Decorative furniture comprising molded furniture part

Abstract

A decorated furniture piece comprising a frame having a front frame member, an opposing backrest, and two arms at opposite ends of the front frame member and the backrest, where at least one of the front frame member and the opposing backrest comprises a wooden component, and where the arms are made of molded plastic, and at least one of the arms is coupled to the wood component. The decorated furniture piece comprises a cover material, wherein at least a portion of the at least one of the arms is covered by the cover material.

Description

[0001] This application is a divisional application with application number 201980050292.0, application date January 27, 2021, and subject matter “Decorated furniture including molded furniture parts”. Technical Field

[0002] The present disclosure relates generally to upholstered furniture and, more particularly, to upholstered furniture including one or more molded components. Background Art

[0003] Upholstered seating, in which substantially all exposed furniture items are covered by a decorative covering, is one of the largest volume items sold in the interior retail furniture market, if not the largest volume item, thereby providing one of the highest revenue streams for retail furniture stores. The market for such upholstered seating is highly competitive, and any improvements in manufacturing that result in an improved product, greater value to the customer, and / or lower manufacturing costs would be welcomed by the industry.

[0004] When manufacturing such decorated seat articles (such as, sofas, loveseats, reclining chairs and similar articles), the structure of the decorated furniture articles is provided by a frame or chassis, which provides structural support for the furniture and provides its basic shape. Traditionally, the frame for the decorated furniture articles is typically constructed of wood materials, such as hardwood, softwood, engineered wood (for example, plywood, cardboard, hemp board, particle board and fiberboard). The part of the wooden frame can be typically covered by a pad or a cushion (such as, foam), and can be covered with fabric, leather, mixed fiber, artificial leather, microfiber or other decorations subsequently. Due to a large number of parts and their material weight, wooden furniture frames are often heavier and have long assembly time, which is partly because they include a large number of parts. For example, only a single arm for a decorated chair, reclining chair and sofa may include up to and more than 10 or 15 different wooden parts, which do not include numerous fasteners required for assembling. Of course, each wooden part needs to be accurately cut. Additionally, a single backrest for chairs, recliners, and sofas may include up to and exceeding 10 or 15 different wood sections, not including the numerous fasteners required for assembly.

[0005] Additionally, attaching trim to complex shaped wooden sofa frame arms can also be tedious because the wooden frame has gaps that need to be covered with cardboard or the like, the trim components (including padding) do not slide over the wooden frame for positioning, and thus, the trim needs to be precisely positioned manually. Furniture manufacturers would greatly appreciate improvements that make it easier to attach trim components to sofa frame arms.

[0006] Furthermore, with the non-uniformity of wood, using multiple wood pieces in constructing sofa and chair components (such as arms) is only as strong as the weakest wood piece and can present difficult quality control issues. Furthermore, wood pieces can crack when fasteners are driven into the multiple wood pieces during assembly of the furniture item.

[0007] The process of manufacturing an upholstered furniture article described above is time consuming and expensive because the multiple parts must be manually assembled to construct the final upholstered furniture article. Thus, there is a need for a simplified method for manufacturing an upholstered furniture article that reduces labor and material costs while providing a product that provides adequate support or an improved level of support and comfort to the user.

[0008] While efforts have been made to utilize plastic components in seating, such efforts have not been commercially successful in upholstered seating and have not taken advantage of the corresponding properties and disadvantages of plastic and wood. Summary of the invention

[0009] Embodiments of the present disclosure include upholstered seating in which the number of parts required to be assembled is minimized for easier assembly, in which assembly time is minimized, and in which the finished product is robust and strong. The inventors have determined the optimal and synergistic use of polymer structural components and non-polymer structural frame components (such as wood frame members) to provide such attributes.

[0010] In an embodiment, a decorative seating article configured as a sofa includes a seat base with a seat cushion, a cushioned backrest, and a pair of armrests with pads. The seat base, the cushion, and the pair of armrests are all covered with decoration on all visible exposed areas (specifically, the top and sides of the sofa). The sofa has a sofa frame or chassis, which includes a pair of blow-molded armrest moldings separated by a spacing distance, and a plurality of cross-type wooden frame members, each of which extends between the pair of molded armrests, and each cross-type wooden frame member has a length greater than the spacing distance and has a wooden frame member end embedded in a recess in the corresponding blow-molded armrest molding. One or more of the multiple wooden frame members are attached to each of the blow-molded armrest moldings in the pair of blow-molded armrest moldings by a plurality of metal screws in a plurality of metal threaded inserts extending into the corresponding armrest moldings. The vertical backrest frame member and the seat platform component are supported by the cross-type frame member and attached to the cross-type frame member. The trim covers the side arm moldings, the backrest, and the cushions such that substantially the entire exposed area of ​​the sofa is covered by the trim.

[0011] Features and advantages of an embodiment are that the furniture article includes a pair of opposed arm member moldings, each arm member molding being integrally formed from a single piece of polymeric material. This structural arrangement provides ease of assembly and cost efficiency by minimizing the number of parts and minimizing the number of assembly steps. In an embodiment, a wooden cross member extends between the pair of opposed arm member moldings. In an embodiment, each arm member defines a plurality of corresponding recesses, each of the corresponding recesses being sized and positioned to receive an end portion of the wooden cross member. In an embodiment, a plurality of threaded metal inserts are supported by each of the arm members. Each of the threaded metal inserts can receive a threaded fastener that helps constrain the wooden cross member relative to the arm member.

[0012] Features and benefits of embodiments are that an upholstered furniture article has a covering material in the form of a decorative pocket positioned over at least a portion of the upholstered furniture article, including each of the arm portions. In embodiments, the decorative pocket includes padding that provides a greater level of comfort to a user of the upholstered furniture article. In embodiments, the upholstered furniture article further includes padding wherein at least a portion of each arm portion is covered by the padding such that the padding is located between the molded component and the covering material.

[0013] Features and advantages of embodiments are that the furniture article includes a pair of opposing arm members, each of the arm members includes a hollow shell, the hollow shell includes a polymer shell wall, the inwardly facing surface of the polymer shell wall defines a void volume, the polymer shell wall having a plurality of low friction polymer outwardly facing surfaces. In embodiments, the low friction polymer outwardly facing surfaces provided by the polymer shell walls facilitate pulling of a decorative covering material over the arm portion of the furniture article. In embodiments, the polymer shell walls provide support structure and provide a basic shape for the arm portion of the furniture article.

[0014] A feature and advantage of an embodiment is that the furniture article comprises an arm portion, each arm portion being integrally formed from a single piece of thermoplastic material. This arrangement allows the arm portion body to be manufactured using an automated and efficient thermoplastic injection molding process.

[0015] A feature and benefit of an embodiment is that an article of furniture includes an arm member having a cross-member receiving recess that orients a wooden cross-member of the furniture. In an embodiment, each of the cross-member receiving recesses is shaped and dimensioned to receive an end portion of a wooden cross-member when the wooden cross-member is disposed in a predetermined orientation relative to the arm member. In an embodiment, the arrangement facilitates fixture-free alignment and assembly of sub-components.

[0016] A feature and benefit of an embodiment is that an article of furniture includes an arm member having a plurality of mounting features. In the embodiment, the plurality of mounting features allow the arm member to be used with a variety of furniture article types / models of furniture articles. Examples of furniture articles include sofas, loveseats, chairs, sectionals, seating units, sofa beds, futon frames, and recliners.

[0017] Features and benefits of embodiments are that the furniture article includes an arm member defining a groove that receives a distal end of a cross member to form a tongue-and-groove joint. In embodiments, the groove extends up and down along a groove axis. In embodiments, the groove is shaped and dimensioned to receive an end portion of a wooden cross member having a uniform thickness along its length. In embodiments, the wooden cross member can be slid downward with each end of the cross member received in a groove defined by opposing arm members to facilitate fixture-free alignment and assembly of subcomponents of the furniture article.

[0018] A feature and advantage of an embodiment is that the furniture article has an arm portion having less than three layers of material between the arm portion and the decorative covering. In an embodiment, the arm portion has a top curved surface about a horizontal axis. In an embodiment, the layer between the arm portion and the decorative covering includes an EVA base layer and a second layer of fibrous material thereon. A feature and advantage of the arm portion is that there is no cardboard layer extending across the wooden frame as in many conventional assemblies.

