U.S. patent application number 11/728328 was filed with the patent office on 2008-09-25 for furniture frame with interlocking joints for use with multiple furniture members and mechanisms.
Invention is credited to Larry P. LaPointe, Mark D. McClung.
Application Number | 20080231089 11/728328 |
Document ID | / |
Family ID | 39773947 |
Filed Date | 2008-09-25 |
United States Patent
Application |
20080231089 |
Kind Code |
A1 |
LaPointe; Larry P. ; et
al. |
September 25, 2008 |
Furniture frame with interlocking joints for use with multiple
furniture members and mechanisms
Abstract
A furniture member frame includes a plurality of commercial
grade plywood frame members connected to create a frame
sub-assembly. A plurality of interlocking joints are defined by
male extending members of first ones of the frame members and
receiving apertures of second ones of the frame members. The
interlocking joints operate when the male extending members of
selected ones of the first ones of the frame members are received
in the receiving apertures of the second frame members to
temporarily connect the frame members. An adhesive applied to at
least the interlocking joints fixedly connects the frame members of
the first frame sub-assembly.
Inventors: |
LaPointe; Larry P.;
(Temperance, MI) ; McClung; Mark D.; (Grandview,
TN) |
Correspondence
Address: |
HARNESS, DICKEY & PIERCE, P.L.C.
P.O. BOX 828
BLOOMFIELD HILLS
MI
48303
US
|
Family ID: |
39773947 |
Appl. No.: |
11/728328 |
Filed: |
March 23, 2007 |
Current U.S.
Class: |
297/83 |
Current CPC
Class: |
A47C 4/021 20130101;
A47C 13/005 20130101; A47C 4/03 20130101 |
Class at
Publication: |
297/83 |
International
Class: |
A47C 1/02 20060101
A47C001/02 |
Claims
1. A furniture member frame, comprising: a plurality of plywood
members, including: at least one first member having at least one
male extending member; at least one second member having a
receiving aperture adapted to receive the male extending member to
operably interlock the first member to the second member without
the use of a fastener; an adhesive applied between a contacting
portion of each of the first member and the second member being
operable to fixedly connect the first member to the second member
to create a frame section.
2. The furniture member frame of claim 1, wherein the at least one
second member further comprises first and second post members
having the first member connected to each of the first and second
post members.
3. The furniture member frame of claim 2, further comprising: a
second frame section defining a mirror image of the first frame
section; and first and second brace members operable to
interconnect the second frame section to the first frame
section.
4. The furniture member frame of claim 3, further comprising a
third member defining a pan member partially received in at least
one second receiving aperture created in each of the first and
second frame sections.
5. The furniture member frame of claim 4, wherein the first frame
section defines a substantially vertically oriented right arm
section and the second frame section defines a substantially
vertically oriented left arm section, the pan member positioned in
a substantially horizontal position and adapted to fixedly connect
the first and second frame sections.
6. The furniture member frame of claim 5, further comprising a
third brace member connected to each of the first and second post
members using a lap joint created between respective ones of the
first and second post members and opposed ends of the brace
member.
7. The furniture member frame of claim 5, further comprising: a
first frame sub-assembly including the first and second frame
sections and the pan member; a second frame sub-assembly having
second ones of the first and second frame posts and at least one
brace connecting the second ones of the first and second frame
posts; a bracket fixedly connecting the second frame sub-assembly
to the first frame sub-assembly operable to prevent relative motion
between the first and second sub-assemblies.
8. The furniture member frame of claim 5, wherein each of the first
and second post members further comprise homogenously extending leg
members extending below the seat pan to operably raise the seat pan
above a floor surface.
9. The furniture member frame of claim 1, wherein the plywood
members comprise a material selected from only a commercial grade
plywood.
10. A furniture member frame, comprising: a plurality of commercial
grade plywood frame members connected to create a first frame
sub-assembly; a plurality of interlocking joints defined by male
extending members of first ones of the frame members and receiving
apertures of second ones of the frame members operable when the
male extending members of selected ones of the first ones of the
frame members are received in respective receiving apertures of the
second ones of the frame members to temporarily connect the
plurality of frame members; and an adhesive applied to at least the
interlocking joints to fixedly connect the plurality of frame
members of the first frame sub-assembly.
11. The furniture member frame of claim 10, further comprising a
second frame sub-assembly defining a mirror image of the first
frame sub-assembly.
12. The furniture member frame of claim 11, further comprising a
plywood brace member fixedly connecting the first frame
sub-assembly to the second frame sub-assembly.
13. The furniture member frame of claim 12, further comprising a
homogenous plywood pan member partially received in a receiving
aperture created in one of the frame members of both the first and
second frame sub-assemblies.
14. The furniture member frame of claim 13, further comprising: a
plurality of sinuous spring members having opposed ends connected
to the pan member and spanning a cavity created in the pan member;
and a clip connected to each of the opposed ends operable to
connect to the pan member.
15. The furniture member frame of claim 10, further comprising a
frame support section operable to rotatably support the first frame
sub-assembly for a motion of the first frame sub-assembly with
respect to the frame support section.
16. The furniture member frame of claim 10, wherein the plurality
of interlocking joints include at least one mortise and tenon
joint.
17. The furniture member frame of claim 10, wherein the plurality
of interlocking joints include at least one lap joint.
18. The furniture member frame of claim 10, wherein the plurality
of interlocking joints include at least one tongue joint.
19. The furniture member frame of claim 10, wherein the plurality
of interlocking joints include each of a mortise and tenon joint, a
lap joint, and a tongue joint.
20. A furniture member assembly, comprising: a plurality of plywood
frame members connected to create each of a first frame
sub-assembly and a second frame sub-assembly; a plurality of
interlocking joints defined by male extending members of first ones
of the frame members individually received within receiving
apertures of second ones of the frame members operable to
temporarily connect the plurality of frame members; an adhesive
applied to at least the interlocking joints to fixedly connect the
plurality of frame members of the frame sub-assembly; and a
mechanism selected from a plurality of functionally different
mechanisms and connected to each of the first and second frame
sub-assemblies.
21. The furniture member assembly of claim 20, further comprising a
third sub-assembly positioned proximate to both the first and
second sub-assemblies.
22. The furniture member assembly of claim 21, further comprising
first and second tracks having the mechanism and the third
sub-assembly independently connected to the first and second
tracks.
23. The furniture member assembly of claim 22, wherein the third
frame sub-assembly is fixed to the first and second tracks having
at least the second sub-assembly moveable with respect to the third
frame sub-assembly.
24. The furniture member assembly of claim 20, further comprising a
support structure adapted to support the mechanism.
25. The furniture member assembly of claim 20, wherein the second
frame sub-assembly is connected to the mechanism independent of the
first frame sub-assembly for rotational motion of the second frame
sub-assembly independent of the first frame sub-assembly.
26. The furniture member assembly of claim 20, wherein each of the
first and second frame sub-assemblies are independently connected
to the mechanism allowing independent motion of each of the first
and second frame sub-assemblies.
27. The furniture member assembly of claim 20, wherein the
mechanism includes an extendable leg rest.
28. The furniture member assembly of claim 20, wherein the plywood
frame members comprise a material selected from only a commercial
grade plywood.
