Digitally printed furniture and methods for manufacture thereof

Abstract

Manufacturing methods for furniture having a durable laminated surface with a digitally printed graphic image of a design include the steps of creating a graphic image of a design, printing the graphic image with a printer onto printer paper laminated to an uncut or precut furniture substrate, coating the paper with a protective coating, and finishing the laminated furniture components for later assembly. Optionally, the graphic image is printed on paper, which is later adhered to uncut or precut furniture substrate. The finishing steps include cutting the laminated furniture substrate into furniture components, edge banding the edges of the laminated furniture components and preparing the furniture components with fastener housings for later assembly. Ready-to-assemble furniture is provided with at least one exterior laminated furniture surface having a high quality digitally printed image of graphic design such as wood grain, wood inlay or other custom design.

1 . A method of manufacturing furniture with a printed graphic image laminated on at least one surface of the furniture, the method comprising the steps of: 
 (a) creating a graphic image of a design for printing on paper;    (b) printing the graphic image with a printer onto the paper adhered with an adhesive to a furniture substrate;    (c) coating the paper with the graphic image adhered to the furniture substrate with a protective coating; and    (d) finishing the furniture substrate into a furniture component for assembly with other corresponding furniture components.    
   
   
       2 . The method of  claim 1 , wherein the step of creating a graphic image of a design for printing on paper comprises generating the image with multi-layered design and adjusting the graphic image to a desired visual effect.  
   
   
       3 . The method of  claim 2 , wherein the graphic image of the design is selected from the group consisting of a wood grain design, an inlay wood grain design, a logo design, a seal design and a custom graphic design.  
   
   
       4 . The method of  claim 1 , wherein the adhesive is a water-based adhesive for membrane application.  
   
   
       5 . The method of  claim 1 , wherein the step of printing the graphic image on paper comprises printing the graphic image on the paper and adhering the paper with the graphic image with an adhesive to a furniture substrate.  
   
   
       6 . The method of  claim 1 , wherein the paper is a double-calendered, 70# paper.  
   
   
       7 . The method of  claim 1 , wherein the step of printing the graphic image on paper comprises digitally printing the graphic image on the paper using a large format printer.  
   
   
       8 . The method of  claim 1 , wherein the step of coating the paper adhered to the furniture substrate comprises applying a layer of a protective coating to the paper printed with the graphic image.  
   
   
       9 . The method of  claim 1 , wherein the layer of protective coating is a 100% solids, acrylated coating.  
   
   
       10 . The method of  claim 1 , wherein the step of finishing the furniture substrate comprises the further steps of: 
 (a) cutting the piece of furniture substrate into the furniture component;    (b) adhering an edge band to an edge of the furniture component; and    (c) boring the furniture component to house fixtures for furniture assembly.    
   
   
       11 . Ready-to-assemble furniture comprising at least one component with a laminated surface having a graphic image printed on paper adhered with an adhesive to a surface of the component, a protective coating applied to an exterior surface of the paper with the graphic image, and an edge band affixed to exposed edges of the component.  
   
   
       12 . The ready-to-assemble furniture of  claim 11 , wherein the adhesive is a water-based adhesive for membrane application.  
   
   
       13 . The ready-to-assemble furniture of  claim 11 , wherein the protective coating is a 100% solids, acrylated coating.  
   
   
       14 . The ready-to-assemble furniture of  claim 11 , wherein the furniture is selected from the group consisting of a desk, a credenza, a book shelf, a hutch, a table and an entertainment unit.  
   
   
       15 . The ready-to-assemble furniture of  claim 11 , wherein the component is selected from the group consisting of a desktop, a door, a drawer front and any component of ready-to-assemble furniture.  
   
   
       16 . The ready-to-assemble furniture of  claim 11 , wherein the graphic image printed on the paper originates from a layered graphic image, and wherein the graphic image is printed digitally on the paper with a printer in one pass.  
   
   
       17 . The ready-to-assemble furniture of  claim 11 , wherein the graphic image is selected from the group consisting of a wood grain design, a wood grain with an inlay design, a logo design, a seal design and a custom design.  
   
   
       18 . A piece of ready-to-assemble furniture comprising at least one component comprising a furniture substrate having a laminated surface, wherein the furniture substrate comprises a wood-based product, the laminated surface comprising a layer of protective coating over a graphic image printed on paper adhered with an adhesive to the furniture substrate, and wherein the component is adapted to receive fasteners used to assemble the component to corresponding components.