in the joinery
frequently differs from the material from which the frame is made
and must be removed, often with some difficulty.
[0007] The forms that are usually provided within the frames of
seat frames of conventional construction are not especially
well-suited for use with upholstered furniture. Seat frames of
conventional construction tend to provide surfaces that are lean
and narrow. Furthermore, components are typically rectangular in
cross-section, defining sharp edges. Thus, in such furniture, large
quantities of, typically expensive, foam or padding are usually
required to provide upholstered furniture which can accommodate the
human body with some degree of comfort (overstuffed upholstered
furniture being a typical, and frequent, expression of this). And,
despite the large quantities of foam or padding usually demanded,
coverage of the frame with such foam or padding is usually not
complete, often reducing the useful life of the upholstery, often
limiting the fabric materials available for use with the
upholstered seat frame to "upholstery grade" materials, and often
further limiting the ease with which upholstered pieces can be
transported (already usually burdened by the relatively great
weight of the frames). The (typical) rectilinear format of
conventional seat frame designs tends to restrict the ability to
facilely produce seat frames or seat frame components that stack or
internest.
[0008] Some furniture is designed to be "knocked-down" (i.e.
disassembled and/or folded so as to occupy a smaller volume than in
the normal use configuration). Seat frames of conventional
construction typically require added hardware in order for the
frames to be knocked-down, adding the cost of fitting and joining
such additional hardware to the seat frame. The various seat frame
designs must be accommodated to the available knock-down hardware.
The material of which such added hardware is made typically
differs, both in composition and strength, from the material from
which the seat frame is made, resulting in stress raisers
(concentrations of stress in a relatively small region) that reduce
the durability of the seat frame. The added hardware also makes the
seat frame more difficult to recycle. Many knock-down designs are
relatively difficult to disassemble and reassemble. Among other
things, this has limited the use of knock-down seat frames with
modular-like interchangeable parts or sections.
[0009] Some furniture provides for relative movement of components
(e.g. recliners, sofa beds, seat frames with adjustable headrests
or adjustable armrests). In conventional seat frame construction
these typically have been produced by joining separate hardware
devices (such as hinges and other pivots, sliding hardware and the
like) to portions of the frame. These designs suffer from defects
similar to those described for knock-down devices (such as cost,
limitation of designs to available hardware, stress raisers and
difficulty of recycling).
[0010] Devices or techniques for therapeutic or comfort enhancement
such as massage, heating, pneumatic variable body support, etc. are
typically coupled to the seat frame by conventional means. Design
and engineering capabilities for the incorporation of such devices
or techniques are restricted by the limited engineering
capabilities of conventional seat frame construction, i.e. the
properties, structural and otherwise, that can be engineered into
the seat frame, especially at modest cost. Design and engineering
capabilities for the incorporation of such devices or techniques
are also restricted by the limited design capabilities of
conventional seat frame construction, and the limited range of
forms that can be produced, and are at least partially defined by
the typically rigid, rectilinear conventional seat frame
format.
[0011] Because of limitations on design and engineering
capabilities in conventional seat frame construction, such as those
indicated above, it is impossible for producers of conventional
seat frames to fully realize the benefits of modern design tools
such as computer-based visualization and 3-D modeling, structural
analysis, process simulation, rapid prototyping and computer-driven
tools. Limits in design and engineering capabilities also result in
a limited range in the choices available for custom-designed and
engineered seat frames and upholstered units.
[0012] There are fundamentally sound reasons for to be
manufacturing a seat frame comprised largely or entirely of a
molded article or molded articles (molded seat frames). The
capabilities of molded construction generally, applied to the
manufacture of seat frames, can answer to the limitations of the
conventional construction of seat frames, limitations both as
process of manufacture, and limitations as regard to the intended
use, and potentially desired capabilities for use, of the seat
frame. The advantages of molded construction are especially useful
for seat frames that are upholstered. The presence of molded seat
frames has increased in recent years, mostly by way of
injection-molded chairs made of plastic. The capabilities of molded
construction generally, applied to the manufacture of seat frames,
have been only modestly realized. Very few molded seat frames are
upholstered.
[0013] Molded seat frames are well-equipped to provide higher
quality and greater value at modest or reduced cost. Molded seat
frames greatly expand the range of properties that can be provided
in a seat frame, particularly at modest cost. Molded seat frames
can be efficiently produced. Often no preprocessing of materials is
necessary, and assembly processes can be simplified or eliminated.
Molded seat frames can be produced with consistent product quality.
The technology of molding is advanced, and continues to
advance.
[0014] The engineering capabilities in molded seat frames are
broad. The properties, structural and otherwise, that can be
engineered into the seat frame, especially at modest cost, are
broad. Molded seat frames need not be governed by strict
perpendicularity, nor have joinery providing non-optimal strength
and durability. The design capabilities in molded seat frames are
broad. It is possible to produce a generous range of forms, and at
modest cost. Seat frame designs need not incline to a rigid,
rectilinear format. Ergonomic features such as lumbar support, can
be readily accommodated. Molded seat frames need not be difficult
to recycle, as joinery can be made integral, or eliminated
entirely.
[0015] Molded seat frames are well-suited for use in upholstered
furniture. Molded seat frames need not provide surfaces being lean
and narrow. Molded seat frames need not be rectangular in
cross-section, defining sharp edges. Use of the molded seat frame
in upholstered furniture makes special sense. Molding makes a wide
range of materials available, and with upholstered furniture the
seat frame need not be exposed, so the aesthetic properties of the
molded materials need not be a concern. Molded seat frames provide
great opportunity to produce seat frames or seat frame components
that stack or internest.
[0016] Molded seat frames that "knock-down" can be made without
added hardware, instead having integral knock-down joinery. Thus,
no cost need be incurred in fitting and joining additional hardware
to the seat frame, the seat frame designs need not be accommodated
to available knock-down hardware, no stress raisers need result
that reduce the durability of the seat frame, and the seat frame
can be less difficult to recycle. Integral knock-down joinery in
molded seat frames can be made to be readily disassembled and
reassembled.
[0017] Molded seat frames providing for relative movement of
components may be made without added hardware, instead having
integral joints and the like for motion. The advantages are similar
to those described for molded seat frames having integral
knock-down joinery (such as cost-savings, the independence of
designs from available hardware, reduced stress raisers and
increased ease of recycling).
[0018] In molded seat frames, devices or techniques for therapeutic
or comfort enhancement such as massage, heating, pneumatic variable
body support, etc., can be readily incorporated into the seat
frame, and by novel means. Design and engineering capabilities for
the incorporation of such devices or techniques are enhanced by the
broad engineering capabilities of molded seat frames. Design and
engineering capabilities for the incorporation of such devices or
techniques are enhanced by the broad design capabilities of molded
seat frames, and the broad range of forms that can be produced.
[0019] Because the design and engineering capabilities in molded
seat frames are broad, producers of molded seat frames can fully
realize the benefits of modern design tools such as computer-based
visualization and 3-D modeling, structural analysis, process
simulation, rapid prototyping and computer-driven tools. Broad
design and engineering capabilities in molded seat frames also
result in a broad range in the choices available for
custom-designed and engineered seat frames and upholstered
units.
[0020] Molded seat frames fall into two fundamental categories,
reflecting two generally distinct approaches to the engineering of
strength within molded articles: (1) Molded seat frames having an
engineering of strength within molded articles largely being as
that largely evident in current injection-molded plastic chairs;
(2) Molded seat frames having an engineering of strength within
molded articles largely being shell-structure (shell-structure
molded seat frames). The latter is preferable in many ways, and
particularly so for molded seat frames that are upholstered.
[0021] In shell-structure molded seat frames, considerable
continuity in structural strength in the seat frame, i.e.
structural integration, i.e. diminishment of stress raisers between
portions of the seat frame, can be readily achieved. This is not
the case with current injection-molded plastic chairs, for a
distinct discontinuity in structural strength in the seat frame,
between the seat portion of the seat frame and surrounding areas,
is common and not always easily redressed. Continuity in structural
strength makes the seat frame more stable, enhancing strength and
durability. It can also reduce the quantities of material required,
and make engineered strength more predictable.
[0022] In shell-structure molded seat frames, structural properties
are enhanced in making the forms wanted for upholstered furniture.