29. A furniture member assembly, comprising: a plurality of plywood
frame members connected to create each of a first and second frame
sub-assembly; a plurality of interlocking joints defined by male
extending members of first ones of the frame members and receiving
apertures of second ones of the frame members operable when the
male extending members are received in respective ones of the
receiving apertures to temporarily connect the plurality of frame
members of each of the first and second frame sub-assemblies; and a
mechanism adapted to support the first frame sub-assembly and
having the second frame sub-assembly connected to the mechanism
independent of the first frame sub-assembly; wherein the mechanism
is operable to permit movement of the second frame sub-assembly
with respect to the first frame sub-assembly.
30. The furniture member assembly of claim 29, further comprising
an adhesive applied to at least the interlocking joints to fixedly
connect the plurality of frame members of each of the first and
second frame sub-assemblies.
31. The furniture member assembly of claim 29, wherein the plywood
frame members comprise a material selected from only a commercial
grade plywood.
32. The furniture member assembly of claim 29, further comprising a
leg rest connected to the mechanism wherein the mechanism is
operable to permit movement of the leg rest with respect to the
first frame sub-assembly.
33. The furniture member assembly of claim 29, wherein the second
frame sub-assembly defines a back rest including a plurality of
sinuous sire members, the back rest movable from a fully upright
position to a fully reclined position.
34. A furniture member frame, comprising: a first plurality of
commercial grade plywood frame members connected to create a first
frame sub-assembly; a second plurality of commercial grade plywood
frame members connected to create a second frame sub-assembly; a
first plurality of interlocking joints defined by male extending
members of first ones of the frame members and receiving apertures
of second ones of the frame members operable when the male
extending members of selected ones of the first ones of the frame
members are received in respective receiving apertures of the
second ones of the frame members to temporarily connect the
plurality of frame members of each of the first and second frame
sub-assemblies; at least one of the first plurality of interlocking
joints defining a mortise and tenon joint; a plywood member pan
assembly having a plurality of apertures adapted to be slidingly
interlocked with corresponding receiving apertures of both the
first and second frame sub-assemblies, the plurality of apertures
and the plurality of receiving apertures defining a second
plurality of interlocking joints when the pan assembly is connected
and oriented substantially transverse to the first and second frame
sub-assemblies; and an adhesive applied to at least the
interlocking joints to fixedly connect the plurality of frame
members and the pan assembly.
35. The furniture member frame of claim 34, further comprising at
least one brace member positioned between each of a first and
second post member of the first and second frame
sub-assemblies.
36. The furniture member frame of claim 35, wherein the pan
assembly further comprises: a plywood member having a portion
removed defining a cavity; and a plywood stiffening member
connected at least at a first end of the plywood member.
37. The furniture member frame of claim 36, further comprising an
leg member homogenously connected to and extending from each of the
first and second post members, each leg member positioned to
elevate the pan assembly above a floor surface.
38. A method for constructing a furniture member frame, the frame
including a plurality of plywood frame members, a plurality of
interlocking joints defined by male extending members of first ones
of the frame members and receiving apertures of second ones of the
frame members, the method comprising: connecting selected ones of
the male extending members into respective ones of the receiving
apertures to create the plurality of interlocking joints of a frame
sub-assembly; and applying an adhesive to at least the interlocking
joints to fixedly connect the plurality of frame members of the
first frame sub-assembly without the use of structural
fasteners.
39. The method of claim 38, further comprising shaping selected
ones of the male extending members as a tenon.
40. The method of claim 39, further comprising creating selected
ones of the receiving apertures as mortise apertures adapted to
slidably receive individual ones of the tenons.
41. The method of claim 38, further comprising shaping selected
ones of the male extending members as a tongue.
42. The method of claim 38, further comprising creating selected
ones of the receiving apertures as a tongue aperture adapted to
slidably receive individual ones of the tongues.
43. The method of claim 38, further comprising connecting the male
extending members to respective ones of the receiving apertures to
create a plurality of lap joints.
44. The method of claim 38, further comprising repeating the
inserting and applying steps to create a second frame
sub-assembly.
45. The method of claim 44, further comprising fixedly connecting
the first and second frame sub-assemblies to each other.
46. The method of claim 44, further comprising movably connecting
the first and second frame sub-assemblies with respect to each
other.
47. The method of claim 44, further comprising selecting each of
the plywood members from only a commercial grade plywood.
48. A method for constructing a furniture member frame, the frame
including a plurality of plywood frame members, the method
comprising: assigning a single inventory part number to an
individual sheet of plywood; withdrawing the individual sheet of
plywood and forwarding the individual sheet to an assembly area;
cutting a plurality of frame members from the individual sheet
operable to be assembled in a single furniture member frame, each
frame member having at least one of a male extending member and a
receiving aperture; and interlocking the plurality of frame members
using the male extending members received in respective ones of the
receiving apertures to assemble the frame, without the use of
fasteners.
49. A method for constructing a furniture member frame, the frame
including a plurality of plywood frame members, the method
comprising: orienting a plywood pan member defining a central
support member for the frame having a seat pitch angle; connecting
a seat suspension system to a substantially flat surface of the pan
member; and attaching a mechanism directly to a face laminate of
the pan member wherein the mechanism operably supports the pan
member and the frame.
50. The method of claim 49, further comprising inserting a
plurality of threaded fasteners through the face laminate to
fastenably connect the mechanism to the pan member.
Description
FIELD
[0001] The present disclosure relates to furniture member frames
adapted to separately receive a motion and/or footrest
mechanism.
BACKGROUND
[0002] The statements in this section merely provide background
information related to the present disclosure and may not
constitute prior art.
[0003] Conventionally, reclining articles of furniture (i.e.,
chairs, sofas, loveseats, and the like) require a mechanism to
extend, stow, and to bias a leg rest assembly in the extended and
stowed positions. Known mechanisms commonly include a large number
of moving parts that tends to increase the manufacturing time and
costs associated with the furniture. A frame structure of the
furniture member is adapted to receive the mechanism. Common
furniture member frames are capable of receiving only a single
mechanism design, therefore multiple frame designs are required for
example to provide furniture members having different functions
such as rocking vice gliding actions.
[0004] Most reclining and rocking furniture members include an
upholstered chair frame supported from a stationary base assembly
in a manner permitting the chair frame to "rock" freely with
respect to the base assembly. In order to provide enhanced comfort
and convenience, many rocking chairs also include a "reclinable"
seat assembly and/or an "extensible" leg rest assembly. For
example, combination platform rocking/reclining chairs, as
disclosed in Applicant's U.S. Pat. Nos. 3,096,121 and 4,179,157,
permit reclining movement of the seat assembly and actuation of the
leg rest assembly independently of the conventional "rocking"
action.
[0005] Common frame structures include hardwood material to
accommodate loads applied by the'seating support members such as
sinuous springs, and to allow fasteners to be inserted in any
exposed side or face of the frame without tear-out, and further to
provide a material which receives fasteners such as staples to
attach padding and upholstery. Hardwood used in these applications
can be cost prohibitive. Wood laminate materials (i.e., marine
grade plywood) have been used to mimic the strength of hardwood,
but are expensive, add weight to the frame, and do not have
acceptable tear-out strength when fasteners are inserted in a
direction parallel to the laminate layers. Common frame designs are
frequently upholstered with the mechanism attached, which requires
the upholsterer to handle the weight of both the frame and
mechanism. When this combined weight is too great to be manually
manipulated, lifting fixtures are required, which increase the
construction costs.