[0019] Features and advantages of embodiments are that the number of parts required to assemble the recliner is greatly reduced, the difficulty of assembly is greatly reduced, the assembly time is greatly reduced, and the cost is correspondingly greatly reduced compared to conventional recliners. In addition, the structural integrity is generally greater.

[0020] In an embodiment, a method of making an upholstered seat includes providing a seat frame comprising a front frame member, an opposing backrest, and two arms at opposite ends of the front frame member and the backrest, wherein at least one of the front frame member and the opposing backrest comprises a wood component, and wherein the arms are made of molded plastic; coupling at least one of the arms to the wood component; and covering at least a portion of the arms with a covering material.

[0021] Features and advantages are: The inventors have discovered that certain polymers, such as polyethylene, can accept staples comparable to wood frame members. This facilitates use of the polymer armrest moldings in existing furniture assembly lines.

[0022] Features and advantages of embodiments are that the blow molded handrail molding may have a wall thickness of from 2 mm to 6 mm. Such thickness provides stability and secure retention of the frame member to which it is attached, while providing a handrail molding that is more resilient than prior art wood handrail frames. Such resiliency may reduce the amount of cushioning material required compared to conventional wood frame handrail moldings.

[0023] In embodiments, attachment of the trim is simplified due to the very low coefficient of friction between the sofa arm molding and the trim material, allowing a suitably sized trim arm portion to slide easily over the arm molding. In embodiments, this facilitates construction of a more complete trim kit at a location remote from the final sofa assembly location of the sofa. For example, a trim kit may include an armrest upholstery portion that already has an armrest pad attached to the trim covering material. This may eliminate the step of having to manually attach one or more padding layers at the final sofa assembly location prior to attaching the decorated portion of the armrest.

[0024] A feature and advantage of an embodiment is that the degree of separation of manufacturing locations for the components of the upholstered seating article is increased. For example, a cushion for an armrest can be attached to an armrest trim portion as part of a trim kit at a location remote from the final seating assembly location. Additionally, each of the armrest moldings can be molded at a location remote from the final seating assembly location and transported to the final seating assembly location.

[0025] Features and benefits of embodiments are arrangements of furniture articles in which the number of parts that need to be assembled is minimized, and assembly time is minimized, and which are robust and sturdy.

[0026] Features and advantages of embodiments are that the specific properties of polymers and wood have been combined in a synergistic manner to construct a wooden frame or chassis for a decorative seat. For example, conventional polymers (e.g., polyethylene) suitable for geometrically large parts (such as furniture parts) may creep over time and may reduce load bearing strength when subjected to tensile loads or large shear loads. However, three-dimensional polymer moldings, particularly hollow polymer moldings, have reasonable compressive load bearing capacity. Downward loads will generally not cause significant creep of the polymer, making some polymers (such as polyethylene) suitable for armrest moldings. In the case where such armrest moldings are used for some limited downward compression loads, any reduction in the strength of the polymer over time should not affect the integrity of the sofa frame and sofa. Polymers have strong capabilities and flexibility in fixing components (such as discontinuously loaded wooden frame members). In embodiments of the present invention, the load from the seat is not isolated from the polymer armrest molding, but the load is directly carried downward from the seat platform to the lower front rail and lower rear rail, both of which are positioned at the lower edge of the sofa. Without feet on the sofa, the load from the seat will be transferred to the floor surface along the length of both the front and back rails. With feet on the sofa, the front and back rails will act as beams supported at the ends, and the floor engaging feet will be positioned under the ends of the front and back rails and transfer the load to the floor through the feet.

[0027] On the other hand, wood has a greater load bearing capacity between the support ends when properly oriented. The use of a wood cross-frame member in combination with the polymeric armrest molding to support the weight of a person sitting on the sofa provides sufficient strength to support a person sitting on the sofa, and does so with a minimum of component parts, minimum assembly time, and potentially reduced cost. The optimal solution is to minimize the load bearing of the larger blow molded parts.

[0028] A feature and advantage of an embodiment is the use of a plurality of cross-type wood frame members between a pair of polymeric handrail moldings, wherein the cross-type wood frame members carrying the seat loads are seated on the upward facing surface of the polymeric handrail. In an embodiment, the upward facing surface is a load bearing platform portion formed in the inner wall portion of the hollow handrail molding, whereby the seat loads transmitted to the platform portion through the ends of the cross-type wood frame members are distributed to the inward facing wall portions on the upper, lower, front and rear portions of the platform portion. In an embodiment, the cross-type frame members can be constructed of metal rather than wood with some of the same advantages.

[0029] Features and advantages of embodiments are: a blow molded polymer handrail molding having a plurality of vertical recesses in the wall portion for increasing the structural strength of the handrail molding. Features and advantages of embodiments are: polyethylene is used for the handrail molding and a threaded insert has an internal threaded surface for receiving a screw placed at the attachment point of the cross-type member in the polymer wall portion, the screw extending through the cross-type frame member to secure the cross-type frame member to the polymer handrail molding. In embodiments, the threaded insert has external threads and is screwed into the polymer wall portion of the handrail molding. In embodiments, the attachment point of the cross-type member is located at a recess in the wall portion of the handrail molding, whereby the end of the cross-type member will be embedded in the recess, the embedding providing a secure fixation of the component relative to the handrail molding.

[0030] Features and advantages of embodiments are that the furniture seating article has a rectangular base, has opposite side polymer structural supports defining opposite short sides of the polymer base, and has a wood baseboard defining long sides of the rectangular base, the ends of the wood baseboard being connected to the polymer structural supports, and wherein the rectangular base supports a seat platform and a backrest, and wherein all load bearing components of the furniture seating article are directly connected to at least one of the front non-polymer support and the rear non-polymer support, or are connected to at least one of the front non-polymer support and the rear non-polymer support through metal or wood components. In other words, none of the components being loaded transfers any load on them exclusively to the polymer structural supports, such loads being shared or primarily carried by the non-polymer frame structure. In embodiments, floor engaging feet are placed under the four ends of the wood baseboard to support the load of the seating article. Through the feet, there is no separate isolated polymer structure (such as a leg) other than the sofa foot to carry the load of the furniture seating article due to the load caused by sitting.

[0031] In an embodiment of the present invention, armrests for stationary upholstered seating articles such as sofas each have a hollow polymer armrest molding that weighs from about 6 pounds to 10 pounds, saving 10 pounds to 16 pounds for two armrest moldings compared to conventional wood frame armrest moldings. In an embodiment of the present invention, recliner armrest moldings can save 14 to 19 pounds by two blow molded armrests compared to conventional wood frame armrest moldings. In a recliner, by using blow molded polymer armrest moldings, the weight of the armrest can be reduced by 50% compared to conventional wood frame armrests.

[0032] The above summary is not intended to describe each illustrated embodiment or every implementation of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The accompanying drawings included in this application are incorporated into the specification and constitute part of the specification. These drawings illustrate embodiments of the present disclosure and, together with the specification, are used to explain the principles of the present disclosure. The accompanying drawings are only illustrations of certain embodiments and do not limit the present disclosure.

[0034] Figure 1A is a perspective view of a sofa with an upholstery according to an embodiment.

[0035] Figure 1B According to an embodiment comprising two molded polymer handrail formations Figure 1A An exploded view of the sofa.

[0036] Figure 1C is a perspective view of an upholstered recliner according to an embodiment.

[0037] Figure 1D yes Figure 1C An exploded view of the upholstered lounge chair.

[0038] Figure 2A is a perspective view of a prior art sofa frame composed primarily of wooden components.

[0039] Figure 2B yes Figure 2A An exploded view of the prior art sofa frame.

[0040] Figure 3A yes Figure 1B A perspective view of the rear side of the sofa frame is shown in FIG.

[0041] Figure 3B is a front perspective view of another sofa frame according to an embodiment.

[0042] Figure 3C yes Figure 3B A rear perspective view of the sofa frame.

[0043] Figure 4A yes Figure 3A and Figure 3B Exploded view of the sofa frame.

[0044] Figure 4B is a cross-sectional view of a wall portion of a molded handrail forming showing a recess for receiving a straddling wood frame member.

[0045] Figure 5 yes Figure 3B and Figure 3C A front outside perspective view of the armrest molding of the sofa frame.

[0046] Figure 6yes Figure 3B and Figure 3C A front elevation view of the armrest molding of the sofa frame.