Forms that are in size less lean, less narrow, broader, fuller, can
enhance overall structural strength in a shell-structure. Forms
that are in shape less rectangular, less sharp-edged, more rounded,
blunter of edge, preferably generously contoured, can enhance
structural integration, durability, efficiency of material use, and
torsional strength, in a shell-structure. Shell-structures lend
themselves to a disassembly and reassembly through means of
overlapping the shell-structure. This can allow for strong,
structurally integrated joints, that can be facilely disassembled
and reassembled. Shell-structures that are hollow allow a stacking
or internesting of the disassembled portions of the seat frame, and
through this means, a larger seat frame might be reduced in size to
a very modest package.
[0023] There are a range of molding processes that by their very
nature are inclined to produce shell-structures (molding processes
intrinsically descriptive of shell-structures). In shell-structure
molded seat frames these molding processes can be utilized,
bringing great advantages to the producer. In shell-structure
molded seat frames made with molding processes intrinsically
descriptive of shell-structures, a way of working a material is
fluently integrated with a way of using the so-worked material in
the engineering of the structure, incorporating the natural
capabilities of a characteristic materials processing with a
characteristic structural engineering.
[0024] The range of molding processes being intrinsically
descriptive of shell-structures makes more molding processes
available for shell-structure molded seat frames. Included among
these are low-cost molding process options using lower-cost molds
and molding machinery (costs should be compared with the
injection-molding process of current injection-molded plastic
chairs, where mold costs can run to several hundred thousand
dollars, for single-seat sized chairs, and the cost of the
injection-molding machinery used can run into the millions of
dollars). Notable among the low-cost molding options are
low-pressure molding processes, such as a process operating at
pressures less than about 100 p.s.i., preferably less than 50
p.s.i. These especially can reduce molding costs, allowing lighter,
thinner molds, and in some cases facilitating a faster cooling of
material, as applicable. In some instances, very lightweight molds
can be made having strength mirroring that of the shell-structure
molded article. Low-pressure molding processes also enable many
variations within the molding process. Complex inter-inflatable
moldable forms can be used in low-pressure molding processes.
Innovative molding processes such as molds that are an inflatable
article can be used. Using molds that are an inflatable article,
seat frames can be transported unconstructed and be molded directly
by the end user. A canister of material with foaming agent, for
example, can be shipped with the inflatable mold. The availability
of low-cost molding options, and particularly lower-cost molds,
means that large molds (as for two-seat or three-seat frames) need
not be prohibitively expensive. It means a reduction in the size of
production runs required to recoup mold costs, so designs can be
turned over more readily, increasing design flexibility for
producers, and enabling an avoidance of clichd designs (clichd
designs being common with current injection-molded plastic chairs).
It also means producers can affordably keep many molds on hand, and
enables frames or components of frames in varying sizes, in varying
versions, with varying ergonomic features, and the like.
[0025] Many materials, in many states, are accessible with molding
processes intrinsically descriptive of shell-structures, making
more materials available for use with shell-structure molded seat
frames. Among materials available are many alternatives to
plastics. The use of plastics in molded seat frames raises
environmental considerations, especially questions as to the
material's long-term recyclability. But perhaps more importantly,
seat frames made of plastic present a fire safety hazard and may
not be well-suited for use indoors, especially in homes in the form
of upholstered furniture.
[0026] The many molding processes intrinsically descriptive of
shell-structures, and the many materials accessible through them,
provides great flexibility for the producer of shell-structure
molded seat frames. There are many options for the producer to
choose among molding processes and materials, or molding
contractors and material suppliers. The producer can tap this range
of molding processes and materials, or molding contractors and
material suppliers, for rapid, localized or decentralized growth.
Growth may also possibly be attained without heavy capital
requirements by tapping the financial base of competing molding
contractors and material suppliers seeking avenues for their
production. Because of the ability to diversify production, the
producer need not be tied to any particular molding process or
molding contractor, or material or material supplier. The producer
is free to adjust production to accommodate changes in material
costs, molding costs, or other concerns. The producer can target
various price points in the market, with seat frames made of
various materials, or processes. A consumer can purchase a favored
seat frame in a lower-cost version (where the seat frame is
upholstered, choosing say, to initially focus on premium
upholstery), then upgrade later to a more expensive version of the
same frame (e.g., stronger and/or more durable, or with additional
features such as disassembly, therapeutic features, etc.). The
producer is also accorded greater flexibility for incorporating
developments in materials and production technology.
[0027] Cast-in stresses in molded articles generally are reduced in
molding processes intrinsically descriptive of shell-structures,
because the molded malleable material, in contacting and taking
it's shape from the defined, moldable form, is apt to travel in
volumes that are broad, and travel at and onto the outer surface
area. Cast-in stresses in molded articles can lead to
stress-cracking and reduce a molded article's useful life, and are
a matter of concern in current injection-molded plastic chairs. The
engineering capacity in molded articles produced using molding
processes intrinsically descriptive of shell-structures is
furthered in that the malleable material, in contacting and taking
it's shape from the defined form, is apt to travel in volumes that
are broad, and travel at and onto the outer surface area, and the
material can often be selectively distributed on the outer surface
area. With many of the molding processes intrinsically descriptive
of shell-structures closed shell construction shell-structures can
be readily produced. This is of great value in that closed shell
construction shell-structures are particularly well-suited for use
in upholstered furniture, providing surface area around all parts
of the seat frame. Further, closed shell construction
shell-structures can enhance the torsional strength and durability
of the seat frame, and provide advantages in seat frames having a
disassembly and reassembly of seat frame components.
[0028] Forms that are scaled, that are in size less lean, less
narrow, broader, fuller, wanted for upholstered furniture, further
the distribution of material in molding processes intrinsically
descriptive of shell-structures. Forms that are contoured, that are
in shape less rectangular, less sharp-edged, more rounded, blunter
of edge, preferably generously contoured, wanted for upholstered
furniture, significantly improve the distribution of material, and
facilitate the pulling of finished parts from molds, in molding
processes intrinsically descriptive of shell-structures.
[0029] Shell-structure molded seat frames have been made for over
50 years. They have been produced with a range of molding
processes, and in a range of materials. The role of shell-structure
molded seat frames in the furniture industry has however always
been a modest one. As the capabilities of molded seat frames have
been only modestly realized, so too have the capabilities of
shell-structure molded seat frames. The advantages shell-structure
molded seat frames provide for use in upholstered furniture has not
been significantly recognized. Very few shell-structure molded seat
frames outside of office chairs have been upholstered. No
upholstered shell-structure molded seat frames of the likes of
traditional upholstered sofas, loveseats and chairs, it is
believed, have achieved significant commercial success.
[0030] Previous shell-structure molded seat frames particularly
suffer these limitations:
[0031] Previous shell-structure molded seat frames do not make as
effective a use as is possible of shell-structure strength in
assuming compressive loading on the seat frame. This limits the
breadth of spans shell-structure molded seat frames are capable of
traversing, and the loads they are capable of assuming, without
undue excess of material, and limits the range of designs and uses
available to them. The durability or life-span of shell-structure
molded seat frames is reduced because of the ineffective use made
of shell-structure strength in assuming compressive loading, and/or
inordinate strains being placed on a portion of the seat frame. The
materials being available for use in shell-structure molded seat
frames is diminished, especially for materials likely to be
incapable of accepting the strains of an inefficient assumption of
bending loading, such as paper or paper/fiber composites.
[0032] Previous shell-structure molded seat frames are not
exceptionally well-suited for use in upholstered furniture.
Previous shell-structure molded seat frames usually do not provide
recessed or open area within the seat portion of the seat frame
such as might accommodate a suspension. Previous shell-structure
molded seat frames do not accommodate a suspension comprised of a
fabric material which can wrap around all sides of the seat portion
of the seat frame, giving firm support to the fabric material
suspension, and distributing strain evenly across the seat frame.
Previous shell-structure molded seat frames do not provide multiple
options for upholstering.
[0033] Previous shell-structure molded seat frames provide less
than optimal opportunities for assembly and disassembly of the seat
frame. Limited opportunities for assembly and disassembly reduce
the molding processes available for the seat frame's manufacture
and may decrease the range of materials available to it. Limited
opportunities for assembly and disassembly decrease the options
available in the packaging and transport of the seat frame. Limited
opportunities for assembly and disassembly decrease options for an
interchanging of parts or sections of the seat frame. Movable parts
or sections are not readily incorporated in previous
shell-structure molded seat frames.