SUMMARY
[0006] According to several embodiments of a furniture frame for
use with and without a mechanism of the present disclosure, a
furniture member frame includes a plurality of plywood members
including at least one first member having at least one male
extending member. At least one second member having a receiving
aperture is adapted to receive the male extending member to
operably interlock the first member to the second member without
the use of a fastener. An adhesive applied between a contacting
portion of each of the first member and the second member is
operable to fixedly connect the first member to the second member
to create a frame section.
[0007] According to other embodiments, a furniture member frame
includes a plurality of commercial grade plywood frame members
connected to create a first frame sub-assembly. A plurality of
interlocking joints are defined by male extending members of first
ones of the frame members and receiving apertures of second ones of
the frame members. The interlocking joints operate when the male
extending members of selected ones of the first ones of the frame
members are received in the receiving apertures of the second frame
members to temporarily connect the frame members. An adhesive
applied to at least the interlocking joints fixedly connects the
plurality of frame members of the first frame sub-assembly.
[0008] According to still other embodiments, a furniture member
assembly includes a plurality of plywood frame members connected to
create each of a first frame sub-assembly and a second frame
sub-assembly. A plurality of interlocking joints defined by male
extending members of first ones of the frame members are
individually received within receiving apertures of second ones of
the frame members to temporarily connect the plurality of frame
members. An adhesive applied to at least the interlocking joints
fixedly connects the plurality of frame members of the frame
sub-assembly. A mechanism selected from a plurality of functionally
different mechanisms is adapted to support each of the first and
second frame sub-assemblies.
[0009] According to additional embodiments, a furniture member
assembly includes a plurality of plywood frame members connected to
create each of a first and second frame sub-assembly. A plurality
of interlocking joints defined by male extending members of first
ones of the frame members and receiving apertures of second ones of
the frame members are operable when the male extending members are
received in respective ones of the receiving apertures to
temporarily connect the plurality of frame members of each of the
first and second frame sub-assemblies. A mechanism is adapted to
support the first frame sub-assembly and the second frame
sub-assembly is connected to the mechanism independent of the first
frame sub-assembly. The mechanism is operable to permit movement of
the second frame sub-assembly with respect to the first frame
sub-assembly.
[0010] According to still other embodiments, a method for
constructing a furniture member frame is provided.
[0011] Further areas of applicability will become apparent from the
description provided herein. It should be understood that the
description and specific examples are intended for purposes of
illustration only and are not intended to limit the scope of the
present disclosure.
DRAWINGS
[0012] The drawings described herein are for illustration purposes
only and are not intended to limit the scope of the present
disclosure in any way.
[0013] FIG. 1 is a left front perspective view of a furniture
member having a furniture frame and mechanism of the present
disclosure;
[0014] FIG. 2 is a left front perspective view of a furniture
member frame assembly of the furniture member of FIG. 1;
[0015] FIG. 3 is a front elevational view of the furniture member
of FIG. 1;
[0016] FIG. 4 is a top plan view of the furniture member of FIG.
1;
[0017] FIG. 5 is a right side elevational view of the furniture
member of FIG. 1;
[0018] FIG. 6 is a left front perspective view of a furniture
member frame assembly modified from the furniture member frame
assembly of FIG. 2;
[0019] FIG. 7 is a right rear perspective view of a high leg
furniture member having a furniture frame and mechanism of the
present disclosure;
[0020] FIG. 8 is a right rear perspective view of a furniture
member frame assembly of the furniture member of FIG. 7;
[0021] FIG. 9 is a right front perspective view of the furniture
member frame assembly of FIG. 8;
[0022] FIG. 10 is a right front perspective view of an upper frame
sub-assembly of the furniture member of FIG. 7;
[0023] FIG. 11 is a side elevational view of the upper frame
sub-assembly of FIG. 10;
[0024] FIG. 12 is a front elevational view of the upper frame
sub-assembly of FIG. 10;
[0025] FIG. 13 is a right front perspective view of a completed
upper frame assembly of the furniture member of FIG. 7;
[0026] FIG. 14 is a side elevational view of the completed upper
frame assembly of FIG. 13;
[0027] FIG. 15 is a left front perspective view of another
embodiment of a furniture member frame assembly of the present
disclosure;
[0028] FIG. 16 is a perspective view of an upper seat pan of the
furniture member frame assembly of FIG. 15;
[0029] FIG. 17 is a perspective view of a lower seat pan of the
furniture member frame assembly of FIG. 15;
[0030] FIG. 18 is a right front perspective view of a motion sofa
furniture member having a furniture frame and mechanism of the
present disclosure;
[0031] FIG. 19 is a right rear perspective view of a left arm
assembly of the furniture member of FIG. 18;
[0032] FIG. 20 is a rotated perspective view of the left arm
assembly of FIG. 19;
[0033] FIG. 21 is a perspective view of a seat pan of the motion
sofa furniture member of FIG. 18;
[0034] FIG. 22 is a right front perspective view of an arm/seat pan
sub-assembly of the furniture member of FIG. 18;
[0035] FIG. 23 is a left front perspective view of a movable frame
sub-assembly of the furniture member of FIG. 18;
[0036] FIG. 24 is a rear perspective view of the movable frame
sub-assembly of FIG. 23;
[0037] FIG. 25 is a left front perspective view of a base frame
sub-assembly of a center section of the furniture member of FIG.
18;
[0038] FIG. 26 is a left front perspective view of an upper frame
sub-assembly of the center section of the furniture member of FIG.
18;
[0039] FIG. 27 is a left front perspective view of a mechanism of
the furniture member of FIG. 18;
[0040] FIG. 28 is a left side elevational view of the furniture
member of FIG. 18;
[0041] FIG. 29 is a front elevational view of the furniture member
of FIG. 18;
[0042] FIG. 30 is a right side perspective view of a furniture
member having an extendable leg rest and rotatable back support
section;
[0043] FIG. 31 is a right side perspective view of the furniture
member of FIG. 30 showing the leg rest in a fully extended
position;
[0044] FIG. 32 is a side perspective view of the furniture member
of FIG. 31 further showing the back support section in a fully
reclined position; and
[0045] FIG. 33 is a right side perspective view of the furniture
member of FIG. 30 showing the back support section in a fully
reclined position.
DETAILED DESCRIPTION
[0046] The following description is merely exemplary in nature and
is not intended to limit the present disclosure, application, or
uses. It should be understood that throughout the drawings,
corresponding reference numerals indicate like or corresponding
parts and features. It should also be understood that throughout
the specification, the terms forward refers to the direction faced
by an occupant seated in the furniture member and rearward refers
the direction facing away from or behind the occupant. Right or
right hand and left or left hand, generally refer to the right side
or left side of an occupant facing forward in the furniture
member.
[0047] Referring generally to FIG. 1, a furniture member 10 of the
present disclosure in the form of a rocking, reclining chair,
includes a frame assembly 12 including each of a lower frame
sub-assembly 14 and an upper frame sub-assembly 16. A mechanism 18
(shown in phantom) is located within lower frame sub-assembly 14 to
provide support and a rocking, reclining capability for lower frame
sub-assembly 14 and frame assembly 12 in general. Mechanism 18 is
in turn supported by a frame support section 20 which can be
positioned on a planar surface such as a floor. Mechanism 18 is
exemplary of a plurality of mechanisms that can be used in
furniture member frames of the present disclosure, therefore the
specific description of the features of mechanism 18 do not limit
the scope of the furniture member frames of the present
disclosure.
