MOLDED MANUFACTURING FOR MODULAR FURNITURE
A method for manufacturing a furniture frame using molding techniques. A structural base is molded to create the base structure for modular furniture. Cushioning material is secured on the base structure of the modular furniture and layer(s) of upholstery material are applied over the cushioning material secured on the base structure.
1 . A method for manufacturing a furniture component, the method comprising:
molding a structural frame;
securing cushioning material to the structural frame; and
applying upholstery material to cover the cushioning material.
2 . The method of claim 1 , wherein the structural frame is molded as a single piece.
3 . The method of claim 1 , wherein the upholstery material also covers at least a portion of the structural frame.
4 . The method of claim 1 , wherein the cushioning material is secured to the structural frame via an adhesive.
5 . The method of claim 4 , wherein the upholstery material is applied to the structural frame and cushioning material via an adhesive.
6 . The method of claim 1 , wherein the cushioning material is secured to the structural frame via mechanical interlocking.
7 . The method of claim 1 , wherein the upholstery material is formed as a slipcover that is applied to the structural frame and cushioning material so that it at least partially surrounds the structural frame and cushioning material, the slipcover upholstery material aiding in securing the cushioning material around the structural frame.
8 . The method of claim 1 , wherein the furniture component is a base or a transverse member of a modular furniture assembly.
9 . The method of claim 1 , wherein applying upholstery material to cover the cushioning material comprises molding a skin layer over the cushioning material.
10 . The method of claim 1 , wherein applying upholstery material to cover the cushioning material comprises molding a polyurethane skin over the cushioning material.
11 . The method of claim 1 , wherein the structural frame comprises:
a hollow body having a side or face that is at least partially open; and
a spring mechanism secured to the body and disposed so as to span over the at least partially open side or face of the hollow body.
12 . (canceled)
13 . (canceled)
14 . The method of claim 11 , wherein the structural frame is molded as two or more pieces which are then secured together.
15 . (canceled)
16 . The method of claim 13 , further comprising molding hardware into the structural frame.
17 . The method of claim 11 , wherein the spring mechanism comprises an elongate portion of flexible material that spans the open side or face of the body of the structural frame.
18 . (canceled)
19 . (canceled)
20 . The method of claim 11 , wherein the upholstery material comprises both an inner layer and an outer layer, wherein the inner layer is an integrally formed skin that forms over the cushioning material during molding of the cushioning material over the structural frame, wherein the outer layer of the upholstery material comprises a separate fabric layer selected for placement over the inner layer to provide desired esthetics selected by the user.
21 . A furniture component of a modular furniture assembly, the furniture component comprising:
a structural frame molded to be at least partially hollow;
one or more springs molded across an open side or face of the structural frame;
a cushioning material secured around an outside of the structural frame so as to cover the structural frame but not the springs; and
upholstery fabric secured around the structural frame, springs, and cushioning material.
22 . The furniture component of claim 21 , wherein the one or more springs comprise an elongate material secured to the base structure, the springs spanning the open side or face of the structural frame.
23 . The furniture component of claim 21 , wherein the structural frame is a single integrally molded piece of plastic.
24 . A method for manufacturing a furniture component, comprising:
molding a structural frame; and
molding cushioning material onto the structural frame, the cushioning material having an outer skin exterior layer, wherein the furniture component can be selectively coupled to another furniture component.
25 . (canceled)
26 . (canceled)
27 . (canceled)
28 . (canceled)
29 . (canceled)
30 . A furniture component of a modular furniture assembly, the furniture component comprising:
a molded structural frame;
cushioning material molded onto the molded frame, wherein the furniture component is a base or transverse member of a modular furniture assembly.
31 . The furniture component of claim 30 , wherein the cushioning material has an outer skin layer.
32 . The furniture component of claim 31 , further comprising a fabric layer mounted on the outer skin layer.
33 . The furniture component of claim 31 , wherein the outer skin exterior layer is substantially smooth while the underlying cushioning material has a cushioned foamed structure.
34 . The furniture component of claim 30 , further comprising a fabric layer mounted on the cushioning material.
35 . The furniture component of claim 30 , further comprising a coupler for selectively coupling the furniture component to another component of a modular furniture assembly.