Support frame for a piece of furniture, mold assembly, and method for manufacturing the same

Abstract

The present invention relates to a support frame for a piece of furniture, such as a bed or sofa, wherein said support frame is manufactured by means of injection molding, and wherein said support frame forms a single piece of material, wherein said support frame comprises an upper surface and a lower surface, wherein the upper surface comprises a plurality of openings in the material, and wherein the support frame comprises a plurality of primary and secondary ribs, and wherein said primary and secondary ribs are formed by hollow material protrusions which extend from the upper surface to the lower surface of the support frame, and in that the primary ribs have a height and / or width that is equal to or greater than the height and / or width of the secondary ribs. Further aspects relate to a mold assembly and method for manufacturing a support frame for a piece of furniture.

Description

[0001] SUPPORT FRAME FOR A PIECE OF FURNITURE, MOLD ASSEMBLY, AND METHOD FOR MANUFACTURING THE SAME

[0002] TECHNICAL FIELD

[0003] The invention relates to a support frame for a piece of furniture, in particular for beds or sofas, as well as to a mold and method for manufacturing the same.

[0004] PRIOR ART

[0005] A support frame for pieces of furniture, such as beds or sofas, must generally satisfy a number of conditions. On the one hand, the support frame must be able to support the load of, for example, a mattress and one or more people, and thus must be sufficiently strong. On the other hand, the support frame should provide sufficient air circulation, whereby the piece of furniture, e.g., the mattress, can be sufficiently ventilated. To satisfy these conditions, the current prior art generally provides for rather complex support frames manufactured from virgin composite materials and / or structures that can be polluting, through the use of non-durable components and / or difficult-to-recycle materials.

[0006] Many of the existing support frames, such as a bed base, are constructed from multiple parts that are fastened to each other, such as metal or wooden beams that are connected with screws or other fasteners. Assembling such a support frame thus requires a certain investment of time and / or knowledge from an installer or end user, on which, moreover, the final quality of the support frame will also largely depend.

[0007] Prior art support frames, in addition to high complexity, also often have a considerable weight. Although heavy support frames are generally stronger, frames constructed from multiple materials, such as wood, metal, or composites, can be heavy and difficult to handle during production, transport, and / or installation. This not only increases the production cost of the support frame itself but can moreover lead to inefficiencies in the supply chain and / or installation.

[0008] Although these complex constructions thus often have good strength properties, they can be susceptible to wear at the connection points, which can lead to loosening of components and / or reduced structural integrity over time. The different materials can moreover be susceptible to wear due to, for example, moisture, such as rotting or corrosion, or under the influence of other environmental factors, which negatively affect the service life of the product.

[0009] More recently, in the field of support frames for furniture, such as beds or sofas, a trend towards circular materials has been seen, which can be understood to include the use of more recyclable or recycled materials. For example, US 2013 / 0025051 describes a support frame for a mattress, which support frame is manufactured from polyvinyl chloride (PVC). The support frame described herein, however, exhibits the same complexity as other support frames from the prior art, i.e., it is constructed from a large number of separate elements. This support frame therefore remains subject to the various disadvantages as described.

[0010] The invention aims to provide a solution to one or more of the aforementioned problems. In particular, the invention aims to find a balance between strength and force distribution on the one hand, and a light weight and good ventilation on the other hand. More particularly, the invention aims to provide a support frame that is well-suited for use in a circular economy.

[0011] SUMMARY OF THE INVENTION

[0012] In a first aspect, the invention relates to a support frame for a piece of furniture according to claim 1.

[0013] The support frame according to the invention is manufactured by means of injection molding and formed in one piece of material, which has the advantage that the support frame is particularly strong. In particular, the support frame forms a seamless whole without potential weak points at connection seams. This increases the structural integrity and durability of the support frame. Manufacturing the support frame by means of injection molding also allows for the use of lightweight plastic materials, which considerably reduces the weight of the support frame compared to commonly used materials, such as wood or metal. Injection molding, moreover, lends itself to the use of recycled and / or recyclable plastic materials, with a view to a more circular economy. In this context, use can be made of post-consumer plastic materials, possibly for more than 90%, for more than 95%, or even for 100% of said plastic materials.