[0048] A plurality of sinuous wire members 22 are suspended over a
cavity 23 created within a frame pan 24 of lower frame sub-assembly
14 and connected to mechanism 18. Sinuous wire members 22 provide
vertical support for the weight of an occupant of furniture member
10. According to several embodiments, sinuous wire members 22 are
made of a spring steel material. Upper frame sub-assembly 16
provides a back or back rest support for an occupant of furniture
member 10.
[0049] Referring now to FIG. 2, frame assembly 12 can be
constructed as shown prior to installation of mechanism 18 or
connection to frame support section 20. Frame assembly 12 can
therefore be upholstered prior to installation of mechanism 18.
Frame assembly 12 and frame assemblies of the present disclosure in
general are constructed to the maximum extent possible using a
laminated wood material, particularly one of the commercial grades
of plywood. Multiple joints used to assemble frame assembly 12 are
controlled tolerance joints to promote self locking between the
various frame members, stiffeners, and braces. The structural
strength of frame assembly 12 derives from the various joints and
the use of an adhesive between the members. Fasteners when used in
the construction of frame assembly 12 (and for frame assemblies of
the present disclosure in general) are generally in the form of
staples, brads, and the like which function to hold various joints
in place while the adhesive cures, but are not relied on for
structural strength.
[0050] Frame assembly 12 includes each of a first arm section 26
defining a right arm section and a second arm section 28 defining a
left arm section. First and second arm sections 26 and 28 can be
mirror images of each other, therefore, the following discussion of
second arm section 28 applies equally to first arm section 26. A
forward post 30 and a middle post 32 have a lower brace 34
connected between the forward and rear posts 30, 32. A first pan
arm 36 of frame pan 24 is joined to forward post 30 and middle post
32. A corner brace 38 is connected between first pan arm 36 and
forward post 30. An arm rest member 40 is also connected to each of
forward post 30 and middle post 32 and also extends rearwardly of
middle post 32 to connect to a rear post 42.
[0051] An adhesive 21 such as a wood glue is applied as a film or
bead to one or both of the frame members to be joined between
opposed contacting faces or surfaces of the members. For example, a
contacting face 23 of the present disclosure can include an
outwardly directed face of forward post 30' where it is notched to
receive lower brace 34'. The opposing contacting face 25 can
include an inwardly directed face of lower brace 34' which is
received in the notch of forward post 30'. The contacting faces can
also be an edge of a frame member that abuts a face or edge of a
corresponding frame member. Adhesive 21 and the joints described
herein together provide the mechanical strength to support the
weight or load of an occupant of the furniture member without the
use of additional "structural" fasteners, which are relied on for
their mechanical or structural strength to hold opposed members
together under load.
[0052] Lower brace 34 is connected to forward post 30 using a lap
joint 44 and is similarly connected to middle post 32 using a lap
joint 44'. Corner brace 38 is connected to first pan arm 36 using a
tongue 46 which mates within a tongue cavity 48 created in first
pan arm 36. Similarly, a second tongue 46' of corner brace 38 is
received in a tongue cavity 49 created in forward post 30.
[0053] Arm rest member 40 is connected to forward post 30 using a
tenon 50 extending from arm rest member 40 which is inserted
entirely through a tenon cavity 52 of forward post 30. Similarly, a
tenon 53 of middle post 32 is received in a tenon cavity of arm
rest member 40. A mortise and tenon joint 54 is created where first
pan arm 36 is joined to forward post 30. Through tenon 50 of arm
rest member 40 carries vertical loads from arm rest member 40 to
forward post 30, and a half-lap joint created proximate to tenon 53
is positioned directly under arm rest member 40 to carry vertical
loads of arm rest member 40 through middle post 32. Rear post 42 is
connected to lower frame sub-assembly 14 using a tenon 56 extending
from first pan arm 36 which is received within a tenon cavity 57
created in rear post 42. Also, a tongue 58 of rear post 42 defines
a portion of lap joint 44'. A tenon at each end of a cross brace 59
which is oriented transverse to frame pan 24 is also received
proximate to tenon 56 of tenon through cavity 57.
[0054] Each of the joints described above used to assembly first
and second arm sections 26 and 28 are created to allow the members
to be hand-assembled and adhesively bonded without the use of
fasteners except when the manufacturer uses fasteners for
temporarily holding the joints in place to allow the adhesive to
set. For example, the use of fasteners such as staples can be used
when creating the joints at lap joints 44, 44', tongues 46, 46',
and tongue 58, as well as through arm rest member 40 proximate to
tenon 53.
[0055] Upper frame sub-assembly 16 includes first and second upper
frame posts 60, 60' which have respective first and second upper
frame wings 61, 61' connected thereto. An upper frame first cross
member 62 and an upper frame second cross member 63 provide
horizontal stiffness and cross support between the upper frame
posts 60, 60'. Each of the upper frame posts 60, 60' are connected
to extending links of mechanism 18 using a fastener bracket 64
connected to each of the upper frame posts 60, 60'. Fasteners (not
shown) are connected through fastener brackets 64 and fastened
using fastener nuts 66. By connecting upper frame sub-assembly 16
to mechanism 18, upper frame sub-assembly 16 is rotatable with
respect to lower frame sub-assembly 14 about an upper frame arc of
rotation "A".
[0056] Referring to FIG. 3, frame support section 20 includes each
of a first leg 68 and a second leg 70. A rear brace member 72 and a
front brace member 74 provide horizontal stabilization of first and
second legs 68, 70. One or more feet 76 can also be connected to a
bottom or floor facing surface of each of first and second legs 68,
70. Feet 76 are made of a resilient material to resist slipping
between first and second legs 68, 70 and a smooth floor
surface.
[0057] To provide a planar surface for attachment of upholstery, a
brace outer face 78 of tongue 46' and a brace outer face 80 of
lower brace 34 are positioned substantially co-planar with or
recessed with respect to a planar edge surface 82 of forward post
30. A similar arrangement is provided for forward post 30'.
[0058] Referring to FIG. 4, a drive rod longitudinal axis 84 is
positioned as shown when furniture member 10 is in its static
position prior to rocking either forward or backwards. As viewed in
FIG. 4, rocking motion of furniture member 10 will appear to
displace drive rod longitudinal axis 84 either upwards or downwards
from the position shown. The frame assembly joints and construction
of the frame assemblies of the present disclosure allow mechanism
18 to be assembled independently of frame assembly 12. Frame
assembly 12 is subsequently positioned over and supported by
contact of frame pan 24 with each of support surfaces 78, 78 ' of
mechanism 18. Fasteners inserted through extension portions 67, 67'
of frame pan 24, and through corresponding apertures (not shown) of
mechanism 18 fixedly connect frame assembly 12 to mechanism 18.
When assembled, furniture member 10 has a frame first width "B"
which according to several embodiments is greater than a frame
second width "C". Frame first width "B" can also be substantially
equivalent to or smaller than frame second width "C" in other
embodiments of the present disclosure.