[0034] Previous shell-structure molded seat frames do not have the
advantage of the light weight and efficient material use of
space-frames for carrying compressive loads, nor join the
advantages of the light weight and efficient material use of
space-frames for carrying compressive loads with the efficiency of
shell-structures for resisting shear and torsion. Previous
shell-structure molded seat frames do not define a space-frame
being scaled and contoured to enhance the properties of the seat
frame for use in upholstered furniture while also providing a seat
frame having exceptional structural integration and torsional
strength. Previous shell-structure molded seat frames do not have
the added design and engineering flexibility provided by
space-frames for selectively positioned structural members.
Previous shell-structure molded seat frames do not have the added
design and engineering flexibility of structural strength in
individual structural members being selectively described.
[0035] The present invention includes the recognition of problems
found in the previous devices. The present invention includes the
recognition of problems in seat frames of conventional
construction, advantages in seat frames being of a molded
construction, advantages in seat frames of a molded construction
being shell-structure molded seat frames, and the recognition of
problems in previous shell-structure molded seat frames.
[0036] According to an aspect of the present invention, the
furniture is provided with a weight-bearing frame largely comprised
of one or more molded components, where the molded components are
largely shell-structure, and where a lattice form is defined by the
molded components around a recessed or open area within the seat
portion of the seat frame. Preferably, the lattice form defined has
the character of a skeletal framework. Preferably, the molded
components are scaled and contoured. Preferably, scaling and
contouring provides substantial structural integration and
torsional strength in the structure defined by the molded
components. Preferably, the lattice form defines a lattice
structure. A lattice structure differs from a lattice form in that
a lattice form may be a representation of the form or a less than
fully integrated structural unit, while a lattice structure
necessarily functions as a significantly integrated structural
unit. Preferably, the lattice form defines a lattice structure in
the form of a space-frame. Preferably, substantially all of the
weight-bearing portions of the frame are molded components.
[0037] In some embodiments, the furniture is upholstered.
Preferably the upholstery and/or foam or padding and/or suspension
is made of elements which can be readily put together and taken
apart, e.g. by the user, preferably such that the user can readily
substantially alter the appearance and/or feel of the furniture by
"dressing" the same frame in different upholstering units.
Preferably upholstery and/or suspension materials define space in
and around the frame in varied ways, with a plurality of formats of
"dress," with upholstery and/or suspension materials spanning or
encircling parts of the frame, and the like. In one embodiment, in
coupling to the frame, upholstery and/or foam or padding and/or
suspension pass through an opening defined in the inner region of
the frame.
[0038] FIGS. 1A through 1F are perspective views of furniture
frames according to embodiments of the present invention;
[0039] FIG. 2A is a rear elevational view of upholstered furniture
according to one embodiment of the present invention;
[0040] FIG. 2B is a cross-sectional view taken along the line 2B-2B
of FIG. 2A;
[0041] FIG. 2C is an end elevational view of the embodiment of FIG.
2A;
[0042] FIGS. 3A through 3C are perspective views of seat frames
according to embodiments of the present invention;
[0043] FIGS. 4A through 4C are perspective views, partially
exploded and partially in phantom of upholstered furniture
according to aspects of the present invention;
[0044] FIGS. 5A through 5C are perspective views of upholstered
furniture according to embodiments of the present invention;
[0045] FIGS. 6A through 6D are perspective exploded views of frame
components according to embodiments of the present invention;
[0046] FIGS. 7A through 7F are perspective exploded views of frame
components according to aspects of the present invention;
[0047] FIGS. 8A through 8D are perspective conceptual views of
shell components;
[0048] FIGS. 9A and 9B are partial side views of movable furniture
frames according to an embodiment of the present invention;
[0049] FIG. 9C is a partial side view of a joint assembly according
to an embodiment of the present invention;
[0050] FIG. 9D is a perspective view of a movable furniture frame
joint according to an embodiment of the present invention; and
[0051] FIGS. 10A through 10N, 11A through 11N and 12A through 12J
depict shell-structures, according to an embodiments of the present
invention.
[0052] To facilitate an understanding of the present invention, it
is useful to provide familiarity with a number of terms used
herein.
[0053] As used herein, a seat or seating includes both single
person seating and multi-person seating (e.g. as in a sofa, couch,
loveseat or divan), and is preferably sized and configured to
accommodate adults. The seats may be static or movable (such as
being reconfigurable, reclining and the like).
[0054] As used herein, furniture frame or seat frame refers to the
(typically three-dimensional) structural or weight-bearing or
load-bearing component or components of furniture, by which the
weight of the user is transferred to the legs and/or floor or other
support surface. Typically, the frame defines one or more spans
(i.e. regions which support a user's weight but which do not
directly vertically overlie a leg or directly extend to the floor
or other support surface). In use, the user may directly contact
and rest on the frame surfaces, or the weight of the user may be
transferred to the frame by suspension devices or materials, or
coverings such as upholstery, which may include, e.g., fabric,
padding, foam and the like.
[0055] As used herein, molding refers to a fabrication process in
which a malleable material contacts and takes its shape from a
defined and moldable form, e.g., a mold. The form defines surface
area and, usually volume.
[0056] As used herein, molded seat frame refers to a seat frame in
which the larger part (i.e., at least 50%) of the seat frame is
comprised of a molded article or molded articles.
[0057] As used herein, shell-structure refers to an article
describing a three-dimensional form, in which the larger part of
strength within the article is strength of material concentrated to
the outer surface area of the three-dimensional form joined to
strength of structural shape in the outer surface area of the
three-dimensional form. Examples of shell-structures in nature
include mollusk shells, egg shells and exoskeletons. The
shell-structure may be either a closed shell construction, in which
a cross-section through the shell defines a closed curve (e.g. as
depicted for the components in FIG. 7C), or an open shell
construction, in which a cross-section defines an open curve, such
as a U-shape (e.g., as illustrated in FIGS. 8A through 8D). In many
instances, closed shell construction provides structural strength
advantages. However, open shell construction can have its
structural strength characteristics enhanced by a number of
techniques, including reinforcement of edges with added strength of
material (enhanced material distribution), reinforcement of edges
with added strength of structural shape (e.g. with turned-inward or
turned-outward edges), reinforcement between edges or on or between
inner surfaces, and increased depth.
[0058] As used herein, shell-structure molded seat frame refers to
a seat frame in which the larger part (i.e., at least 50%) is
comprised of a molded article or molded articles, in which the
larger part (i.e., at least 50%) of the molded article or molded
articles is shell-structure.
[0059] As used herein, molding processes intrinsically descriptive
of shell-structures refers to molding processes that by their
nature are inclined to produce shell-structures. In molding
processes intrinsically descriptive of shell-structures, the molded
malleable material, in contacting and taking its shape from the
defined form, tends to travel or migrate in volumes that are broad
rather than volumes that are narrow, tends to travel at and onto
the outer surface area rather than through the volume, and tends to
concentrate to the outer surface area rather than elsewhere.
Examples of such molding processes are stamping, thermoforming (and
variants thereof), twin-sheet thermoforming, blow-molding,
spray-molding, dip-molding, rotational molding, and foam-molding
with broader volumes and material concentrated to the outer surface
area. Distributed multiple-head injection-molding and distributed
multiple-head reaction injection-molding may also, in some
circumstances, intrinsically define shell-structures.
[0060] As used herein, lattice structure refers to a structure
defining a lattice form, being comprised of structural elements or
structural members that together function as an integrated
structural unit. The primary structural strength in a lattice
structure is in, and between, the structural elements or members.
The structural strength of the structural elements or members in a
lattice structure are in relative balance one with another.
Preferably the structural strength of the structural elements or
members are in relative balance one with another such that no given
structural element or member, during normal use, bears
substantially more or less load, on average, than other structural
elements or members and, preferably, stress or load is, on average,
in normal use, distributed substantially equally among structural
elements or members (e.g., such that in normal use, average stress
on any given structural element or member is within about 35%,
preferably within about 25%, more preferably within about 15% and
even more preferably within about 5% of the normal use average
stress on any other structural element or member).
[0061] As used herein, space-frame refers to a lattice structure
having the character of a skeletal framework.
[0062] As used herein, skeletal framework refers to a bone-like
framework.