[0014] The primary and secondary ribs with their height and / or width ratios as described herein moreover provide for good force distribution and stability of the support frame and allow a support frame with a low weight to be obtained. Openings on the upper surface, moreover, allow for ventilation of the supported piece of furniture.

[0015] Preferred embodiments of the support frame are presented in dependent claims 1-16. The various embodiments of the support frame provide a balance between strength and force distribution on the one hand, and a light weight and good ventilation on the other hand.

[0016] In a second aspect, the invention relates to a mold suitable for manufacturing a support frame for a piece of furniture according to claim 17.

[0017] A preferred embodiment of the mold is presented in dependent claim 18.

[0018] In a third aspect, the invention relates to a method for manufacturing a support frame for a piece of furniture according to claim 19.

[0019] Preferred embodiments of the method are presented in dependent claims 20 and 21.

[0020] DESCRIPTION OF THE FIGURES

[0021] Figure 1 shows a three-dimensional view of a support frame according to an embodiment of the present invention, as seen from below.

[0022] Figure 2 shows a three-dimensional view of a support frame according to an embodiment of the present invention, as seen from the top.

[0023] Figure 3 shows a bottom view of a support frame according to an embodiment of the present invention.

[0024] Figure 4 shows a top view of a support frame according to an embodiment of the present invention.

[0025] DETAILED DESCRIPTION

[0026] The invention relates to a support frame for a piece of furniture.

[0027] Unless otherwise defined, all terms used in the description of the invention, including technical and scientific terms, have the meanings as commonly understood by a person skilled in the art to which the invention pertains. For a better understanding of the description of the invention, the following terms are explicitly explained.

[0028] In this document, "a" and "the" refer to both the singular and the plural, unless the context presupposes otherwise. For example, "a segment" means one or more segments.

[0029] The terms "comprise," "comprising," "consist of," "consisting of," "provided with," "have," "having," "include," "including," "contain," "containing" are synonyms and are inclusive or open terms that indicate the presence of what follows, and which do not exclude or prevent the presence of other components, characteristics, elements, members, steps, as known from or disclosed in the prior art.

[0030] Quoting numerical ranges by endpoints includes all integers, fractions and / or real numbers between the endpoints, these endpoints included.

[0031] A first aspect of the present invention relates to a support frame for a piece of furniture, such as a bed or sofa. Said support frame is manufactured by means of injection molding and forms a material in one piece. The support frame comprises an upper surface and a lower surface, wherein the upper surface comprises a plurality of openings in the material, and wherein the support frame comprises a plurality of primary and secondary ribs. In particular, these primary and secondary ribs are formed by hollow material protrusions which extend from the upper surface to the lower surface of the support frame. The primary ribs preferably have a height and / or width that is equal to, or greater than, the height and / or width of the secondary ribs.

[0032] In the context of the present invention, the term "support frame" should be interpreted as a structural element that is designed to bear the load of a piece of furniture, such as a bed or sofa, wherein the frame provides support to the overlying material, such as a mattress or seat, and provides stability to the whole assembly.

[0033] In the context of the present invention, the term "piece of furniture" is understood to mean an object that is used in a domestic, commercial, or industrial environment to support human activities such as sitting, lying down, or working, including, but not limited to, beds, sofas, couches, and chairs.

[0034] In the context of the present invention, the term "injection molding" should be understood as a production process in which a liquid material, such as plastic, is injected into a mold, after which the material cools and hardens to form a molded part that corresponds to the cavity of the mold.

[0035] In the context of the present invention, the term "ribs" should be interpreted as, preferably linear, structural elements that are integrated into the support frame and serve to improve the strength, stability, and weight distribution of the frame, wherein the ribs can be arranged in primary and secondary patterns.

[0036] In the context of the present invention, the term "material protrusion" is understood as an extension of the base material of the support frame, wherein this material protrusion forms a hollow structure that extends between two surfaces, such as the upper surface and the lower surface of the support frame.

[0037] In the context of the present invention, the term "height of the rib" should be interpreted as the distance between the lower surface of the support frame and the opposite upper end of the rib.

[0038] In the context of the present invention, the term "width of the rib" is defined as the maximum horizontal distance between the sides of the rib, measured perpendicular to the longitudinal axis of the rib.