[0059] Referring now to FIG. 5, furniture member 10 has several
motions with respect to first and second legs 68, 70. Starting when
furniture member 10 is positioned substantially in an upright and
"non-rocked" position defined by a central axis 85, a rocking
member 87 is supported by a leg upper surface 86 of both first and
second legs 68, 70. From this position, furniture member 10 can
rock forward about a forward arc of rotation "D" to a forward
rocking limit 88. Furniture member 10 can also rock rearward in a
rearward arc of rotation "E" to a rearward rocking limit 90.
Independent of either of the rocking motions for furniture member
10 upper frame sub-assembly 16 can be rotated about a seat back arc
of rotation "F" from the position shown to an upper frame rearward
rocking limit 92.
[0060] Referring now to FIG. 6, a frame assembly 94 is modified
from frame assembly 12 to provide a brace member 96 connected
between each of the extension portions 67, 67' using a first
bracket 98 and a second bracket 100. Brace member 96 can also be a
homogeneous extension of frame pan 24 of frame assembly 12 and in
this embodiment first and second brackets 98, 100 are omitted. Use
of brace member 96 can inhibit the rocking motion for this
embodiment where a non-rocking or gliding mechanism is desired for
a furniture member of the present disclosure. Use of brace member
96 also eliminates upholstery connection member 25 shown in FIG. 1
which must be independently connected to mechanism 18. Brace member
96 also provides for additional stiffness between first pan arms
36, 36'.
[0061] Referring now to FIG. 7, a furniture member 102 which is
commonly referred to as a high leg chair includes each of an upper
frame assembly 104 and a base frame assembly 106. A first rear leg
108 and a second rear leg 110 extend downwardly from a rear section
of furniture member 102. A first front leg 112 and a second front
leg 114 (not clearly shown in this view) extend downwardly from a
forward portion of furniture member 102.
[0062] Referring to FIG. 8, base frame assembly 106 includes a
right side arm assembly 116 and a left side arm assembly 118 which
are substantially mirror images of each other. Right side arm
assembly 116 includes a right arm support member 120, having a
mounting flange 122 adhesively attached and fastened thereto, and a
right arm piece 124 adhesively attached and fastened to right arm
support member 120. Right side arm assembly 116 further includes a
right arm post 126 which is connected using a half lap joint 128 to
a base pan 130 created from a plywood sheet. A first base pan
tongue 132 is connected to first rear leg 108 using a tongue joint
134. A second base pan tongue 136 is connected to first front leg
112 using a second tongue joint 138. Right arm support member 120
is connected to an upper portion of first rear leg 108 using a half
lap joint 140.
[0063] Left side arm assembly 118 includes a left arm support
member 142 having a second mounting flange 144 adhesively and
fastenably secured thereto. A left arm piece 146 is also adhesively
and fastenably connected to left arm support member 142. A left arm
post 148 is connected to second front leg 114 using a half lap
joint similar to half lap joint 128.
[0064] Base pan 130 includes a plurality of clearance apertures and
cavities which are provided for clearance to various components of
a mechanism 224 shown and described in better detail in reference
to FIG. 17. A first clearance aperture 150 and a second clearance
aperture 152 are provided in the rearward portion of base pan 130.
A clearance cavity 154 is created at a forward facing end of base
pan 130 to provide clearance for a moveable leg rest extension
portion of the mechanism.
[0065] With reference now to FIG. 9, a tongue 156 of right arm
support member 120 is used to create a partial tongue joint 158
joining right arm support member 120 to right arm post 126. A
tongue 160 of right arm piece 124 is similarly used to create a
partial tongue joint 162 joining right arm piece 124 to right arm
post 126. Similar joints are shown which are used to join left arm
support member 142 and left arm piece 146 to left arm post 148.
[0066] Referring now to FIG. 10, an upper frame sub-assembly 164
includes a right frame member 166 and a left frame member 168 both
generally having an L-shaped configuration. A right shoulder board
170 extends outwardly from right frame member 166 and, similarly, a
left shoulder board 172 extends outwardly from left frame member
168. A top cross member 174 connects to both right and left
shoulder boards 170, 172. A spacer block 176,176' is used to
connect, and provide a predetermined spacing between, right and
left shoulder boards 170, 172 and right and left frame members 166,
168. A crown brace 178 is connected to top cross member 174 to
further stiffen top cross member 174 and add an additional level of
detail for upholstering. A rear lower corner of upper frame
sub-assembly 164 is created using an upright cross brace 180 having
a tenon 182 at opposing ends to mate with each of the right and
left frame members 166, 168. A horizontal cross brace 184 is
positioned in abutment with upright cross brace 180 and oriented
substantially traverse to upright cross brace 180.
[0067] A tenon 186 extending from opposite ends of horizontal cross
brace 184 abuts with the corresponding tenon 182 of upright cross
brace 180 to collectively create a mortise and tenon joint 188 in
each of right and left frame members 166, 168. Forward directed
legs 190, 190' of right and left frame members 166, 168 have an
interconnecting horizontal stiffening member 192. Additionally, a
brace member 194 abuts each of right and left frame members 166,
168 at opposed ends of brace member 194 and is adhesively (and
fastenably if desired) connected to horizontal stiffening members
192. A tongue 196 extending from opposite ends of horizontal
stiffening member 192 is used to create a half lap joint 198 with
each of right and left frame members 166, 168.
[0068] Referring now to FIG. 11, exemplary locations for a
plurality of fasteners such as staples are shown which are used to
temporarily hold the various members of upper frame sub-assembly
164 together while the adhesive which binds the various members
cures. These fasteners include a first fastener group 200 used to
join an upper portion of right shoulder board 170 to crown brace
178. A second fastener group 202 can be used to join right shoulder
board 170 to spacer block 176 (not clearly visible in this view). A
third fastener group 204 can be used to fasten right frame member
166 to upright cross brace 180. A fastener 206 can be used to
fasten right frame member 166 to horizontal cross brace 184 (not
clearly visible in this view). A fastener 208 can be used to fasten
right frame member 166 to horizontal stiffening member 192, and a
fastener 210 can be used to fasten right frame member 166 to brace
member 194. Similar fastener groups can be used when assembling
left frame member 168.
[0069] Referring to FIG. 12, each of a fourth and a fifth fastener
group 212, 214 are shown which can be used to join right frame
member 166 to spacer block 176, and to join left frame member 168
to spacer block 176', respectively. Each of right and left shoulder
boards 170, 172 are spaced from their respective right or left
frame member 166, 168 by a shoulder board clearance dimension "G".
Shoulder board clearance dimension "G" increases the overall width
of upper frame sub-assembly 164 in the shoulder area of an
occupant.
[0070] Referring now to FIG. 13, when upper frame sub-assembly 164
is complete, additional components and hardware are added to create
upper frame assembly 104. These include a plurality of back support
sinuous wire members 216 shown as sinuous wire members 216, 216',
216''. Each of the sinuous wire members 216 are joined to
respective ones of right and left frame members 166, 168 using a
clip 218 which retains opposed ends of sinuous wire members 216 in
contact with one of the right or left frame members 166, 168. A
plurality of seat support sinuous wire members 220 are similarly
connected by clips 218', 218'' to horizontal cross brace 184 and
horizontal stiffening member 192 respectively. Each of the sinuous
wire members 220 span a cavity 222 created between horizontal cross
brace 184 and horizontal stiffening member 192 and between each of
right and left frame members 166, 168. Cavity 222 is provided to
permit occupant clearance to and motion of various component parts
of a mechanism 224. Similar to each of the furniture members
described herein, mechanism 224 can be one of a plurality of
mechanism types, allowing for leg rest extension, rocking motion, a
gliding motion, seat back rotation, and member rotation, and the
like. An exemplary mechanism 224 is shown and described in U.S.