[0063] In FIG. 8A a shell-structure is depicted (it is open shell
construction). FIG. 8A depicts an article describing a
three-dimensional form 82, in which the larger part of strength
within the article is strength of material concentrated to the
outer surface area of the three-dimensional form joined to strength
of structural shape in the outer surface area of the
three-dimensional form (its convex shape). The structural shape of
the shell-structure depicted in FIG. 8A is an effective structural
shape. The orientation of the shell-structure (downward facing)
depicted in FIG. 8A is effective for compressive loads, and
provides the surface area appropriate for use in furniture. FIG. 8B
depicts the shell-structure of FIG. 8A as it might extend across
space, e.g. to span a distance. FIG. 8C demonstrates that the
shell-structures of FIGS. 8A and 8B, to perpetuate across space,
particularly a broader and/or wider space, e.g. to span a distance,
particularly a broader and/or wider distance, in an ultimately
effective manner, preferably defines a lattice form (in FIG. 8C a
series of lattice forms are defined, having plurality of openings
80a through 80d). In FIG. 8C the series of lattice forms defined,
having plurality of openings 80a through 80d, define a series of
lattice structures having plurality of openings 80a through 80d.
FIG. 8D depicts a shell-structure having characteristics of the
shell-structures of FIGS. 8A through 8C, defining a lattice form
having the character of a skeletal framework. In FIG. 8D the
shell-structure having characteristics of the shell-structures of
FIGS. 8A through 8C, and defining a lattice form having the
character of a skeletal framework, defines a lattice structure in
the form of a space-frame.
[0064] As used herein, a scaled frame refers to a frame in which
the exterior surfaces are relatively wide and/or broad,
particularly such as to make the frame especially well-suited for
use in upholstered furniture, i.e., such that the upper, front
portion of the frame is greater than about 2 inches (about 5
centimeters) preferably greater than about 3 inches (about 7.5
centimeters) and more preferably greater than about 4 inches (about
10 centimeters).
[0065] As used herein, a contoured frame refers to a frame in which
the exterior surfaces provide a relatively smoothly shaped surface,
particularly such as to make the frame especially well-suited for
use in upholstered furniture, i.e., substantially without sharp
angles, i.e., such that the smallest radius of curvature defined by
the cross-section is greater than about 0.5 inches (about 1.2
centimeters), preferably greater than about 0.75 inches (about 2
centimeters), more preferably greater than about 1 inch (about 2.5
centimeters), and most preferably greater than about 1.5 inches
(about 4 centimeters). A frame or frame component is generously
contoured if no region of the surface of the upper portion of the
frame defines, in cross-section, a radius of curvature less than
about 1 inch (about 2.5 centimeters).
[0066] Structural integration refers to the character and degree of
integration of structural strength in a structure. A structure with
substantial structural integration is a structure having high
integration of structural strength, low or minimized stress
raisers, high or maximized stress distribution, and preferably high
torsional strength, between the various elements in, or component
parts of, the structure. A structure with substantial structural
integration might be an optimized structure, i.e. a structure in
which maximum strength is achieved using minimum material. A
structure with substantial structural integration may also be an
efficient structure, i.e. a structure in which the dimensionless
ratio of strength to mass is at least 80%, preferably at least
90%.
[0067] FIGS. 1A through 1D depict single-seat furniture frames
according to embodiments of the present invention. The embodiments
of FIGS. 1A through 1F depict shell-structures as can be seen,
e.g., from the cross-sectional view of FIG. 1G. In the embodiments
of FIGS. 1A through 1F, substantially all load bearing components
of the frame are shell-structures. The frames of FIGS. 1A through
1F define openings 102a, 102a', 102b, 102b', 102b", 102c, 102d,
102f, 102g. The embodiments of FIGS. 1B and 1F have legs 104a, b,
c, d, which are part of the frame itself while the embodiments of
FIGS. 1A, 1C, 1D, and 1E are configured to receive separate,
non-integral legs, as illustrated by legs 106a-f, coupled to the
frame 100a-f, e.g., by a coupling such as a screw coupling,
friction coupling, bolt and nut coupling, latch coupling, wedge
coupling and the like, e.g. by receiving a leg component in sockets
108a, 108b (FIG. 11G) formed in or coupled to the frame 100.
[0068] As another example of a method and apparatus for connecting
legs, it is possible to use a structure similar to the common metal
vegetable steamer/strainer used in pots of varying sizes to steam
vegetables, such as those with sides that overlap and collapse
inwards. In this embodiment, such a structure may be coupled to the
frame by inserting backwards through a hole in the frame at the
area where the leg is to be located. The hole may have a diameter
of, e.g. about one inch (about 2.5 centimeters). The device is then
pulled back so as to expand and become fixed structurally. The leg
piece, with regular metal threads, is screwed through a receiving
threaded, reinforced part in the structure. The leg piece itself
can have a screw fixed in it or joined to it during the user's
assembly of the frame.
[0069] FIGS. 2A through 2C depict an upholstered couch. It is
covered with padding and/or foam and/or fabric 202, e.g., by
materials and methods described more fully below.
[0070] Frames such as depicted in FIGS. 1A through 1F can be formed
using a number of methods and materials. Preferably, the frame
and/or frame components are made using a molding process.
Preferably, the molding process is a molding process which is
intrinsically descriptive of shell-structures. Being a fabrication
process in which a malleable material contacts and takes its shape
from a defined and moldable form, molding can be as simple as a
foam poured into a tray and setting, or as exotic as a structure
grown in a form (e.g., crystals), or biological materials or
organisms grown in a form (e.g., as might grow, die, and leave in
their wake a structure).
[0071] The frame can be made by methods other than molding such as
carving or grinding, or laser-cutting. Laser sintering can possibly
by used. The materials processed by these means might be foamed
articles, with reinforcement later affixed on outer surfaces (or
spray-molded onto the article). In a laser cutting or a laser
sintering of a foamed article, a shell-structure may be formed in
reaction to the laser, e.g., by a chemical reaction in the
material, or by a melting of the material. The frame also can be
made through an extrusion process where the extruding head is
movable and directable and so may progressively define the frame,
analogous to frosting material squeezed through a tube onto a cake,
or toothpaste decoratively squeezed across a surface. The size
and/or shape of the extruding head can vary, as can the properties
of the material composition (as through a selective foaming of
material within the extruding head, or as through the threading of
reinforcing fibers through the extruding head). An extrusion
process such as this can be used in conjunction with molds.
Computer-driven tools are applicable for all of the above processes
described.
[0072] Frames such as depicted in FIGS. 1A through 1F can be formed
using a wide range of materials. Preferably the frame and/or frame
components are formed of a material such as steel, glass, paper or
paper/fiber composite, and the like (i.e., commodity materials that
are readily recyclable and relatively fire-safe). Plastics both
thermoset and thermoplastic can be used, including fiber-reinforced
composite constructions such as fiberglass and other composite
constructions. For plastics, commodity thermoplastics such as
polyethylene and polypropylene are preferred, and may be undyed.
Fiber-reinforced composite constructions and other composite
constructions can also be produced using materials other than
plastics. Material distribution within the molded articles may be
"taffy-like." Material distribution within the molded articles may
be an engineered foam composition. Material distribution within the
molded articles may incorporate areas of varied material density.
The shell-structure may have a double-walled construction. Other
materials can be used such as various metals, sheets of mesh of
aluminum or steel, super-plastic steel, ceramic, ceramic metal,
ceramic foam, resin impregnated paper or wood fiber, or bonded
fibers of other materials such as glass, and the like.
[0073] With the capabilities of molding a wide variety of
properties, structural and otherwise, can be engineered into the
seat frame and the materials comprising it. Variations in rigidity
and elasticity can be engineered into the frame through the shape
of the shell-structure (e.g., with pleating-like, gently contoured
forms) or its material composition (e.g., with material selectively
removed as through strategically placed holes, with material
distribution selectively enhanced, with variations in material
density within the shell-structure forms, or with selectively
distributed reinforcement fibers). The properties of foam/padding
may be engineered directly into the seat frame in a rotational
molding process by entering into the mold in stages materials of
varying density during the molding process. It is also possible
that properties of foam/padding can be configured directly in the
seat frame using an engineered foam material composition having
areas of varied material density. The seat frame readily
accommodates ergonomic and/or therapeutic features such as lumbar
support 110, incorporated as a part of the frame itself. The
spatial variation and stress distribution arising from a mid-span
depth increase 112, as depicted in FIG. 1F and/or mid-span
concavity 114.