[0039] A support frame manufactured by means of injection molding and formed in one piece of material has the advantage that the support frame is particularly strong. In particular, the support frame forms a seamless whole without potential weak points at connection seams. This increases the structural integrity and durability of the support frame. Manufacturing the support frame by means of injection molding also allows for the use of lightweight plastic materials, which considerably reduces the weight of the support frame compared to commonly used materials, such as wood or metal. Injection molding, moreover, lends itself to the use of recycled and / or recyclable plastic materials. In this context, use can be made of post-consumer plastic materials, possibly for more than 90%, for more than 95%, or even for 100% of said plastic materials.

[0040] The primary and secondary ribs with their height and / or width ratios as described herein moreover provide for good force distribution and stability of the support frame and allow a support frame with a low weight to be obtained. Openings on the upper surface, moreover, allow for ventilation of the supported piece of furniture.

[0041] Preferably, said primary ribs form a primary grid pattern of cells. In the context of the present invention, the term "grid pattern" should be interpreted as a geometric distribution of lines or structures that intersect to form a network of polygonal, preferably rectangular, or square, segments.

[0042] In the context of the present invention, the term "cells" is understood as the individual segments or compartments that are formed by the grid pattern of the ribs, wherein each cell forms an enclosed area that contributes to the distribution of ferees and stability of the support frame.

[0043] The primary ribs form a primary grid pattern of cells, which has the advantage of an efficient force distribution over the support frame. This provides stable support for the piece of furniture and prevents deflection or deformation under load.

[0044] According to some embodiments, the primary and / or secondary ribs can be straight. According to some embodiments, the primary and / or secondary ribs can be curved.

[0045] More preferably, the primary ribs are orthogonally arranged and form a primary grid pattern of rectangular cells.

[0046] In the context of the present invention, the term "orthogonal arrangement" should be interpreted as an arrangement in which the ribs or other structural elements intersect at an angle of 90 degrees, such that a pattern of right angles is formed.

[0047] The use of a primary grid pattern of rectangular cells is particularly advantageous because it can provide improved stiffness and strength to the support frame, in particular in the orthogonal direction. This makes the support frame particularly suitable for pieces of furniture where the forces are unevenly distributed, such as in beds or sofas with an elongated shape.

[0048] Even more preferably, the primary ribs form a primary grid pattern of square cells.

[0049] This has the advantage that the forces are distributed even more uniformly, while the design remains simple. This contributes to the stability and consistency of the support and is particularly suitable for supporting pieces of furniture with a rectangular or square underside. According to some embodiments, the primary ribs form a primary grid pattern of triangular, quadrangular, pentagonal, hexagonal, heptagonal, or octagonal cells. According to a particular embodiment, the primary ribs form a primary grid pattern in a so-called honeycomb structure, which provides a particularly good weight distribution for the support frame.

[0050] According to some embodiments, the primary ribs form a primary grid pattern of cells which are at least partially filleted.

[0051] In the context of the present invention, the term "filleted," in particular a cell which is filleted, should be interpreted as a cell wherein the inner edges of an originally polygonal cell shape are rounded, so that the cell takes on a more fluid shape, such as an oval or circular structure. This further increases the structural integrity and improves the force distribution within the cell.

[0052] According to a further or other embodiment, the primary ribs form a primary grid pattern of oval-shaped or circular cells. Preferably, the primary ribs form a primary grid pattern of circular cells.

[0053] According to a further or other embodiment, said secondary ribs form a secondary grid pattern of cells. The secondary grid pattern provides additional support to the primary grid pattern and makes it possible to obtain a support frame with a lower weight.

[0054] Preferably, the secondary ribs are orthogonally arranged and form a secondary grid pattern of rectangular cells. This is particularly advantageous because it provides extra strength in certain directions, in particular in the orthogonal direction.

[0055] More preferably, the secondary ribs form a secondary grid pattern of square cells. A secondary grid pattern of square cells is optimally suited for supporting pieces of furniture with a rectangular or square underside.

[0056] According to some embodiments, the secondary ribs form a secondary grid pattern of triangular, quadrangular, pentagonal, hexagonal, heptagonal, or octagonal cells. According to a particular embodiment, the secondary ribs form a secondary grid pattern in a so-called honeycomb structure, which provides a particularly good weight distribution for the support frame. According to some embodiments, the secondary ribs form a secondary grid pattern of cells which are at least partially filleted.