[0047] Figure 7 yes Figure 3B and Figure 3C A rear elevation view of the armrest molding of the sofa frame.

[0048] Figure 8 yes Figure 3B and Figure 3C An outer elevation view of the armrest molding of the sofa frame.

[0049] Fig. 9 yes Figure 3B and Figure 3C A top plan view of the armrest molding of the sofa frame.

[0050] Fig.10 yes Figure 3B and Figure 3C An inner elevation view of the armrest molding of the sofa frame.

[0051] Fig.11 yes Figure 3B and Figure 3C A bottom plan view of the armrest molding of the sofa frame.

[0052] Fig.12 yes Figure 1A The armrest molding of the sofa, and the cushion and buffer material Figure 3B and Figure 3C A front outside perspective view of the sofa frame.

[0053] Fig.13 yes Figure 1A The armrest molding of the sofa, and also includes arm fibers and decorative covering materials Figure 3B and Figure 3C A front inner perspective view of another embodiment of the sofa frame.

[0054] Fig.14 is Figure 1B A cross-sectional view of the decorative sofa arm soft cover taken at line 14-14.

[0055] Fig.15A is Figure 1B A cross-sectional view of the backrest trim cover taken at line 15A-15A.

[0056] Fig. 15B is Figure 1D A cross-sectional view of the recliner decorative cover taken at line 15B-15B.

[0057] Fig.16 is a perspective view of a prior art recliner frame that does not include any molded plastic components.

[0058] Fig.17 is a perspective view of a recliner frame having a recliner seat and recliner mechanism according to an embodiment including a molded backrest portion and two molded armrest moldings, the recliner frame such as in Figure 1D Shown in.

[0059] Fig.18A yes Fig.17 An exploded view of the recliner components.

[0060] Fig.18B yes Fig.17 A rear exploded view of the recliner.

[0061] Fig.19 is a front perspective view of a backrest portion according to an embodiment of the present disclosure.

[0062] Fig. 20 yes Fig.19 A front perspective view of a back molding of a chair frame.

[0063] Fig.21 yes Fig.19 A right side elevation view of the back molding of the chair frame.

[0064] Fig. 22 yes Fig.19 A rear elevation view of the back molding of the chair frame.

[0065] Fig.23 yes Fig.19 A front elevation view of the backrest molding of the chair frame.

[0066] Fig.24 yes Fig.17 A front outside perspective view of the armrest molding of the chair frame.

[0067] Fig.25 yes Fig.17 A rear elevation view of the armrest molding of the chair frame.

[0068] Fig.26 yes Fig.17 An inside elevation view of the armrest molding of the chair frame.

[0069] Fig. 27 yes Fig.17 A bottom plan view of the armrest molding of the sofa frame.

[0070] Fig.28 yes Fig.17A perspective view of a single mold of four molded components of the chair frame, including the molded back portion, the molded footrest portion and two molded arms.

[0071] Although the embodiments of the present disclosure may be subjected to various modifications and alternative forms, the details thereof have been shown in the drawings by way of example and will be described in detail. However, it should be understood that it is not intended to limit the present disclosure to the specific embodiments described. On the contrary, it is intended to cover all modifications, equivalents and substitutes that fall within the spirit and scope of the present disclosure. DETAILED DESCRIPTION

[0072] refer to Figure 1A , an upholstered sofa 30 is illustrated. The sofa 30 typically has a seat base 32 with a seat platform 33, a seat cushion 34 located on the seat platform, an upright backrest 38 extending from the seat base, and a pair of armrests 40, 42 connected to opposite ends 46, 47 of the seat base. Upholstery 50 covers the exposed portions of the armrests, seat base, backrest, and seat cushion. That is, the top side 52, left side 53, right side 54, back side 55, and front side 56 of the sofa have upholstery on them. The bottom side 57 may have a decorative panel folded and attached to the frame, but is typically not completely covered by the upholstery. Sofa feet 59 are attached to the sofa on the bottom side and provide separation of the sofa base from the floor surface. When used herein, upholstery includes fabric, leather, synthetic fabric, artificial leather, microfiber, or other sheet material used as a covering for the sofa.

[0073] refer to Figure 1B , which shows additional components of the sofa, and these additional components include a structural frame 60, a seat back decorative portion 62, armrest decorative portions 64, 65, and a front base decorative portion 67 attached to the seat platform 33. The seat platform can be a textile seat platform as described in WO2018 / 081471, which is owned by the owner of the present application and is incorporated herein by reference for all purposes. Alternatively, the seat platform can include conventional steel springs as is well known. The structural frame 60 includes unitary polymer arm rest forms 68, 69 discussed in detail below.

[0074] refer to Figure 1C The reclining chair 70 has a seat portion 72 with a seat cushion 73, a pair of armrests 74, 75, a backrest 78 and a footrest 80. Figure 1DThe recliner also has a recliner frame 84 including a pair of polymer armrest moldings 87, 88 and a backrest molding 90. Each of the armrest moldings is monolithic and molded by blow molding. A backrest trim cover portion 92 and side arm cover portions 93, 94 cover the frame. The seat portion includes a seat platform 95, which may include a frame member 96 and a metal spring 97; a recliner mechanism 99 is positioned below the seat platform.

[0075] Although in Figure 1B and Figure 1D In the embodiments, the backrest decorative portion, armrest decorative portion and base decorative portion (in the sofa) are drawn as separate decorative parts to be attached to the sofa frame. However, in embodiments, they can be combined into an integrated decorative covering having connected separate parts before being installed on the sofa or recliner frame. In embodiments, the decoration for the sofa and recliner can be provided as a kit that is manufactured at a location remote from the final assembly location of the sofa. When used in this article, "portion" can be all or part of something. Portions are not considered to be restrictive.

[0076] Reference to existing technology Figure 2A and Figure 2B, depicts a wooden structural frame 100 for a conventional sofa. Certain portions of the frame 100, such as the arm portions, once assembled, may be covered with cardboard or fiberboard to provide further shape and close openings, and may be further covered with padding or cushioning, such as foam. The frame 100 is then covered with fabric, leather, a blended fabric, artificial leather, microfiber, or other decorative or covering materials. Such padding and covering materials are not depicted in FIGS. 1 and 2 . As depicted, the frame 100 includes many different parts. These parts may include, for example, one or more front rails 102 (which may be made of oriented strand board or "OSB") forming the front of the sofa frame 100; one or more rear rails or back rails forming the rear of the sofa frame 100, such as a chest rail 104 (which may be made of oriented strand board or "OSB"), a top rear rail 106 (which may be made of hardwood or "HW"), a lower rear rail 107, and a spring rail 108 (which may be made of hardwood or "HW"). The front and rear portions of the frame 100 may be connected by two arms 110 and one or more seat frames 112 (which may be made of metal). The rear of the frame 100 may also include one or more uprights 114 (which may be made of oriented strand board or "OSB") also forming the rear of the sofa frame 100. The frame 100 may include a plurality of connecting blocks 116 (which may be made of hardwood or "HW") that are used to connect the components of the frame 100 together and maintain the proper positioning and angles of the frame 100. The numerous wooden components need to be precisely shaped by sawing or milling, and are typically connected with fasteners (such as staples) and sometimes adhesives.

[0077] Each prior art armrest frame 110 may include a plurality of components, including a front post 118 and a rear post 120 (which may be made of oriented strand board or "OSB") that provide the shape of the arm 110, connected by one or more leg rails 122 (which may be made of oriented strand board or "OSB") and one or more wall pulls 124 (which may be made of hardwood or "HW"). Each of the arm frames 110 may include one or more connecting blocks 126 (which may be made of hardwood or "HW") for connecting the components of the arm together and maintaining the position and angle of the arm 110. As depicted, each arm 110 of the sofa frame 100 includes as many as 10 or 15 parts or even more, which are connected with a large number of fasteners (such as, U-shaped staples).

[0078] refer to FIG. 3A to FIG. 4A, the structural frame 60 according to an embodiment of the present disclosure includes two molded polymer parts, specifically, two armrest moldings 68, 69. Once assembled, the frame 60 can be covered with a cushion or pad (such as a load-bearing polymer, arm fiber and / or foam), and can be subsequently covered with fabric, leather, mixed fabric, artificial leather, microfiber or other furniture decoration or covering materials (including the arm 210, which is in Figure 12-13 depicted with covering material).