[0074] FIGS. 10A through 10N, 11A through 11N, and 12A through 12J
illustrate various constructions of shell-structures 1001a-1001n,
1101a-1101n, 1201a-1201j. These illustrations are based on the
molding process of stamping, particularly such as using a
high-tensile strength steel, but the illustrated shell-structure
constructions apply to other molding processes as well.
[0075] FIG. 10A shows a basic stamped shell-structure article.
FIGS. 10B and 10C show two ways of joining basic stamped
shell-structure articles.
[0076] FIG. 10D depicts a shell-structure given decorative
treatment. In this illustration, material is removed from the steel
sheet and forms a decorative pattern. For example, the pattern
might be characteristic of a metal Persian screen. Such patterning
can also be etched into the material or stamped into it. The steel
article can be painted including enameling of the steel.
[0077] FIG. 10E illustrates a shell-structure which is internally
foamed.
[0078] FIG. 10F depicts a shell-structure in which the depth of the
shell-structure is increased in the center of the span.
[0079] FIG. 10G depicts an embodiment in which material is added so
as to reinforce the top. In stamping in a slush-molding, this can
also be added to the material as it is molded.
[0080] FIGS. 10H and 10I depict an embodiment in which strength
through structural shape is added so as to reinforce the top.
[0081] FIG. 10J depicts an embodiment in which a structural member
is incorporated but the molded article remains a
shell-structure.
[0082] FIG. 10K depicts a device in which two pieces are joined. It
would also be possible to provide a device in which three or more
pieces are joined.
[0083] FIG. 10L depicts a device with a molded-in recess 1002l
providing strength through structural shape, along a portion of the
top.
[0084] FIG. 10M depicts a device with a molded-in recess 1002m
along the extent of the top providing strength through structural
shape.
[0085] In the embodiment of FIG. 10N, sharp edges 1002n, 1003n,
1006n, 1009n, provide added strength in the part while the
contoured shape is still substantially maintained.
[0086] In the device of FIG. 11A structural elements 1002a, 1003a
are incorporated across the shell-structure.
[0087] FIG. 11B depicts a device in which strength is enhanced
through added material 1102b, 1102c achieved with structural
elements added to the shell-structure reinforcing across the
shell-structure. This is similar to the structural model
represented by bamboo in which added material and added strength
through structural shape also reinforce a shell-structure. A
comparable structure can be achieved as molded-in, with
rotational-molding, using foamed parts or web-like material
inserted in the mold for the molding process and drawing a section
of the rotational-molded material onto its surface.
[0088] The structure in FIG. 11C shows strength enhanced through
structural shape achieved with pieces added to the shell-structure,
reinforcing across the shell-structure.
[0089] FIG. 11D depicts strength through structural shape
molded-in, reinforcing across the shell-structure. A spiral,
overlapping format for this construction can also be used. A spiral
format may be particularly advantageous for creating an
engineered-level of flexibility within the shell-structure
frame.
[0090] FIG. 11E depicts reinforcement along a portion of a side of
the shell-structure through a shell's molded-in structural shape
1102e.
[0091] FIG. 11F depicts reinforcement along the length of the sides
of the shell-structure through molded-in structural shape 1102f,
1103f.
[0092] FIG. 11G depicts reinforcement along the bottom edge of an
open shell construction shell-structure 1102g, 1103g. In this
embodiment reinforcement is provided as a folding over of the lower
edges to be used if molding processes permit.
[0093] FIG. 11H depicts reinforcement along the bottom edge of an
open shell construction shell-structure through an added piece
1102h, 1103h.
[0094] FIG. 11I depicts reinforcement of a bottom edge of a
shell-structure by narrowing the shape of the shell-structure along
its lower edge 1102I.
[0095] FIG. 11J depicts reinforcement of a shell-structure by
narrowing overall sides in the center portion 1102j.
[0096] FIG. 11K depicts reinforcement along a portion of the bottom
shell-structure through a molded-in structural shape 1102k.
[0097] FIG. 1L depicts reinforcement along the length of the bottom
shell-structure through a molded-in structural shape 1102t.
[0098] FIG. 11M depicts removal of material from the
shell-structure 1102m through 1107m. FIG. 11N depicts removal of
material from a shell-structure with a lattice structure being
described through, within the shell-structure.
[0099] FIG. 12A depicts removal of material from a shell-structure
(in this embodiment with a lattice structure being described
through, within the shell-structure) with zigzagging, e.g. 1202a,
between areas being used for creating an engineered degree of
flexibility with the shell-structure frame.
[0100] FIG. 12B depicts adding of a material to a shell-structure,
e.g. providing two adjacent surfaces.
[0101] FIG. 12C depicts adding a material to a shell-structure with
a lattice structure being described through, within the
shell-structure.
[0102] FIG. 12D depicts structural shape incorporated within the
shell-structure.
[0103] FIG. 12E depicts structural shape incorporated within the
shell-structure with a lattice structure being described through,
within the shell-structure.
[0104] FIG. 12F depicts a particularly pronounced (with depth)
structural shape within the shell-structure.
[0105] FIG. 12G depicts a particularly pronounced (with depth)
structural shape within the shell-structure with a lattice
structure being described through, within the shell-structure. A
similar construction in nature can be seen in the structure of
certain cacti, including, e.g., a prickly pear cactus.
[0106] FIG. 12H depicts a structural shape within the
shell-structure (here shown with lattice structure being described
through, within the shell-structure), with depth of that structural
shape within the shell-structure being varied, as for selective
reinforcement of structural strength.
[0107] FIG. 12I depicts a particularly pronounced (with depth)
structural shape within the shell-structure with that particularly
pronounced (depth) structural shape as might be used for division
and assembly of the shell-structure.
[0108] FIG. 12J depicts a molded structure within the
shell-structure, with holes penetrating the surface, being
particularly useful for use in passing strapping-like material
through for control of motion elements and directing its travel.
With rotational-molding this can be achieved using inflatable bags
such as Teflon.TM. for such added structure within the shell. In
rotational-molding, using such Teflon.TM. inflatable in the molding
process, the holes penetrating the mold itself, through which
Teflon.TM. bags pass, can be made large, with reinforcement added
to the sidewalls of the Teflon.TM. bags, so that various variations
in bag types or configurations of the frame can be enabled with a
limited set of original molds.
[0109] Rotational molding is particularly useful for seat frames
produced as a single integrated unit and is particularly apt for
producing closed shell construction shell-structures. Rotational
molding is a low-pressure molding process. Relatively lightweight,
inexpensive molds can be used, particularly lightweight molds of
stamped steel having strength mirroring that of the molded article.
Rotational molding can readily incorporate inter-inflatable
moldable forms, such as inflatable Teflon.TM. bags. Complex
inter-inflatable moldable forms can be used to create complex
joints (e.g. for movable joints), passageways for weaving strapping
or similar materials through the forms (e.g. as for use in
directing the travel of joints, and/or distributing stresses
arising at joints throughout the larger article) and that might be
analogous in ways in character to the character of a worm-eaten
article, cavities or voids within the form that may in novel
fashion accommodate therapeutic or comfort capabilities such as
massage or pneumatic variable body support (or microwavable heated
gel pads that might in occasional use be inserted within the form,
such as in areas around the user's neck, shoulders, or lower back),
and the like. Rotational molding provides for flexibility in
engineering material composition, including selective distribution
of material, variability of wall thickness, selective distribution
of reinforcing fibers, selective foaming of material, and
combinations of the same. Pressure (e.g. air pressure) may be
incorporated between stages in the molding process, or after the
final stage of the molding process, so as to increase density in
the molded materials. Calibrated valves may be used to create a
measured increase in pressure within the mold, and on the materials
inside the mold.
[0110] Another forming process useful in connection with the
present invention is stamping, particularly using high-tensile
steel. Using this process, thin forms of great strength can be
made. The thin forms are excellent for seat frames having
disassemblable and reassemblable component parts, and disassembled
component parts can be shaped so as to optimally internest for
compact shipping. Disassemblable or component parts are in fact
preferable for use with this forming process because the smaller
size of the forms means smaller presses can be used.