Issued Pat. No. 5,503,453 to Saul et al. commonly assigned to the
assignee of the present disclosure, the subject matter of which is
incorporated herein by reference. A portion of mechanism 224 is
shown connected to left frame member 168.
[0071] Referring to FIG. 14, in an un-loaded or non-deflected
condition, sinuous wire members 220 define an upwardly curved shape
as shown. This shape provides additional clearance below sinuous
wire members 220 to accommodate deflection from the weight of an
occupant while providing sufficient clearance between the occupant
and mechanism 224 for operation of mechanism 224. According to
several embodiments, mechanism 224 includes each of a foot rest
support link 226 and a plurality of pantograph links 228 which are
used by mechanism 224 to extend or retract foot rest support link
226. A fully retracted position of foot rest support link 226 is
shown.
[0072] As best seen in FIG. 15, a base frame assembly 230 is
modified from base frame assembly 106 but retains the capability to
fixedly receive upper frame assembly 104. Base frame assembly 230
includes a right side arm assembly 232 and a left side arm assembly
234. Right and left side arm assemblies 232, 234 are substantially
a mirror image of each other. Right side arm assembly 232 includes
a right front leg 236 and a right arm post 238 connected to right
front leg 236. A right arm inner support member 240 and a right arm
outer support member 242 are connected between right arm post 238
and a right rear leg post 244. Right rear leg post 244 includes a
homogenously extending right rear leg member 246. Right arm inner
support member 240 is connected to right rear leg post 244 using a
half lap joint 248.
[0073] Similar to right side arm assembly 232, left side arm
assembly 234 includes a left front leg 250 connected to a left arm
post 252. A left arm inner support member 254 and a left arm outer
support member 256 are connected between left arm post 252 and a
left rear leg post 258. A left rear leg member 260 defines a
homogenous extension of left rear leg post 258. A half lap joint
similar to half lap joint 248 is also used to connect left arm
inner support member 254 to left rear leg post 258. According to
several embodiments, all of the component parts of base frame
assembly 230 are created from a commercially available grade of
plywood, except right front leg 236 and left front leg 250, which
can also be made from a hardwood material due to their geometry, or
from a composite material.
[0074] A left pan support member 262 is connected between left
front leg 250 and left rear leg member 260. A similar support
member 262' (not clearly visible in this view) is provided between
right front leg 236 and right rear leg member 246. In addition to
bracing the respective arm posts 238, 252 to the rear leg members
246, 260, left and right pan support members 262, 262' also support
an upper seat pan 264 which in several embodiments can be created
from a single sheet of plywood. A lower seat pan 266 connected to
upper seat pan 264 acts to increase the overall thickness and
therefore the stiffness and weight-carrying capacity of upper seat
pan 264. Upper seat pan 264 is supported to right front leg 236
using an overlap joint 268. A similar overlap joint 268' is used to
join upper seat pan 264 to left front leg 250. First and second
tongues 270, 270' extend front a rearward facing side of upper seat
pan 264. Each of the tongues 270, 270' are received in notches
created in right and left rear leg members 246, 260 to create
tongue joints 272, 272'. A clearance cavity 274 is created by
removing material from each of upper and lower seat pans 264, 266.
Clearance cavity 274 provides operating clearance to a mechanism
such as mechanism 224 (not shown). To provide clearance for
operation of or access to components of the mechanism a plurality
of apertures are provided. These include first clearance apertures
276, 276' and second clearance apertures 278, 278'.
[0075] Referring now to FIG. 16, upper seat pan 264 can also
include a plurality of clearance notches 280, 280' in addition to
the above noted clearance apertures for additional clearance for
moving components of the mechanism. Upper seat pan 264 has a seat
pan thickness "H" corresponding to a commercially available
thickness of plywood material. Clearance cavity 274 is created by
removing sufficient material from upper seat pan 264 to define a
major support section 282 having a major support section depth "J".
Major support section depth "J" maintains the structural integrity
of upper seat pan 264 to accommodate an occupant's weight on the
furniture member, while also providing clearance for actuation and
operation of the lower positioned mechanism.
[0076] Referring to FIG. 17, lower seat pan 266 is reduced in
overall size compared to upper seat pan 264. First clearance
notches 286, 286' correspond in location to second clearance
apertures 278, 278' of upper seat pan 264. Second clearance notches
288, 288' correspond in location to first clearance apertures 276,
276' of upper seat pan 264. Lower seat pan 266 has a seat pan
thickness "K" which can be substantially equal to, less than, or
greater than seat pan thickness "H" of upper seat pan 264. A major
support section 284 has a major support section depth "L" which is
less than the major support section depth "J" of upper seat pan
264.
[0077] Referring now to FIG. 18, a furniture member 290 according
to several embodiments defines a multi-section motion sofa, which
can include each of a left side reclining portion 292, a fixed
center section 294, and a right side reclining portion 296 (shown
in phantom). Right side reclining portion 296 is removed for
clarity to better illustrate each of a first track member 298 and a
second track member 300, which according to several embodiments are
L-shaped metal channels which extend under each of left side
reclining portion 292, center section 294, and right side reclining
section 296. Each of the sofa portions are fixedly connected to
first and second track members 298, 300. Center section 294 is
fixedly connected to first and second track members 298, 300 using
a plurality of L-brackets 302 and a plurality of fasteners 304.
Center section 294 includes each of a base frame sub-assembly 306
and an upper frame sub-assembly 308 which is connected to base
frame sub-assembly 306 using a plurality of connecting members.310
and fasteners (not shown). Center section 294 also includes a fixed
front panel 312. According to several embodiments, upper frame
sub-assembly 308 is fixedly connected to base frame sub-assembly
306 and is unable to move relative to base frame sub-assembly
306.
[0078] Left side reclining portion 292 and right side reclining
portion 296 are substantially a mirror image configuration of each
other, therefore the following discussion of components used for
left side reclining portion 292 applies also to right side
reclining portion 296. Left side reclining portion 292 includes a
base frame sub-assembly 314. A mechanism 316 is provided, such as
the mechanism disclosed in U.S. patent application Ser. No.
11/328,772 entitled "Wall Proximity Reclining Chair With In-Line
Linkage Mechanism", filed Jan. 10, 2006, and commonly owned by the
assignee of the present disclosure, the subject matter of which is
incorporated herein by reference. A foot rest panel 318 is
extendable by operation of mechanism 316. Base frame sub-assembly
314 is connected to a left side arm sub-assembly 320 and fixed with
respect to base frame sub-assembly 314. A left side moveable frame
sub-assembly 322 is connected to mechanism 316 for rotation from
the upright position shown to a reclined position (not shown). One
or more mechanism connection links 324 are used to fastenably
connect mechanism 316 and thereby base frame sub-assembly 314 and
left side arm sub-assembly 320 to each of the first and second
track members 298, 300 using one or more L-channels 326. L-channels
326 are oriented substantially transverse to each of first and
second track members 298, 300.