[0079] As depicted, the frame 60 may include one or more spanning wood frame members 201 that may be configured as a front rail 202 (which may be made of oriented strand board or "OSB") that constitutes the front portion of the frame 60; one or more rear rails or lower rear rails 203, a chest rail 204 (which may be made of oriented strand board or "OSB"), a top rear rail 206 (which may be made of hardwood or "HW"), and a spring rail 208 (which may be made of hardwood or "HW") that constitute the rear portion of the frame 60. The front and rear portions of the spanning wood frame members 201 are received in recesses 207 defined in the wall portions of two handrail moldings 210. The recesses 201.2 capture, limit, and positionally secure the ends 201.2 of the spanning wood frame members 201. The differently configured recesses 201.2 are shown in FIG. Figure 5-Figure 11 Many of the recesses are defined by wall portions including an upwardly facing surface 207.3 on which the cross-type wood frame members sit, see in particular Fig. 9 and Fig.10 .

[0080] refer to Figure 3A and Figure 4A The handrail portions 210 are separated by a distance D1, and the cross-type wood frame members have lengths L1, L2, L3, L4, L5, L6 that are all greater than the handrail spacing distance D1. The cross-type wood frame members can be a single-piece wood board, including OSB and plywood.

[0081] The frame 60 may include one or more seat frames 212 (which may be made of metal). The rear portion of the frame 60 may also include one or more upright frame members 214 (which may be made of plywood or oriented strand board or "OSB"), which further form the rear portion of the frame 60. The frame 60 may include one or more connecting blocks 216 (which may be made of hardwood or "HW") for connecting the components of the frame 60 together and maintaining the positioning and angle of the frame 60.

[0082] The molded part, here the handrail molding 210, can be connected to the handrail by various fasteners, such as brackets, screws, clips, dowels, and other fasteners. FIG. 3A to FIG. 4A Other components of the sofa frame 60 are shown in FIG. Figure 4B , a metal insert 217 having a threaded hole 217.4 can be driven into an eyelet 217.6 formed in the wall portion 217.8 of the blow molded handrail molding or other blow molded component. See U.S. Patent Nos. 9,651,080 and 9,028,185, each of which is incorporated herein by reference. The metal threaded insert 217 can receive a bolt 217.9, such as, by way of example only, a 1 / 4-20 bolt, to connect the molded component to other components. Such a connection can be between the blow molded component and other components, which are made of materials such as, for example, hardwood, softwood, engineered wood (such as plywood, hardboard, millboard, particleboard and fiberboard), metal and plastic. Specifically, the insert can securely attach the cross-type wooden frame member 201.

[0083] The armrest molding 210 can be molded by a molding method such as blow molding (injection blow molding, extrusion blow molding, injection stretch blow molding), and can be molded from different materials including, for example, polyethylene (PE) (such as high-density polyethylene (HDPE) and low-density polyethylene (LDPE)), polyvinyl chloride (PVC), polypropylene (PP), nylon, and polyethylene terephthalate (PET), thermoplastic elastomer (TPE), acrylonitrile butadiene styrene (ABS), polyphenylene oxide (PPO), nylon / polyamide (PA), polycarbonate (PC), polyester and copolyester, urethane and polyurethane, and acrylic and polystyrene. In other embodiments, the molded part can be molded by different molding methods, such as injection molding (overmolding, insert molding, cold runner injection molding, hot runner molding, rotational molding).

[0084] In an embodiment, generally, ballast material may be added to the arm 210 to provide further stability and sound insulation to the arm 210 and frame 60. Such ballast material may include foam, such as high density foam, sand, cement, or other materials. In an embodiment, ballast may be added to the arm 210 through a port or other opening (not depicted) in the handrail molding, which may include a cap or other closure structure that can be permanently or selectively closed.

[0085] In an embodiment, compared to the frame 100 depicted in FIGS. 1 and 2 , Figure 3A The frame 60 depicted in FIG. 4 can have 10 and more fewer parts, 20 and more fewer parts, or even fewer. Furthermore, not only is the number of parts that need to be assembled minimized, but the frame is easier to assemble and the assembly time is minimized, in part because there are fewer secondary operations. Furthermore, with respect to shipping, the lighter weight reduces shipping costs. However, the frame 60 is robust, sturdy, and comfortable.

[0086] Blow molded handrail molding 210 is also Figure 5-Figure 11 The arm molding may be formed into any of a variety of desired furniture arm shapes, including, for example, rail, ruched, modern scroll, block, nailed rail, key, modern English, shelter, pleated, and saddle. The arm molding may include a top 218, a bottom 220, an outer side 222, an inner side 224, a front 226, and a rear 228. Reference Fig.10 , the inner wall portion 224 may include one or more recesses 207 or slots configured for one or more rails, such as, for example, a spring rail slot 230 for receiving a spring rail 208 and a chest rail slot 231 for receiving a chest rail 204. The inner wall portion 224 may also include one or more structural recesses 232 that may provide additional structure, robustness, and firmness to the sofa. The inner side 224 may also include one or more holes or openings 233 for use with metal insert threaded connectors that are used to connect the arm to other components of the furniture structure.

[0087] refer to Figure 5 and Figure 6 , the front wall portion 226 may include one or more recesses 207 configured for one or more rails, such as the front rail recess 234. The front wall portion 226 may also include one or more holes or openings 236 for use with threaded metal inserts 217 for connecting the arm to other components of the furniture structure. Figure 8, the rear wall portion 228 may include one or more recesses configured for one or more rails or uprights, such as a bottom rear rail recess 238, an upright recess 240, and a spring rail recess 241. The rear wall portion 228 may also include one or more holes or openings 242 for use with connectors that are used to connect the armrest molding to other components of the furniture structure. The outer wall portion 222 may also include one or more structural recesses 242 for providing additional structure, robustness, and firmness to the sofa frame.

[0088] refer to Figure 12-13 , the armrest molding may be covered with a pad or cushion (such as a load-bearing polymer, arm fiber and / or foam) and may subsequently be covered with a cover material. Fig.12 and Fig.13 In the depicted embodiment, the armrest molding 210 may be covered by arm fabric 244 and a covering material 246. Fig.14 In another embodiment depicted in FIG. 15 , the armrest molding 210 can be covered by a load polymer 250, arm fibers 246, and a covering material 248. In an embodiment, the load polymer 250 can include polyurethane foam. In an embodiment, the arm fibers 246 can include dense fibers. The covering material 248 includes fabric, leather, blended fabric, artificial leather, microfiber, or other decorative or covering materials.

[0089] refer to Figure 1B and Fig.14 The cross section of the decorative part 255 configured as a decorative soft cover has a shape that conforms to the armrest molding 68. A cushioning material layer 257 is integrated on the inner surface of the decorative material 256. The decorative part with cushion can be slid on the armrest molding without the cushion being previously attached to the armrest molding. Decorative panels 258, 259 can be attached to the bottom side of the sofa frame, for example, by U-shaped staples or other fasteners to the bottom wall portion of the armrest molding.

[0090] refer to Figure 3A and Fig. 15B , the cross-section of the back trim pocket 260 is form-fitted with the back frame 262 and has cushioning material 264 integrated therein and back support straps 265. See U.S. Patent No. 10,299,606 for illustration of such straps and integrated cushioning material. Said patent is owned by the owner of the present application and is incorporated herein by reference for all purposes.

[0091] refer to Figure 1D and Fig.15AThe backrest trim portion 267 configured as a trim pocket with integrated cushioning material 268 can be form-fitted with and easily slide on the molded backrest molding 404 due to the low coefficient of friction of the polymer backrest molding with many trim materials. Fasteners (such as U-shaped staples) can be used to secure the trim portion to the backrest molding 404.

[0092] refer to Fig.16 , depicting a prior art structural frame 300 of a reclining chair. Certain portions of the frame 300, such as the arm portions, once assembled, may be covered with cardboard or fiberboard to provide further shape, and may also be covered with pads or cushions, such as load-bearing polymers, arm fibers and / or foams, and may subsequently be covered with fabric, leather, blended fibers, artificial leather, microfibers, or other decorative or covering materials. As depicted, the prior art chair frame 300 generally includes a seat box 302, a back molding 304, two arms 306, and a foot rest 308.