[0111] In another stamping process, shapes can be formed using a
slush-like mass of material (instead of, e.g., a sheet material),
in a process not unlike compression or transfer molding, and
referred to herein as slush-molding. This process can be used in
connection with, e.g., paper or paper/fiber composites or wood
fiber composites, wherein stamping can create the relatively high
density in these materials preferable for their use in furniture.
The volume of material can be selectively distributed, and
reinforcing fibers selectively positioned. A net-like integrated
mesh of fiber reinforcement can be incorporated to provide security
for the molded construction at the end of its useful life (i.e.
such that the molded seat frame may give way, rather than collapse,
at the end of its useful life).
[0112] Another forming option is foam-molding, which is a
relatively low-pressure process. In some embodiments, the form, or
portions thereof, may be an inflatable article. In one embodiment,
the inflatable mold and molding material can be compactly packaged
and transported and may be moldable directly by the end user in
some instances.
[0113] In another embodiment, the form can be provided by a process
of spraying material, such as fiberglass, against a mold, or onto
an article such as a lightweight, foamed, pre-molded article,
hereinafter called spray-molding. In one embodiment, a chopper gun
cuts a continuous strand of fiber material into small pieces, which
join with a spray of resin, and is sprayed against a mold. Precise
and sophisticated control of spray-molding can be achieved using,
e.g., computer control in a fashion analogous to ink-jet printers
to provide highly-controllable spatial variation of the molded
form. In one embodiment, glass fiber and/or molten glass in fibrous
form is sprayed against a mold or onto an article.
[0114] The lattice form defined by the seat frame may be a plural
lattice form, i.e., having a plurality of openings 102.
[0115] The embodiment of FIG. 1A shows an "openwork" configuration,
with the area surrounding the lattice form being open, in contrast
to the embodiments of FIGS. 3A through 3C. The openwork seat frame
is preferable for some molding processes. It is advantageous in
assembly and disassembly of the seat frame, enhancing options for
packaging and transport, interchangability of parts or sections of
the seat frame and the like. It is preferable in application of the
fabric material for suspension and it is preferable for
upholstering of the seat frame, as described more thoroughly
below.
[0116] FIGS. 7B and 7D, respectively, illustrate closed shell
construction and open shell construction shell-structures. The
closed shell construction shell-structure seat frame is preferable
for some molding processes. It is advantageous in assembly and
disassembly of the seat frame, enhancing options for packaging and
transport, interchangability of parts or sections of the seat
frame, etc. It is advantageous for embodiments which are
upholstered. It can increase the loading strength of the
shell-structure elements or members forming the seat frame, and can
enhance the overall structural integration and torsional strength
of the seat frame.
[0117] As depicted in FIGS. 7A through 7E, the frame, rather than
being substantially integral as depicted in FIGS. 1A through 1F,
can be provided in two or more parts which may be coupled together.
Preferably, the coupling mechanism is substantially integral with
the frame members such as by friction fitting of collars 706 into
corresponding sockets formed in adjacent sections. To enhance
security of coupling, the coupled devices may be further secured by
ribbing or other friction-enhancing surfaces, or by couplers such
as screws, nuts and bolts, snap fasteners or snap-in fittings,
living hinges, and the like. Where a limited cross-sectional area
is available, the given cross-sectional area of the frame available
for joining the forms may be increased by multiplying the forms
within the given area of the frame such as by scalloping or other
convolution.
[0118] In some configurations, the shell-structure is not radially
symmetrical such that there is an axis of depth or elongation 718
(FIGS. 7C and 7D) wherein the shell-structure, in cross-section, is
deeper (having greater depth in the vertical dimension) than it is
wide (i.e., extent in horizontal direction). Vertical orientation
of the depth can enhance strength for assuming bending loading from
the (typical) vertical load of a user. In the depicted embodiment,
the shell-structures are typically arched 120 (FIGS. 1C and 1G),
which may enhance loading strength, and are in general shaped so as
to better transfer loads to legs 106 or other points of
distribution so as to provide for more even distribution of load
and/or stress. In one embodiment, by providing a frame which is
more easily designed and fabricated, such as by molding, the frame
can be custom fit to a user, i.e., specially designed and
manufactured to conform more closely to the characteristics of the
body of a particular user.
[0119] In one embodiment, the frame is designed and constructed to
provide a controlled degree of flexibility, rather than being
substantially rigid, such as through variations in shape within the
shell-structure forms, or through variations in the material
composition of the shell-structure, e.g., strategically placed
holes or otherwise selectively distributed material, selectively
distributed reinforcing fibers and the like. It is believed that
providing a measured degree of flexibility within the frame may
enhance its usefulness by absorbing and distributing stress, such
as in absorbing the momentum or impact of an individual sitting
down on the frame.
[0120] In one embodiment, seat frames 100a are configured to easily
and, preferably, efficiently, internest and/or stack (as depicted
in FIG. 6A) e.g., to facilitate transportation and/or storage. In
one embodiment, the shell can be disassembled into two or more
parts along a side seam to define upper and lower halves 132a, 132b
which are, preferably, stackable and/or internestable, or as
depicted in FIGS. 7A through 7F, 6D and 6E, e.g., for ease of
transportation and/or storage. In disassembling a seat frame,
disassembly can be both along side seams and across sections. FIG.
6E depicts, e.g., internesting. Preferably, the frame can be
disassembled and/or stacked and/or internested (as a whole, or
component-wise) by the end-user, such as using the coupling
configuration depicted in FIGS. 7A through 7F, which can be
typically conveniently used by an end-user.
[0121] In one embodiment, two or more portions of the frame can be
moved relative to each other to provide, e.g., moveability or
collapsibility or to provide for user comfort or features, such as
reclining features or reconfiguration (e.g., sofa bed) features.
Such capabilities generally, can be very constructive in expanding
the range of designs possible in furniture, and its usefulness and
comfort (such as by providing an adjusting backrest) and the range
of uses to which the construction might be applied (such as sofa
beds and the like). The use of a molded construction is widely
advantageous in he design and production of movable furniture. For
molded shell-structure frames, forms descriptive of a lattice form,
and especially on skeletal framework, are particularly
accommodative of such constructions. In one embodiment,
reconfiguration can be accommodated by providing interchangeable
parts, such as substituting a first backrest 602 having a first
lumbar shape for a second backrest 604 having a second lumbar
shape. Reconfiguration or other types of movement can also be
implemented providing relative movement of frame components. A
number of types of movement can be accommodated such as telescoping
or other linear movement, relative sliding movement, bellows or
accordion-type movement, linkage-controlled movement, cam or lever
movement and the like. Rotation movement is particularly useful in
furniture frames. Rotation movement is particularly useful in
furniture frames. Rotation may be directly along a longitudinal
axis (FIG. 9D), or about a normal axis (FIGS. 9A, 9B and 9C).
[0122] Rotation movement can also be simultaneously both along a
longitudinal axis and about a normal axis.
[0123] Rotation along a longitudinal axis may be controlled by,
e.g., stopping travel at particular points using a
pull-out-and-reset option 902a, 902b, a push and release spring
action countered by the shapes of the rotating form, or a pull and
release spring action (similarly countered).
[0124] Among the options for joints contemplated for motion are
joints analogous to those in the leg of a mantis, analogous to
those in the leg of a crab, analogous to joints between bones such
as the hop joint or elbow joint in the human body, analogous to
joints in the human spine (i.e., in the joining action between
vertebrae), and the like.
[0125] As depicted in FIGS. 9A and 9B, a knuckle joint provides for
end members contoured to fit a curved knuckle surface 904, and held
in compression thereagainst, e.g., by a tensioning element which
may be, e.g., internal to the shell-structure components 906a,
906b.