[0079] Base frame sub-assembly 314 also includes a seat pan
assembly 328 which has a seat pan member constructed of a single
homogenous piece of plywood. A cavity created in seat pan assembly
328 provides operating clearance for mechanism 316. It is noted
that mechanism 316 can be modified from the mechanism shown within
the scope of the present disclosure.
[0080] Referring now to FIG. 19, left arm assembly 330 is
constructed similar to the previously discussed frame assemblies
and sub-assemblies using plywood material throughout. A front post
332, a center post 334, and a rear post 336 are each cut from one
or a minimum number of sheets of plywood. A left arm piece 338 is
connected to front post 332 and center post 334. A left arm support
member 340 is connected to each of front post 332, center post 334,
rear post 336, and left arm piece 338. A brace member 342 similar
to left arm support member 340 is connected to each of front post
332, center post 334, and rear post 336. A tongue 344 extending
from left arm piece 338 is connected to center post 334 defining a
lap joint 346. An end 348 of a curved member portion 350 of left
arm support member 340 is connected to rear post 336 defining a lap
joint 352. A lap joint 354 is created between center post 334 and
brace member 342. A tongue 356 extending from brace member 342 is
connected to rear post 336 defining a lap joint 358.
[0081] Multiple slots and through apertures are created in various
ones of the front post 332, center post 334, and rear post 336
which are adapted to engage portions of seat pan assembly 328. A
first slot 360 is created in front post 332. A second slot 362 is
created in center post 334. A third slot 364 is created in rear
post 336. Each of a first and second through aperture 366, 368 are
also created in front post 332. It is noted that each of the
members used to create left arm assembly 330 are assembled and
fixedly connected using an adhesive such as glue and optionally
fastened for example using staples to hold the assembly together
while the adhesive cures.
[0082] Referring now to FIG. 20, additional features of left arm
assembly 330 include a tenon 370 extending from left arm support
member 340 which is inserted into front post 332 defining a mortise
and tenon joint 372.
[0083] Referring now to FIG. 21, with the exception of fastener
receiving nuts 373 made of a metal adapted to receive fasteners
used for attaching seat pan assembly 328 to a mechanism, seat pan
assembly 328 components can be created entirely from a commercial
grade of plywood material. A plywood panel 374 defines a major
surface of seat pan assembly 328. An attachment brace 376 also acts
as an upholstery attachment member at a forward facing side of seat
pan assembly 328. A stiffening brace 378 is positioned below
plywood panel 374 and attachment brace 376. A spacer member 380 is
positioned under a left facing side of plywood panel 374. A rear
stiffening brace 382 is positioned under plywood panel 374 at a
rearward facing end of seat pan assembly 328. Plywood panel 374
also includes each of a horizontal elongated slot 384, a narrow
slot 386, and a corner notch 388 which are created in a left arm
assembly facing side 390. A mechanism clearance and seat suspension
cavity 392 are created by removing material from plywood panel 374.
It is noted that material removed to create mechanism clearance and
seat suspension cavity 392 can be used to manufacture various ones
of the components of furniture member 290. The slots and notch
created in side 390 are used to subsequently attach seat pan
assembly 328 to left arm assembly 330 which will be described in
better reference to FIG. 26.
[0084] Referring to FIG. 22, an arm/seat-pan sub-assembly 394 is
created by joining seat pan assembly 328 to left arm assembly 330.
A corner brace 396 is positioned between a lower surface of plywood
panel 374 and abutted to a rearward facing surface of front post
332. At this time, a first tenon 398 of corner brace 396 is
extended through first through aperture 366 of front post 332 to
create a mortise and tenon joint 400. At the same time, a second
tenon 402 of corner brace 396 is inserted through second through
aperture 368 of front post 332 to create a mortise and tenon joint
404. A lap joint 406 is created between plywood panel 374 and
center post 334 using narrow slot 386 shown in FIG. 25. Similarly,
a lap joint 408 is created between plywood panel 374 and rear post
336 using corner notch 388 shown in FIG. 25. Similar to other
joints created for furniture members of the present disclosure,
each of the joints of arm/seat-pan sub-assembly 394 are joined
using an adhesive, with the optional use of fasteners such as
staples if desired.
[0085] Referring to FIG. 23, left side moveable frame sub-assembly
322 also includes framing components made from plywood material.
These include a frame member 410 connected to each of a first frame
side 412 and second frame side 414. A frame brace 416 is connected
between the bottom ends of both first and second frame sides 412,
414 defining a lap joint 418, 418' at opposed ends of frame brace
416. A mortise and tenon joint 420 is created to join second frame
side 414 to frame member 410. A similar mortise and tenon joint
(shown in FIG. 28) is used to connect first frame side 412 to frame
member 410. An extended frame side 422 is connected using a butt
joint 424 to a freely extending end of frame member 410 which
extends beyond first frame side 412. A spacer block 426 is
connected between each of extended frame side 422 and first frame
side 412. A butt joint 428 is created between spacer block 426 and
first frame side 412 which can be through-fastened from an opposing
face of first frame side 412 if desired. A cavity 430 created in
frame member 410, similar to other cavities used in the present
disclosure, can also serve as a source of material for individual
parts of the various assemblies.
[0086] Referring now to FIG. 24, mortise and tenon joint 420 is
created from a tenon 432 extending from second frame side 414 which
is received in a mortise aperture 434 of frame member 410.
Similarly, a mortise and tenon joint 436 is created from a tenon
438 of first frame side 412 extending through a similar mortise
aperture of frame member 410. A tenon 440 extending outwardly from
spacer block 426 is used to create a mortise and tenon joint 442 to
connect spacer block 426 to frame member 410.
[0087] Referring now to FIG. 25, base frame sub-assembly 306 is
shown in its installed position with reference to first and second
track members 298, 300. Base frame sub-assembly 306 includes a
first frame wall 444 and an oppositely positioned second frame wall
446. First and second frame walls 444, 446 are substantially a
mirror image of each other. A stiffening brace 448 connects first
and second frame walls 444, 446 and is positioned proximate to and
partially over fixed front panel 312. An upholstery attachment
member 450 is connected to an upper facing side of stiffening brace
448 and acts to receive fasteners used when attaching upholstery to
base frame sub-assembly 306. A rear stiffening brace 452 is
connected between first and second frame walls 444, 446 similar to
stiffening brace 448. A brace support member 454 is oriented
substantially transverse to rear stiffening brace 452 and is
connected to each of rear stiffening brace 452 and first and second
frame walls 444, 446. Lap joints 456, 456' are used to join
stiffening brace 448 to each of first and second frame walls 444,
446. Similarly, lap joints 458, 458' are used to join rear
stiffening brace 452 to first and second frame walls 444, 446. A
plurality of clips 460 are fastened to each of stiffening brace 448
and rear stiffening brace 452. Clips 460 will subsequently create
attachment points for a plurality of sinuous wire members (not
shown) which are subsequently connected to base frame sub-assembly
306 to provide support for an occupant.
[0088] With reference now to FIG. 26, upper frame sub-assembly 308
is constructed from a plurality of plywood frame members including
a first frame sidewall 462 and an opposing second frame sidewall
464. An upper brace 466, a middle brace 468, and a lower brace 470
are each connected between and to first and second frame sidewalls
462, 464, respectively defining each of an upper lap joint pair
472, 472', a middle lap joint pair 474, 474', and a lower lap joint
pair 476, 476'. Corner braces 478 can also be installed where upper
ends of first and second frame side walls 462, 464 join upper brace
466, to minimize twisting of these members.