[0093] Each prior art handrail frame 306 may include a plurality of components, including an outer arm rail 310, an inner arm rail 312, and a plurality of arm fillers 314 connecting the outer arm rail to the inner arm rail. A plurality of connecting blocks 316 may be included for connecting the components of the wall - in Fig.16 Only one connection block is depicted in FIG. The armrest frame 306 may also include cardboard or fiberboard to provide further shape or support to the arm (not shown). Fig.16 As depicted, each handrail frame may include approximately 19 parts (excluding fasteners). Typically, a number of fasteners (such as U-shaped staples and wood glue) are used to assemble the handrail frame.

[0094] The prior art backrest 304 may include multiple components, including a top back rail 318, a bottom back rail or wing mount 320, one or more wings 322, one or more back posts 324, one or more back post stiffeners 326, a back brace 328, a breast rail 330, and a web 332. As depicted, the backrest includes approximately 15 parts. A number of fasteners, such as staples, are used to assemble the backrest.

[0095] refer to Fig.17 18, depicts a chair frame 400 according to an embodiment of the present disclosure, specifically, a frame for a reclining chair, including four molded parts (specifically, two arms 402, a backrest 404, and a footrest or footrest 406). The frame 400 also includes a reclining mechanism 408 for reclining function, and a back rail 409. Figure 1C and Figure 1DAs depicted in , the recliner frame 400, once assembled, can be covered with pads or cushions (such as, load-bearing polymers, arm fibers and / or foams), and can subsequently be covered with fabric, leather, mixed fibers, artificial leather, microfibers, or other decorative or covering materials. Fasteners (such as, U-shaped staples) can be used to attach the covering material to the molded parts.

[0096] The molded parts (here, the armrest molding 402, the back molding 404, and the footrest 406) can be connected to other parts of the frame 400 by various fasteners, such as brackets, screws, clips, dowels, and other fasteners. The back molding 404 can also be attached to the frame 400 by a steel bracket 410 having a plurality of fasteners such as a bracket 410. Fig.19 A hole or opening in a molded component (described below) may include an insert 217 (in Figure 4B ), into which bolts (such as, by way of example only, 1 / 4-20 bolts) can be threaded to connect the molded component to other components, such as the seat platform and the recliner mechanism.

[0097] The molded parts can be formed by molding methods such as blow molding (injection blow molding, extrusion blow molding, injection stretch blow molding), and can be formed from different materials including, for example, polyethylene (PE) (such as high-density polyethylene (HDPE) and low-density polyethylene (LDPE)), polyvinyl chloride (PVC), polypropylene (PP), nylon, and polyethylene terephthalate (PET), thermoplastic elastomers (TPE), acrylonitrile butadiene styrene (ABS), polyphenylene oxide (PPO), nylon / polyamide (PA), polycarbonate (PC), polyesters and copolyesters, urethanes and polyurethanes, and acrylic and polystyrene. In other embodiments, the molded parts can be formed by different molding methods, such as injection molding (overmolding, insert molding, cold runner injection molding, hot runner molding, rotational molding).

[0098] In an embodiment, ballast material may be added to the arm 402 to provide further stability and sound insulation to the arm 402 or chair frame 400, generally. Such ballast material may include foam, such as high density foam, sand, cement, or other materials. In an embodiment, ballast may be added to the arm 210 through a port or other opening in the arm 402, which may include a cap or other closure structure that can be permanently or selectively closed.

[0099] The backrest molding 404 is further Figure 19-Figure 23. The back molding 404 includes a top portion 412 and a bottom portion 414 extending from the top portion 412. The back molding 404 also includes a front wall portion 416, a rear wall portion 418, and side wall portions 420. The front wall portion 416 and the rear wall portion 418 may include one or more structural recesses 421 to provide further structure, robustness, and firmness to the sofa. The side wall portion 420 may include one or more holes or openings 422 for use with connectors that are used to connect the back molding to other components of the furniture structure. In a construction such as Fig.19 , the back molding includes a bracket 410 for operably coupling the back molding 404 to another portion of the frame 400, such as the reclining mechanism 408 and / or the arm 402. The bracket 410 can be connected to the back molding through the hole 422. The back molding 404 or a portion thereof can be covered with a cushion or pad, such as a load-bearing polymer, arm fiber, and / or foam, and can subsequently be covered with fabric, leather, a blended fabric, artificial leather, microfiber, or other decorative or covering materials.

[0100] The handrail molding 402 is further Figure 24-Figure 27 . The arm molding can be formed into any furniture arm shape, including, for example, rail, hem, modern scroll, pad, nailed rail, key, modern English, shutter box, pleat, and saddle. The arm molding 402 can include a top 424, a bottom 426, an outer side 428, an inner side 430, a front 432, and a back 433. Reference Fig.26 , the inner side 430 may include one or more recesses or slots 434 configured to connect with the reclining mechanism 408 or a portion of the seat box. The inner side 430 may also include one or more holes or openings 436 used with a connector to connect the arm 402 to other parts of the furniture structure, and a protrusion 446 containing the hole or opening 436, the hole or opening 436 is used to connect the arm 402 to other parts of the furniture structure (such as the reclining mechanism 408). Fig.25 and Fig.26 The rear portion 433 may also include one or more recesses or slots 438 configured for connection with the rear rail 409, and one or more holes or openings 440 for use with a connector to connect the arm to other components of the furniture structure. Fig.24 The outer wall portion 428 may include one or more structural recesses 442 that provide further structure, robustness, and rigidity to the chair frame 400, and an opening 444 for coupling with a portion of the reclining mechanism 408 (e.g., a handle or lever (not depicted) for operating the reclining mechanism 408). Fig. 27, the bottom wall portion 426 may include a hole or opening 450. The armrest molding 402 or portions thereof may be covered with a cushion or pad such as a load-bearing polymer, arm fiber and / or foam, and may subsequently be covered with fabric, leather, blended fabric, artificial leather, microfiber, or other decorative or covering material.

[0101] refer to Fig.28 , depicting Fig.17 A single mold 900 of the four molded components of the chair frame 400 of the embodiment of the present invention includes a molded back molding 404, a molded footrest 406, and two molded armrest moldings 402. Once the molding is completed, the flash 902 will be trimmed and any secondary operations will be performed. The processing time for the molded back molding 404, the molded footrest 406, and the two molded armrest moldings 402 will be less than about five minutes, preferably less than about three minutes, and optimally less than one or two minutes. Advantageously, the use of polyethylene for the blow molded components allows the use of regrind drums, which is environmentally and economically advantageous.

[0102] The various directional terms used herein are used as a convenient way to discuss the objects shown in the figures. It will be understood that many directional terms relate to the instant orientation of the described objects. It will also be understood that the objects described herein can assume various orientations without departing from the spirit and scope of this specific embodiment. Therefore, directional terms (such as, "upward", "downward", "forward", "backward") should not be interpreted as limiting the scope of the present invention as described in the appended claims.

[0103] The following U.S. patents are hereby incorporated by reference herein: U.S. Patent Nos. US7070243, US6854806, US6702391, US6679558, US5582460, US5755489, US5575533, US4775187, US3877087, US3669495, US3658382 US10299606, US10117521, US10034554, US9839295, US9474381, US8777319, US8448314, US8438716, US7988236, US7806482, and US7438362. The entire contents of the above U.S. patent references in all sections of this application are incorporated herein by reference for all purposes. The components illustrated in these patents may be used with the embodiments herein.Incorporation by reference is discussed, for example, in MPEP Section 2163.07(B).

[0104] All features disclosed in this specification (including references incorporated by reference, including any accompanying claims, abstract and drawings) and / or all steps of any method or process so disclosed may be combined in any combination, except where at least some of such features and / or steps are mutually exclusive.

[0105] Unless expressly stated otherwise, each feature disclosed in this specification (including references incorporated by reference, any accompanying claims, abstracts and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose. Thus, unless expressly stated otherwise, each feature disclosed is only an example of a general series of equivalent or similar features.

[0106] The present invention is not limited to the details of the above embodiments. The present invention extends to any novel feature, or any novel combination of the features disclosed in this specification (including any feature, any accompanying claim, abstract and drawings incorporated by reference), or any novel step, or any novel combination of the steps of any method or process so disclosed. The entire contents of the above references in all sections of this application are incorporated herein by reference for all purposes.