[0126] Joints may also be held together through shaping and joining
one part within another. Preferably, the regions nearest to joints
are reinforced, e.g., through structural shape, such as externally
contoured with concavities 910. Reinforcement in regions nearest
joints can also be achieved through other variations in structural
shape and/or through the material composition of the
shell-structure (e.g, through enhanced material distribution in the
region of the joint). Material composition within joint regions may
also define solid articles (or substantially solid articles, as may
be characterized with a use of some engineered foam constructions)
such that progressively merge to form shell-structure forms (a
composition not dissimilar to that in many bones, such as in the
thigh bone of the human leg). Preferably, enhanced structural
strength in joint regions is integrally distributed through the
shell-structure forms beyond the area of the joint for a maximized
distribution of stress. In some instances, as appropriate,
friction-reducing surfaces may be applied to areas of direct
contact between joints. The joint portion of the frames can be made
separately and then assembled to the seat frame. The joint portion
of the frames can be made by integrating mechanical parts of a
conventional type within the joint assembly (FIG. 9C). In the
device depicted in FIG. 9C, the shell-structure 912a, 912b, which
can be, e.g., stamped, are joined to the plates 914a, 914b, with
ball bearings encased 916. Travel in joints may be controlled by a
mechanical device within the joint area such as a gear mechanism,
or by the shape of the shell walls in the area of the joint. In one
embodiment, stresses arising in the region of the joint are
distributed through adjacent structural forms in a fashion
analogous to the distribution of stress in the human elbow joint
through a series of muscle tendons. For example, a strap-like
material (or a series of such materials) may be woven through the
shell-structure form. The strapping may have an elastic property
which varies, e.g., longitudinally, to provide components in the
seat frame with a degree of "give," and which may also be useful in
further enhancing stress distribution between component parts. In
one embodiment, with each rotation of the joint the strapping works
its way through the form, constantly varying the areas in the
strapping encountering higher than average stress and thus
extending the life-span of the strapping. In one embodiment, the
shell-structure form is particularly shaped to accommodate the
strapping and/or its travel (e.g., with depressions or shaped
recesses within the shell-structure form). Travel in joints may be
controlled by regulation of the travel of the strapping via spring
tension or friction on its surface, or by incorporating into the
strapping a device, e.g., a shaped article, designed to lock in
position at various stages in its travel through the form, e.g., as
various shapes within the shell-structure form are encountered.
Shapes within the shell-structure may be further designed to
actuate a mechanism within the device, such as a counter, as to
further monitor and regulate travel.
[0127] Being a molded seat frame, the frame structure readily
accommodates, and by novel means, therapeutic devices such as
massagers, vibrating devices, pneumatic support devices and
controls, and the like.
[0128] As depicted in FIGS. 4A-4C and 5A-5C, fabric and/or padding
and/or other upholstery and/or suspension materials and devices can
be coupled to the seat frame, if desired, in a number of fashions.
The elements usually comprising an upholstered seat frame, in
addition to the seat frame itself, are suspension, foam or padding,
and upholstery material. In some instances these elements can be
merged, such as in the case of an upholstery material joined to a
foam part in a discrete molding of the foam part, and such as in
the case of a skin formed on a foam part in a discrete molding of
it, a skin that may be additionally textured, colored, etc. The
absorption properties of discretely molded foam parts can be
engineered through such methods as depressions of varying shapes
and sizes in the foam part, and composition of the foam density, so
as to create a very refined and engineered sitting experience. Foam
parts may in some instances appropriate the absorption properties
of a suspension.
[0129] In traditional upholstered furniture, suspension is usually
made with springs. Often suspension is coupled directly to frames
using methods such as stapling, which decrease recyclability of the
upholstered seat frame, and are further less than optimal for use
with molded seat frames, particularly molded seat frames of
materials such as many plastics, steel, etc. It is preferred in the
present invention to employ strapping and/or elastic material for
suspension. Rather than coupling directly to the seat frame, it is
preferred in the present invention to couple the suspension to the
seat frame by fastening it to itself, such as by wrapping fully or
partially around a span. This provides further advantages in that
the suspension remains independent of the material of which the
frame is made. Preferably the user may adjust tension in the
suspension so as to acquire desired seating properties, or as to
compensate for any sagging in the suspension material over time.
Detailed absorption properties may be engineered into the
suspension, such as through the properties within the fabric
material comprising it. Foam or padding parts may be attached to
the suspension and/or elastic material, e.g., by a hook and loop
material. In providing a frame having forms that are scaled and
contoured, such as are wanted for upholstered furniture, the
suspension material can be more easily stretched over the seat
frame and adjusted, and have reduced wear.
[0130] In most upholstered seat frames the foam that is used is
produced in blocks that are cut into rectilinear sections. Such
rectilinear foam sections are appropriate for use with conventional
seat frames, but are more limited for use with complex or
non-rectilinear shapes, e.g. as may characterize many molded
shapes. Foam also is often attached to seat frames directly through
gluing. Preferably, in the present invention, the foam parts are
made in individual (discrete) molds. As noted before, this provides
enhanced opportunities for engineering the composition of the foam
parts. A batting material or other fabric material can be joined
with the foam parts, including in the foaming process, and be used
to wrap sections of the seat frame, thus holding the foam parts in
place. Foam parts can be compressed and shipped flat. Foam parts
can be transported unconstructed and be molded directly by the end
user. In one embodiment, some or all of the foam or padding-like
properties are incorporated into the shell-structure frame in the
process of molding.
[0131] In attaching upholstery material a range of detachable
fittings can be used such as Velcro, snap fittings, buttons,
zippers and the like.
[0132] In the embodiment of FIG. 4A, a suspension material 402,
such as a fabric or elastic material, covers and spans a frame
and/or frame opening 102 and is held in place by coupling to
itself, e.g., using a buckle type device. Coupling the material to
itself is accommodated by wrapping portions of the material around
frame spans which define the openings 102 and/or inserting some or
all portions of the material through opening 102. After the
suspension material 402 is coupled to the frame 100a, a final
upholstery and/or padding component 406, 408 can be coupled to the
frame 100a, e.g., with batting material or other fabric material
wrapping the frame and having hook and loop tabs 410 to achieve the
final upholstered furniture depicted in FIG. 4C.
[0133] Other shapes and configurations of upholstery can be coupled
to achieve different furniture dressings for a single given frame,
preferably adjustable and interchangeable by the user to provide
different appearances 416, 418, 420. Preferably, the upholstery
and/or suspension and/or foam or padding parts is readily
adjustable by the user, e.g., by releasing and reattaching hook and
loop or other attachment devices and materials. Suspension material
402, by being adjustable, can provide for different levels of
resiliency as preferred by the end user. In one embodiment, the
fabric material contains portions having hook and loop tabs 410
which extend over the side of the foam parts and are used to fasten
the upholstery and/or foam to the frame and/or to the suspension.
In one embodiment, the foam parts are produced in individual molds
and are shaped specifically to conform to a given frame
contour.
[0134] In light of the above description, a number of advantages to
the present invention can be seen. The elements of the upholstered
seat frame are readily put together and taken apart by the user,
interchanged and adjusted. The seat frame is a flexible and dynamic
platform with which the user can interact. The assembly of the
upholstered seat frame can be simplified and consistency of quality
of the assembly can be further enhanced. Production of the
upholstered seat frame need not be centralized prior to
distribution. The elements of the upholstered seat frame can be
produced at separate locations and assembled at the retail outlet
or shipped separately to the consumer. Inventory costs can be
reduced as the elements of the upholstered seat frame are not
lastingly joined and the producer or retailer need not wager on a
single configuration or design. A large number of options are
available in packaging and transport generally. Replacement parts
for elements comprising the upholstered seat frame are more
accessible, and by such means the useful life of the upholstered
seat frame can be extended. Having the elements comprised in the
upholstered seat frame be adjustable, where feasible, can also
extend the useful life of the upholstered seat frame.
[0135] The upholstered seat frame can be much more convenient in
use as regards cleaning and the like. The recyclability of the
upholstered seat frame is very significantly improved, reflecting
the principle of design for disassembly. The ability to customize
the upholstered seat frame is enhanced, making practical custom
furniture available "to go." The enhanced ability to customize the
upholstered seat frame greatly expands the potential for individual
expression and the ability to satisfy diverse tastes. The enhanced
ability to customize allows various price points in the market to
be accessed through different configurations, broadening the market
for the producer.
[0136] The elements of the upholstered seat frame are highly
engineerable; the upholstered seat frame is a highly engineered
construct; the user has wide discretion in selecting the engineered
properties of the upholstered seat frame.
[0137] The elements of the upholstered seat frame are very
designable. The upholstered seat frame is a very designed construct
and the user has wide discretion in selecting the design
characteristics of the upholstered seat frame.