[0089] Referring now to FIG. 27, mechanism 316 is representative of
a plurality of mechanisms which can be used in the furniture
members of the present disclosure. For example mechanism 316
provides L-channels 326, 326' which are fastened to each of first
and second track members 298, 300 when creating furniture member
290. Mechanism 316 can also include a first foot rest support
member 480, and a second foot rest support member 482 which are
extended using a pantograph linkage set 484 to allow the foot rest
(not shown) to be extended from a stowed to a fully extended
position. Mechanism 316 can also provide both a first frame support
member 486 and a second frame support member 488 on opposed sides
of the mechanism. First and second frame support members 486, 488
include apertures adapted to receive fasteners (not shown) to
fixedly connect seat pan assembly 328 to mechanism 316 before or
after upholstery is applied to seat pan assembly 328.
[0090] Referring now to FIG. 28, when furniture member 290 is
assembled as shown, a side wall 490 is connected to foot rest panel
318 defining a standoff distance "Z" between front post 332 and
foot rest panel 318. As also shown, left side moveable frame
sub-assembly 322 can be rotated about an arc of rotation "M" by
clearance provided between a curved surface 492 of extended frame
side 422 and a corresponding curved surface 494 of curved member
portion 350.
[0091] Referring to FIG. 29, a clearance dimension "N" is created
between center section 294 and left side reclining portion 292 to
both provide for space for applied upholstery, and to allow
subsequent rotation of left side moveable frame sub-assembly 322. A
clearance dimension "P" is also provided between fixed front panel
312 and foot rest panel 318 to both provide for space for the
applied upholstery, and to allow displacement of foot rest panel
318.
[0092] Referring now to FIGS. 30 through 33, a furniture member 496
includes a plywood frame sub-assembly 498 having a homogenous, one
piece brace/seat pan 500. In FIG. 30 a handle 502 is attached to a
mechanism which is operable when rotated to extend a leg rest 504
away from or to return the leg rest 504 back to a leg rest stowed
position shown, and a backrest sub-assembly 506 is shown in a fully
upright position. As shown in FIG. 31, handle 502 is fully rotated
in a counterclockwise direction which extends the leg rest 504 to a
fully extended position. As shown in FIG. 32, the leg rest 504 is
in the fully extended position and the backrest sub-assembly 506 is
shown rotated to a fully reclined position. As shown in FIG. 33,
only the backrest sub-assembly 506 is rotated to its fully reclined
position.
[0093] Referring back to each of FIGS. 6, 8, and 22, each of items
36, 130, and 328 define a plywood deck or pan member which
according to several embodiments provides a central support member
for the entire frame or frame assembly. The plywood deck or pan
member a seat pitch angle, provides a substantially flat surface
for a seat suspension (including sinuous wire members and clips),
and provides a face laminate for attachment of a mechanism which
supports the pan member and thereby the frame. In several
embodiments, threaded fasteners can be inserted through the face
laminate, thereby eliminating the need for secondary attachment
devices such as tee nuts.
[0094] Each of the tenons and tongues described herein define male
extending members of a first frame member received in "close
tolerance" receiving apertures, slots, or notches of a second (or
more) frame member(s) which together define an interlocking joint.
Close tolerance apertures, slots, or notches (collectively referred
to as receiving apertures) as described herein refer generally to
apertures which are sized to receive the male extending member with
an interference fit, a sliding fit, or a lap fit which temporarily
interlocks the members to allow the joined frame members to remain
together for a time period to allow an adhesive to cure which bonds
the two (or more) frame members without the use of fasteners. The
male extending members of the present disclosure can maximize joint
strength by orienting the male extending members to receive applied
loads from an occupant of the furniture member transverse to the
overlapped layers of material. Fasteners including staples and
brads described herein which optionally aid in assembly of the
various frame members during the application of adhesives are
"non-structural" fasteners, meaning the fastener is not
subsequently relied on for its structural strength to hold the
frame members together when an occupant weight or load is applied
to the furniture member. The capability to hold the frame members
together is provided by the combination of the joints provided and
the use of adhesive(s) between contacting portions of the frame
members.
[0095] Commercial grade plywood referred to herein is commonly
identified as grade "CDX" type plywood, having no sanded or
finished faces. Commercial grade plywood does not include "marine
grade" plywood which is known in some furniture member applications
because it can approximate the holding strength of a hardwood or
softwood member when a fastener is received parallel to a plane
defined between any joined pairs of the material plies. Marine
grade plywood can be substituted for the furniture frame members of
the present disclosure, but is not defined herein as commercial
grade plywood.
[0096] The use of plywood for the frame members of the present
disclosure also offers the advantage of material use efficiency.
Many of the individual frame members such as the braces, corner
braces, and stiffener members are made from material cut from the
aperture or cavity areas of items such as the seat pan. Also, by
nesting the various parts, it is possible to cut the individual
frame members for a single frame from approximately a single
4.times.8 foot (1.22.times.2.44 m) sheet of plywood. It is further
noted that seat pan thickness "H" can be a common thickness for all
frame members of a frame or frame sub-assembly of the present
disclosure. All frame members can therefore be cut from a single
thickness of plywood, which permits a plywood sheet having a single
inventory part number to be delivered to a work station for
manufacture of the frame. This feature obviates the common practice
to inventory and gather multiple parts with multiple inventory part
numbers from a warehouse to manufacture a furniture frame.
[0097] The interlocking joints or features of the present
disclosure permit the frame assemblies to be constructed without
the use of ancillary fixtures to hold the parts. The frame
therefore acts as its own fixture during assembly. Specialized
assembly training for assembly personnel is therefore eliminated,
and a reduced number of assemblers can be used to assemble frames
of the present disclosure, further reducing construction costs.
[0098] Furniture members of the present disclosure offer several
advantages. By using a commercial grade of plywood for
substantially all framing components, the cost of the furniture
member frames are reduced compared to commonly used materials such
as hardwood and metal. By assembling the frames of the present
disclosure using interlocking joints and adhesive, the frames of
the present disclosure can be assembled without fasteners if
desired, and connect using the advantageous overlapped strength
provided by multiple, overlapped layers of the plywood material
without fastening into the ends of the plies where tear-out
strength of the plywood material is reduced. The all-plywood,
interlocked frames of the present disclosure are also adapted to be
upholstered before the frames are connected to a mechanism, which
minimizes the weight of the frame assembly which must be
manipulated during the upholstery phase. This further reduces
handling complexity and cost of the resulting furniture member.
Frames of the present disclosure are also adapted to receive
multiple mechanism designs, permitting a single frame assembly to
be used in multiple applications such as rocking/reclining members,
rocking only members, leg rest extendable members, and the like.
The mechanism when used in a furniture member sub-assembly of the
present disclosure can be selected from a plurality of functionally
different mechanisms, therefore furniture members of the present
disclosure can support multiple furniture member platforms or
types. The functionally different mechanisms can include but are
not limited to rocking, reclining, rotating, fixed, leg rest
extending, fixed leg panel, gliding, backrest fixed, and backrest
rotatable designs, and the like. The furniture member types which
are supported include but are not limited to chairs, love seats,
sofas, ottomans, and the like.
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