[0107] Although specific examples have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement calculated to achieve the same purpose can replace the specific examples shown. The application is intended to cover the adaptation or variation of this theme. Therefore, it is intended that the present invention is limited by the appended claims and their legal equivalents, and the accompanying illustrative aspects. The above-described aspect embodiments of the present invention only describe its principles and are not considered to be limitations. Those skilled in the art will expect other modifications of the present invention disclosed herein, and all such modifications are considered to be within the scope of the present invention.

Claims

1. A method of constructing a seat with an upholstery, comprising: Blow-molded armrests and backrest frame. Each handrail profile comprises a hollow shell including a polymeric shell wall, an inwardly facing surface of the polymeric shell wall defining a void volume, The back frame includes a hollow shell including a polymeric shell wall, an inwardly facing surface of the polymeric shell wall defining a void volume, covering the pair of armrest moldings and the backrest frame with a decorative portion, A recliner mechanism is attached between the pair of armrest moldings and connected to the backrest frame.

2. The method according to claim 1, wherein: The polymer shell wall of each armrest has a low friction polymer outwardly facing surface, wherein the trim portion for covering each armrest comprises a soft cover, and wherein the method comprises sliding a respective soft cover for each armrest onto a respective armrest molding.

3. The method according to claim 1 or 2, wherein: Each upholstery cover includes an integrated cushioning layer, and sliding the respective upholstery cover for each armrest onto the respective armrest molding includes sliding the integrated cushioning layer onto the corresponding each armrest molding.

4. An upholstered chair comprising a pair of upholstered armrests, an upholstered seat base having a cushion thereon and positioned between the armrests, and an upholstered backrest extending upwardly from the seat base and positioned between the armrests; in, Each armrest comprises a one-piece blow molded polymeric armrest molding covered with a trim, each armrest molding comprising a hollow shell including a polymeric shell wall having an inwardly facing surface defining a void volume, wherein the backrest frame comprises a blow molded polymer backrest covered with an upholstery, the backrest frame comprising a hollow shell comprising a polymer shell wall, the inwardly facing surface of the polymer shell wall defining a void volume, Therein, a recliner mechanism positioned between the armrest moldings is connected to the backrest frame.

5. The upholstered seat according to claim 4, wherein: The recliner mechanism is directly connected to each armrest molding.

6. The upholstered seat according to claim 4 or 5, wherein: The polymer shell wall of each armrest has a low friction polymer outwardly facing surface that facilitates sliding around a corresponding trim portion.

7. An upholstered chair comprising a pair of upholstered armrests, an upholstered seat base having a cushion thereon, and an upholstered backrest, the upholstered seat base being positioned between the armrests, the upholstered backrest extending upwardly from the seat base and being positioned between the armrests; in, each armrest comprising a one-piece blow molded polymer armrest molding covered with decoration, each armrest molding comprising a hollow shell, the hollow shell comprising a polymer shell wall, the polymer shell wall having an outwardly facing low friction polymer surface, the inwardly facing surface of the polymer shell wall defining a void volume, the polymer shell wall having a low friction polymer outwardly facing surface for sliding the decorated portion therearound, wherein the backrest frame comprises a blow molded polymer backrest covered with an ornament, the backrest frame comprising a hollow shell, the hollow shell comprising a polymer shell wall, the inwardly facing surface of the polymer shell wall defining a void volume, the polymer shell wall having a low friction polymer outwardly facing surface for sliding the ornamented portion therearound, wherein a seat base extends between the pair of armrest moldings and is attached to the armrest moldings and has a pad thereon.

8. The upholstered seat of claim 7, wherein: The seat base includes a recliner mechanism, and an upholstered back frame is attached to the recliner mechanism.

9. A method of assembling a sofa with an upholstery, comprising: providing a pair of one-piece, blow-molded polymer handrail moldings, each of said handrail moldings being hollow, said handrail moldings being disposed at a spaced distance relative to each other; The handrail forming part includes a hollow shell, the hollow shell includes a polymer shell wall, the inwardly facing surface of the polymer shell wall defines a void volume, and the polymer shell wall has an outwardly facing low friction polymer surface; Attaching a backrest frame and a seat base, the seat base having a plurality of cross-type wood frame members, each of the cross-type wood frame members having a length greater than the spacing distance, the plurality of cross-type wood frame members including a lower front rail and a lower rear rail, the attachment of the lower front rail comprising: inserting an end of the lower frame member into a pair of front recesses defined in a corresponding handrail molding, each of the front recesses opening forwardly and downwardly, and securing the ends of the lower front rail to the corresponding handrail molding by a plurality of bolts extending through the ends of the lower front rail into threaded metal inserts located in a forward facing wall of the corresponding handrail molding; Attachment of the lower rear rail includes inserting ends of the lower rear rail into a pair of rear recesses defined in a respective handrail molding, each of the rear recesses opening rearwardly and downwardly, and securing the ends of the lower rear rail into a threaded metal insert located in a rearwardly facing wall of the respective handrail molding, wherein the entire length of the lower rear rail is rearwardly exposed; providing a plurality of decorative portions that are form-fitted with each of the pair of armrest moldings and the backrest frame; and The trim portion is attached to the pair of armrest moldings and the backrest frame, and the low friction polymer surface of the polymer shell wall facilitates pulling of the trim covering material over the armrest moldings.

10. The method according to claim 9, wherein: Attaching the backrest frame includes: An upright backrest frame member is secured to the lower rear rail.

11. The method according to claim 9, wherein: The method further includes mounting the lower front rail to a lower front edge of each polymeric handrail molding, and mounting the lower rear rail to a lower rear edge of each polymeric handrail molding.

12. A method of assembling a sofa with an upholstery, comprising: providing a pair of one-piece, blow-molded polymer handrail moldings, each of said handrail moldings being hollow, said handrail moldings being disposed at a spaced distance relative to each other; The handrail forming part includes a hollow shell, the hollow shell includes a polymer shell wall, the inwardly facing surface of the polymer shell wall defines a void volume, and the polymer shell wall has an outwardly facing low friction polymer surface; Attaching a backrest frame and a seat base, the seat base having a plurality of cross-type wood frame members, each of the cross-type wood frame members having a length greater than the spacing distance, the plurality of cross-type wood frame members including a lower front rail and a lower rear rail, the lower front rail being mounted in a corresponding recess at a lower front edge of each of the polymer armrest moldings, the recess being open forward and downward, and the lower rear rail being mounted in a corresponding recess located on the polymer armrest moldings, being open rearward and downward, at a lower rear edge of each of the polymer armrest moldings; installing a seat platform having a front spring rail and a rear spring rail and one of a metal spring and a textile plate extending fore and aft between the front spring rail and the rear spring rail by securing the front spring rail along its length to the lower front rail and securing the rear spring rail to the lower rear rail via at least two upright backrest frame members extending from a lower edge of the lower rear rail and an inner surface of the rear rail to a top of the backrest; A plurality of trim portions are provided and attached to the pair of armrest moldings and the backrest frame, the low friction polymer surface of the polymer shell wall facilitating the pulling of a trim covering material over the armrest moldings.

13. The method according to claim 12, wherein: The front spring rail and the rear spring rail each have two ends, and the method further includes inserting each of the two ends of the front spring rail and the rear spring rail into a corresponding shape-fitting recess in each of the pair of armrest moldings.

14. The method according to claim 13, further comprising: Each end of the rear spring rail is engaged with a rearwardly facing stop surface on the inner wall portion of a corresponding pair of handrail moldings.

15. The method according to claim 13 or 14, further comprising: Each end of the rear spring rail is engaged with a rearwardly facing stop surface on the inner wall portion of a corresponding pair of handrail moldings.

16. The method according to claim 3, wherein: The method also includes attaching four floor engaging feet to and below each end of the lower front and rear rails.

17. The method of any one of claims 9, 10, 11, 12, 13, 14 or 16, further comprising: A plurality of cushions are added to the seat base, each cushion having a decorative covering selected to match the plurality of decorative portions that are form-fitting with each of the pair of armrest moldings and the backrest frame.

18. The method of any one of claims 9, 10, 11, 12, 13, 14 or 16, wherein: Attaching the trim portion to each of the pair of armrest forming pieces does not include adding padding to each of the armrest forming pieces prior to attaching the trim portion.

