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.

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.