[0138] Being a molded seat frame, the seat frame avoids the
constraints and disadvantages of conventional materials and
processes, can provide higher quality and greater value at modest
or reduced cost, can reduce the amount of pre-processing of
materials required, the amount of assembly required and the amount
of labor required, can be produced with consistent product quality,
increases the range of properties that can be engineered into the
seat frame, reduces the need to adhere to strict perpendicularity,
can increase strength and durability, increases design
capabilities, reduces the need to incline to a rigid rectilinear
format, provides for ease in accommodating ergonomic features, can
increase the ability to recycle, can readily provide forms that are
well-suited for upholstered furniture, particularly forms having
surfaces that are less lean, less narrow, i.e. broader and/or
fuller than in typical upholstered seat frames, and forms that are
less rectangular, less sharp-edged, i.e. more rounded and blunter
of edge than in typical upholstered seat frames, can reduce the
need for foam and/or padding, can increase the useful life of
upholstery and the range of materials that can be used for
upholstery, can increase the ease of transportation of the seat
frame and/or components, increases options for internesting and/or
stacking of the seat frame and/or components, provides for ease of
designing and using knock-down furniture and/or components,
provides for ease of designing or using furniture with motion
and/or therapeutic or comfort capabilities, allows the designer or
manufacturer to realize the benefits of modern design and
manufacturing tools, and/or increases the range of available design
choices, including custom design capabilities.
[0139] Being a shell-structure molded seat frame, the seat frame
can more readily provide a molded seat frame having considerable
integration in structural strength, can provide a molded seat frame
having forms being well-suited for upholstered furniture that also
increase the structural properties of the molded seat frame,
provides strong, structurally integrated joints, that can be
facilely disassembled and reassembled, provides increased options
for a stacking or internesting of disassembled portions of the
molded seat frame, increases the range of molding processes that
can be utilized in the manufacture of the molded seat frame,
provides low-cost molding processes using lower-cost molds and
molding machinery, reducing the costs for large molds such as for
two-seat or three-seat frames, reducing the size of production runs
required to recoup mold costs and increasing design flexibility for
producers and the ability to avoid clichd designs, increasing the
number of molds producers can affordably keep on hand and
increasing the ability of producers to affordably provide frames or
components of frames in varying sizes, in varying versions, with
varying ergonomic features and the like, provides low-pressure,
low-cost molding processes allowing lighter and thinner molds,
allowing faster cooling of material as applicable, and very
lightweight molds having strength mirroring that of the
shell-structure molded article, and molding processes incorporating
complex inter-inflatable moldable forms, and innovative molding
processes such as molds that are an inflatable article, increases
the materials available for use in the molded seat frame, including
alternatives to plastics probably more appropriate for use indoors,
and in homes in the form of upholstered furniture, increases
flexibility for the producer of the molded seat frame through the
ability to choose among molding processes and materials, or molding
contractors and material suppliers, provides molding processes that
generally reduce cast-in stresses in the molded seat frame,
reducing the probability of stress-cracking and increasing the
useful life of the seat frame, provides molding process in which
engineering capacity is furthered, provides molding processes that
can readily produce lightweight closed-forms (closed shell
construction shell-structures), provides molding processes in which
the forms being well-suited for upholstered furniture further the
distribution of material in the molding process and facilitate the
pulling of finished parts from molds.
[0140] Being a shell-structure molded seat frame of the present
configuration, the seat frame provides an effective use of
shell-structure strength in assuming compressive loading on the
seat frame, increases the breadth of spans shell-structure molded
seat frames are capable of traversing, and the loads they are
capable of assuming, without undue excess of material, increases
the range of designs and uses available to shell-structure molded
seat frames, increases the durability or life-span of
shell-structure molded seat frames, increases the materials being
available for use in shell-structure molded seat frames, provides a
seat frame exceptionally well-suited for use in upholstered
furniture, provides a seat frame having recessed or open area
beneath the seat area accommodating of a suspension, provides a
seat frame accommodating a suspension comprised of a fabric
material which can wrap around all sides of the seat portion of the
seat frame, provides a seat frame having multiple options for
upholstering, increases opportunities for assembly and disassembly
of the seat frame, increases the options available in the packaging
and transport of the seat frame, increases the options for an
interchanging of parts or sections of the seat frame, provides for
movable parts or sections to be readily incorporated in the seat
frame, provides the advantages of the light weight and efficient
material use of space-frames for carrying compressive loads,
provides the advantages of the light weight and efficient material
use of space-frames for carrying compressive loads joined with the
efficiency of shell-structures for resisting shear and torsion,
provides a seat frame defining a space-frame and being scaled and
contoured to enhance the properties of the seat frame for use in
upholstered furniture while also providing a seat frame having
exceptional structural integration and torsional strength, provides
a seat frame having the added design and engineering flexibility
provided by space-frames for selectively positioned structural
members, provides a seat frame having the added design and
engineering flexibility of structural strength in individual
structural members being selectively described.
[0141] In one embodiment, the present invention comprises furniture
for seating having a frame (preferably three-dimensional and
preferably adult-sized), where the seat frame largely is comprised
of one or more molded components, where the molded components are
largely shell-structure, and where a lattice form is defined by the
molded components around a recessed or open area within the seat
portion of the seat frame. Preferably, the lattice form defined has
the character of a skeletal framework. Preferably, the molded
components are scaled and contoured. Preferably, scaling and
contouring provides substantial structural integration and
torsional strength in the structure defined by the molded
components. Preferably, the lattice form defines a lattice
structure. Preferably, the lattice form defines a lattice structure
in the form of a space-frame. Preferably, substantially all of the
weight-bearing portions of the frame are molded components.
[0142] In one embodiment the lattice form is provided in a
plurality form. In one embodiment the frame is an openwork. In one
embodiment the frame is a closed shell construction
shell-structure. "Depth" and "orientation" are particularly useful
for shell-structures specifically. In one embodiment the depth of
the molded components are orientated so as to maximize strength for
assuming bending loading. In one embodiment the depth of the
shell-structure is increased in the center of a span. In one
embodiment the shell-structure is shaped to transfer loads to
points of distribution. In one embodiment, ergonomics are
incorporated in the molded components, e.g. lumbar support. In one
embodiment the frame is custom fit to a user. In one embodiment,
scaling of the seat frame is custom fit to the user. In one
embodiment, flexibility is incorporated into the molded components.
In one embodiment, foam or padding-like properties are incorporated
in the molded components during the molding process. Preferably,
individual seat frames or components can be stacked or internested
and the molded components are disassemblable, preferably with
stacking or internesting of disassemblable parts or sections and/or
interchangeability of parts or sections.
[0143] In one embodiment, the seat frame incorporates moveable
parts or sections. Joints can be formed integral to the molded
components. Joints can be controlled using strapping or tension
devices. In one embodiment the seat frame incorporates devices or
techniques for massage, pneumatic variable body support, heating,
etc.
[0144] Preferably the shell-structure molded seat frame is produced
with a molding process which is intrinsically descriptive of
shell-structures. In one embodiment low-pressure molding processes
are used, possibly with supplemental inter-inflatable forms, and
possibly with moldable inflatable forms. Molding processes may
include rotational molding, stamped-in, high-tensile steel,
stamped-in slush molding, foam molding and/or spray molding.
[0145] Upholstery elements are preferably readily put together and
taken apart by the user, readily adjustable by the user, and
readily interchanged by the user. Preferably, suspension material
wraps a portion of the seat frame and joins to itself. Preferably,
suspension material passes through an opening defined in the inner
region of the seat frame. Preferably, suspension fabric material is
adjustable, resilient, possibly with variable resilience, and
contains an attachment such as a buckle. In one embodiment, foam
parts are produced in individual molds. Fabric material may extend
over the sides of the foam parts and be used to fasten them in
place on the seat frame. The density of foam parts may be
engineered in the molding process. Upholstery materials define
space in the seat frame in varied ways with a plurality of formats
of dress, preferably with upholstery materials spanning or
encircling parts of the frame. Preferably, detachable fittings are
used in attaching the upholstering materials.
[0146] A number of variations and modifications in the invention
can be used. It is possible to use some aspects of the invention
without using others. For example, it is possible to provide a
shell-structure molded seat frame defining a lattice form around a
recessed or open area within the seat without providing upholstery.
Although the present invention has been described in connection
with seating furniture, other furniture can also make use of the
present invention including day-beds, beds or fold-up bed portion
of the seat frame.
[0147] Although the present invention has been described by way of
preferred embodiments and certain variations of modifications,
other variations of modifications can also be used. The invention
being defined by the following claims.
* * * * *