19. The method of any one of claims 9, 10, 11, 12, 13, 14 or 16, wherein: The trim portion for each of the pair of armrests is configured as a soft cover, and attaching the trim portion to each of the pair of armrest moldings includes sliding the respective trim portion around and down the armrest molding.

20. The method of any one of claims 9, 10, 11, 12, 13, 14 or 16, further comprising: Each of the pair of armrest moldings is molded by blow molding.

21. The method according to claim 20, further comprising: The blow molding is controlled so that each handrail profile has an average wall thickness of 1.5 mm to 6 mm.

22. The method according to claim 20, further comprising: The blow molding is controlled so that each of the pair of armrest moldings weighs between 8 pounds and 14 pounds.

23. The method of claim 20, further comprising: The blow molding is controlled so that each of the pair of armrest moldings weighs between 9.5 pounds and 12 pounds.

24. The method according to any one of claims 12 to 14, further comprising: A breast plate is attached that extends between and seats into corresponding breast plate recesses in each of the pair of armrest formations.

25. The method according to claim 24, wherein: Each breast plate recess is a groove extending vertically on the inwardly facing surface of the corresponding handrail molding and having an upwardly facing surface, and the method further comprises engaging each of the two ends of the breast plate with the corresponding upwardly facing surface.

26. The method according to claim 25, wherein: Each of the plurality of upright back frame members has a recess defined in part by a downwardly facing surface, and wherein the method further comprises engaging the breast plate with the downwardly facing surface and attaching the breast plate to each of the corresponding upright back frame members.

27. A method of assembling a sofa with an upholstery, comprising: blow molding a pair of one-piece, polymeric handrail moldings, each of said handrail moldings being hollow, and positioning said handrail moldings at a spaced distance relative to each other; The handrail forming part includes a hollow shell, the hollow shell includes a polymer shell wall, the inwardly facing surface of the polymer shell wall defines a void volume, and the polymer shell wall has an outwardly facing low friction polymer surface; Attaching a plurality of cross-type wood frame members between the pair of handrail moldings, each of the plurality of cross-type wood frame members having a length greater than the spacing distance, the attaching comprising: inserting ends of the cross-type wood frame members into recesses defined in corresponding handrail moldings, and fixing the ends to the corresponding handrail moldings; The plurality of cross-type wood frame members include a lower front rail and a lower rear rail, and the method further includes: installing the lower front rail in a corresponding recess at the lower front edge of each polymer handrail molding, the recess opening forward and downward, and installing the lower rear rail in a corresponding recess located on the polymer handrail molding, in a corresponding recess opening backward and downward, at the lower rear edge of each polymer handrail molding, A plurality of trim portions are provided and attached to the pair of armrest moldings and the backrest frame, the low friction polymer surface of the polymer shell wall facilitating the pulling of a trim covering material over the armrest moldings.

28. A method of assembling a sofa with an upholstery, comprising: blow molding a pair of one-piece, polymeric handrail moldings, each of said handrail moldings being hollow, and positioning said handrail moldings a spaced distance relative to each other; The handrail forming part includes a hollow shell, the hollow shell includes a polymer shell wall, the inwardly facing surface of the polymer shell wall defines a void volume, and the polymer shell wall has an outwardly facing low friction polymer surface; Attaching a plurality of cross-type wood frame members between the pair of handrail moldings, each of the plurality of cross-type wood frame members having a length greater than the spacing distance, the attaching comprising: inserting ends of the cross-type wood frame members into recesses defined in corresponding handrail moldings and fixing the ends to the corresponding handrail moldings, each of the recesses opening forward, rearward or upward; wherein the plurality of cross-type wood frame members include a lower front rail and a lower rear rail, and the method further includes: mounting the lower front rail to the lower front edge of each of the polymer handrail moldings, and mounting the lower rear rail to the lower rear edge of each of the polymer handrail moldings, wherein the cross-type frame members include a front spring plate and a rear spring plate, and the method further includes: inserting the ends of the front spring plate and the rear spring plate into the mating recesses in the pair of handrail moldings, A plurality of trim portions are provided and attached to the pair of armrest moldings and the backrest frame, the low friction polymer surface of the polymer shell wall facilitating the pulling of a trim covering material over the armrest moldings.

29. The method according to claim 27 or 28, wherein: The method also includes attaching four floor engaging feet to each end of the lower front rail and lower rear rail and below each end of the lower front rail and lower rear rail, the lower front rail and lower rear rail will act as a beam with its ends supported, and these four floor engaging feet will be positioned below the ends of the lower front rail and lower rear rail, and will transfer loads from the seat through the lower front rail and lower rear rail to the floor through these four floor engaging feet.

30. A method of assembling a sofa with an upholstery, comprising: providing a pair of one-piece, polymeric handrail moldings, each of said handrail moldings being hollow, said handrail moldings being disposed at a spaced distance relative to each other; The handrail forming part includes a hollow shell, the hollow shell includes a polymer shell wall, the inwardly facing surface of the polymer shell wall defines a void volume, and the polymer shell wall has an outwardly facing low friction polymer surface; Attaching a backrest frame and a seat base between corresponding armrest moldings, the backrest frame comprising a plurality of upright backrest frame members and a cross-type frame member, the cross-type frame member being attached to and extending between corresponding polymer armrest moldings, the attachment comprising: inserting ends of the cross-type frame members into recesses defined in corresponding armrest moldings and securing the ends to the corresponding armrest moldings, each of the recesses opening forward, rearward or upward and also being attached to each of the upright backrest frame members; providing a pair of trim sections, each of the trim sections having an outer trim material and an inner padding that matches the shape of each of the pair of armrest moldings; and The trim portion is attached to the pair of armrest moldings without adding additional padding to the armrest moldings, wherein the low friction polymer surface of the polymer shell wall facilitates pulling of a trim covering material over the armrest moldings.

31. The method according to claim 30, wherein: The trim portion for each of the pair of armrests is configured as a soft cover, and attaching the trim portion to each of the pair of armrest moldings includes sliding the corresponding trim portion around and down the corresponding armrest molding.

32. The method of claim 27, 28, 30 or 31 further comprising: Each polymeric handrail profile is blow molded and the blow molding of each polymeric handrail profile is controlled such that each handrail profile has an average wall thickness of 1.5 mm to 6 mm.

33. The method of claim 27, 28, 30 or 31 further comprising: Each polymeric handrail molding is blow molded and the blowing of each polymeric handrail molding is controlled such that each handrail molding weighs between 8 pounds and 14 pounds.

34. The method of claim 27, 28, 30 or 31 further comprising: Each polymeric handrail molding is blow molded and the blowing of each polymeric handrail molding is controlled such that each handrail molding weighs between 9.5 pounds and 12 pounds.

35. The method of claim 27, 28, 30 or 31 further comprising: Each polymer handrail profile was blow molded and polyethylene was selected as the polymer to be blow molded.

36. The method of claim 35, further comprising: Choose high molecular weight polyethylene.

37. The method of claim 35, further comprising: Polyethylene comprising at least 90% regrind polyethylene from recycling drums is used.

38. A method of assembling a sofa with an upholstery, comprising: providing a pair of one-piece, polymeric handrail moldings, each of said handrail moldings being hollow, said handrail moldings being disposed at a spaced distance relative to each other; The handrail forming part includes a hollow shell, the hollow shell includes a polymer shell wall, the inwardly facing surface of the polymer shell wall defines a void volume, and the polymer shell wall has an outwardly facing low friction polymer surface; Attaching a plurality of cross-type wood frame members between the pair of handrail moldings, each of the plurality of cross-type wood frame members having a length greater than the spacing distance, the attaching comprising: inserting ends of the cross-type wood frame members into recesses defined in corresponding handrail moldings, each of the recesses opening forward, rearward or upward; wherein the plurality of cross-type wooden frame members include lower front and rear rails, a chest plate, a front spring plate, and a rear spring plate; and the method further comprises: installing a plurality of upright backrest frame members, the plurality of upright backrest frame members being attached to the lower rear rail, the chest plate, and the rear spring plate, Wherein a plurality of trim portions are provided and attached to the pair of armrest moldings and the backrest frame, the low friction polymer surface of the polymer shell wall facilitates pulling of the trim covering material over the armrest moldings.

39. The method of claim 38, further comprising: The lower front rail is mounted flush with the lower front edge of each of the polymeric handrail moldings, and the lower rear rail is mounted flush with the lower rear edge of each of the polymeric handrail moldings.

40. The method of claim 39, wherein: The method also includes attaching four floor engaging feet to the sofa below each end of the lower front rail and lower rear rail, whereby the lower front rail and lower rear rail will act as a beam with its ends supported, and the four floor engaging feet will be positioned below the ends of the lower front rail and lower rear rail, and the load from the seat passing through the lower front rail and lower rear rail will be transferred to the floor through the four floor engaging feet.

41. The method according to any one of claims 38 or 39, further comprising: providing a pair of trim portions configured as soft covers and form-fitting with each of the pair of armrest moldings; and The decorative portion is attached to the pair of armrest moldings by surrounding the armrest moldings and sliding down along the armrest moldings to the lower edge of the sofa.

42. A sofa with decoration, comprising: a pair of one-piece, polymeric handrail profiles, each of said handrail profiles being hollow and disposed a spaced distance relative to one another; The handrail molding comprises a hollow shell, the hollow shell comprising a polymer shell wall and having an outwardly facing low friction polymer surface, the inwardly facing surface of the polymer shell wall defining a void volume; a backrest frame and a seat base having a plurality of cross-type wood frame members extending between the pair of armrest moldings, each of the cross-type wood frame members having a length greater than the spacing distance, each end of the cross-type wood frame members being positioned into a suitable recess defined in a corresponding armrest molding, each of the recesses opening forward, rearward or upward; a plurality of upright wood back frame members attached to the plurality of cross-type wood frame members and positioned intermediate the pair of polymeric armrest moldings; a pair of decorative parts, the pair of decorative parts are matched with each of the pair of armrest moldings and are respectively attached to each of the pair of armrest moldings, Therein, the low friction polymer surface of the polymer shell wall facilitates pulling of the decorative covering material over the armrest molding.

43. The upholstered sofa of claim 42, wherein: The cross-type wood frame member includes a lower front rail and a lower rear rail, and the lower front rail is installed flush with the lower front edge of each polymer handrail molding, and the lower rear rail is installed flush with the lower rear edge of each polymer handrail molding.

44. The upholstered sofa of claim 42, wherein: The cross-type wooden frame member includes a front spring rail and a rear spring rail, and one of a metal spring and a textile plate extending front and rear between the front spring rail and the rear spring rail, the front spring rail is connected to the pair of armrest moldings and extends between the pair of armrest moldings, the rear spring rail is connected to the pair of armrest moldings and extends between the pair of armrest moldings, and the rear spring rail is connected to each of the plurality of upright wooden backrest frame members.

45. The upholstered sofa of claim 43, wherein: The cross-type wooden frame member includes a front spring rail and a rear spring rail, and one of a metal spring and a textile plate extending front and rear between the front spring rail and the rear spring rail, the front spring rail is connected to the pair of armrest moldings and extends between the pair of armrest moldings, the rear spring rail is connected to the pair of armrest moldings and extends between the pair of armrest moldings, the front spring rail is fixed to the lower front rail along its length, and the rear spring rail is fixed to the lower rear rail along its length through the multiple upright backrest frame members, each of the multiple upright wooden backrest frame members extends from the lower edge of the lower rear rail to the top of the backrest.

46. ​​An upholstered sofa according to any one of claims 42 to 45, wherein: Each of the cross-type wood frame members has an end with an outwardly facing surface, and each end engages the handrail molding in a recess, wherein the recess is partially defined by an inwardly facing surface, which faces the corresponding outwardly facing surface, and wherein each recess is open forwardly, rearwardly or upwardly.

47. The upholstered sofa of any one of claims 42-45 further comprising a breast plate extending between and seated into corresponding breast plate recesses in each of the pair of armrest moldings.

48. The upholstered sofa of claim 47, wherein: Each of the breast plate recesses is a vertically extending slot on an inwardly facing surface that engages each of the two ends of the breast plate.

49. The decorated sofa of claim 48, further comprising a plurality of upright back frame members having a recess defined in part by a downwardly facing surface, and wherein the breast plate engages the downwardly facing surface and is attached to each corresponding upright back frame member.

50. The upholstered sofa according to claim 43 or 45, further comprising: Four floor engaging feet are attached to the sofa, one floor engaging foot being located below each end of the lower front rail and lower rear rail.

51. An upholstered sofa according to any one of claims 42-45, wherein: Each trim portion has a pad located therein before it is installed on the corresponding armrest molding.

52. The upholstered sofa of any one of claims 42-45, excluding the addition of padding to each of the arm moldings prior to attaching the upholstered portion.

53. An upholstered sofa according to any one of claims 42-45, wherein: The decorative portion for each of the pair of armrests is configured as a soft cover, and attaching the decorative portion to each of the pair of armrest moldings includes sliding the corresponding decorative portion around the corresponding armrest molding and down to the lower edge of the sofa.

54. An upholstered sofa according to any one of claims 42-45, wherein: Each of the pair of armrest moldings is molded by blow molding.

55. The upholstered sofa according to any one of claims 42-45, wherein: Each handrail profile has an average wall thickness of 1.5 mm to 6 mm.

56. An upholstered sofa according to any one of claims 42-45, wherein: Each armrest forming piece of the pair of armrest forming pieces weighs between 8 pounds and 14 pounds.

57. An upholstered sofa according to any one of claims 42-45, wherein: Each of the pair of armrest forming pieces weighs between 9.5 pounds and 12 pounds.

58. A seat with decoration, comprising: A seat box, a backrest located behind the seat box and extending upward from the seat box, and two arms located on opposite sides of the seat box and the backrest, wherein the backrest and the seat box include a plurality of cross-type wood frame members and each of the arms includes a blow-molded polymer armrest molding, the armrest molding includes a hollow shell, the hollow shell includes a polymer shell wall, the inwardly facing surface of the polymer shell wall defines a void volume, and the polymer shell wall has an outward low-friction polymer surface, the polymer armrest molding has a plurality of recesses for receiving ends of the cross-type wood frame members, the ends of the cross-type wood frame members are attached to the polymer armrest molding at corresponding said plurality of recesses, each of said plurality of recesses opens forward, rearward or upward; A trim covering the top, sides, front and back of the seat including the arm molding, wherein the trim is attached to the backrest, the low friction polymer surface of the polymer shell wall facilitating pulling of the trim covering material over the arms.

59. The upholstered seat of claim 58, wherein: The backrest consists of molded plastic and the backrest is covered by a covering material.

60. A seat with decoration, comprising: a pair of upholstered armrests, an upholstered seat base having a cushion thereon, an upholstered backrest, the upholstered seat base being positioned between the armrests, the upholstered backrest extending upwardly from the seat base and being positioned between the armrests; wherein each armrest comprises a one-piece molded polymer armrest molding covered with trim, the armrest molding comprising a hollow shell, the hollow shell comprising a polymer shell wall, the polymer shell wall having an outwardly facing low friction polymer surface, the inwardly facing surface of the polymer shell wall defining a void volume, each one-piece molded polymer armrest molding having an underside with an underside surface, an inwardly facing side with an inwardly facing side surface, a front side with a front side surface, and a bottom side with a bottom side surface; wherein the seat base includes a front plurality of cross-type wood frame members extending between and attached to the armrest moldings, wherein the plurality of cross-type wood frame members include a lower front rail having a length, a height and a thickness, the lower front rail also having a bottom surface, a top surface, a front surface and a rear surface, and also having opposite ends with outwardly facing end surfaces, wherein the front rail having a length is attached to each armrest molding at a front rail recess, the front rail recess being open forwardly so that the entire length of the front rail is exposed forwardly on the seat base when the trim does not cover the seat base, wherein a bottom surface of the front rail is flush with a bottom surface of each corresponding armrest molding, and wherein the front surface of the front rail is flush with a front side surface of each armrest molding, Therein, the low friction polymer surface of the polymer shell wall facilitates pulling of the decorative covering material over the armrest.

61. The upholstered seat of claim 60, wherein: Each end of the front rail has an upper corner that is form-fittingly received in a mating corner of a corresponding front rail recess defined by the polymeric armrest molding, wherein the upper corners are visible forwardly when the trim is not covering the seat base.

62. The upholstered seat of claim 58 further comprising a plurality of upright back frame members positioned intermediate said two polymer armrests, each of said upright back frame members being attached to a plurality of said cross-type wood frame members.

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