[0057] According to a further or other embodiment, the secondary ribs form a secondary grid pattern of oval-shaped or circular cells. Preferably, the secondary ribs form a primary grid pattern of circular cells.

[0058] According to a further or other embodiment, said primary ribs form a primary grid pattern of cells and said secondary ribs form a secondary grid pattern of cells, wherein said cells of the primary grid pattern each enclose at least two cells of the secondary grid pattern. The height and / or width ratio between the primary and secondary ribs, in particular combined with the configuration of cells of the primary and secondary grid pattern as described herein, allows a good strength and weight distribution of the support frame to be obtained, whereby the weight of the support frame can be kept low. In particular, the support frame is resistant to high loads without deforming significantly. The combination of the primary and secondary grid pattern as described herein thus allows for a good balance between strength and weight distribution on the one hand, and a low weight on the other hand.

[0059] According to some embodiments, said cells of the primary grid pattern enclose at least three cells of the secondary grid pattern. According to some embodiments, the cells of the primary grid pattern enclose at least four, five, six, seven, or even eight cells of the secondary grid pattern. An increasing number of cells of the secondary grid pattern within a cell of the primary grid pattern succeeds in further reducing the weight of the support frame.

[0060] According to a preferred embodiment, said primary ribs are orthogonally arranged and form a primary grid pattern of square cells, and said secondary ribs are orthogonally arranged and form a secondary grid pattern of square cells, wherein said cells of the primary grid pattern each enclose at least four cells of the secondary grid pattern. The support frame as described herein achieves a further improved balance between strength and weight distribution on the one hand, and a low weight on the other hand.

[0061] Arranging the primary ribs and secondary ribs orthogonally in square cells has the advantage of yielding a simple, symmetrical structure, which provides for an efficient distribution of forces over the entire frame. This minimizes deformation and further improves the structural stability. Moreover, this configuration is particularly suitable for supporting pieces of furniture with a rectangular and / or square underside. According to a further or another embodiment, the cells of the secondary grid pattern each enclose at least two openings of the upper surface. The openings allow for ventilation of the supported piece of furniture, i.e., through improved air circulation through the support frame, without adversely affecting its strength or weight distribution.

[0062] Preferably, the cells of the secondary grid pattern each enclose at least three openings of the upper surface. More preferably, the cells of the secondary grid pattern each enclose at least four, five, six, seven, or even eight openings of the upper surface. An increasing number of openings in each cell of the secondary grid pattern further improves the air circulation through the support frame, and thus also the ventilation of the supported piece of furniture. Moreover, the weight of the support frame is in turn lowered, without compromising its structural strength.

[0063] According to a further or other embodiment, the height of the primary ribs and the height of the secondary ribs are related in a ratio between 4:3 and 4: 1. Within this range, it has been found that the support frame has sufficient strength, while having a lightweight construction. Moreover, the ratio described herein between the height of the primary and secondary ribs may be conducive to the air circulation through the openings of the upper surface.

[0064] Preferably, the height of the primary ribs and the height of the secondary ribs should be in a ratio between 3:2 and 3: 1. The ratio described herein between the height of the primary and secondary ribs further contributes to an improved balance between strength and light weight of the support frame.

[0065] According to a further or another embodiment, the width of the primary ribs and the width of the secondary ribs have a ratio comprised between 3:3 and 3: 1. Within this range, it has been found that the support frame has sufficient strength, while having a lightweight construction. Moreover, the ratio described herein between the width of the primary and secondary ribs may be conducive to the air circulation through the openings of the upper surface.

[0066] According to some embodiments, the height of the primary ribs and the height of the secondary ribs have a ratio comprised between 4:3 and 4: 1, and the width of the primary ribs and the width of the secondary ribs have a ratio comprised between 3:3 and 3: 1. Advantages such as strength, weight distribution, light weight, and air circulation are thereby even better balanced.

[0067] According to a further or another embodiment, said primary and secondary ribs are respectively formed by hollow material protrusions with a primary material thickness comprised between 6 and 12 mm, and a secondary material thickness comprised between 3 and 6 mm.

[0068] In the context of the present invention, the term "material thickness of the ribs" is to be interpreted as the thickness of the material from which the ribs are formed, measured perpendicular to a surface of the ribs.

[0069] The range of material thicknesses of the primary and secondary ribs as described herein provides a very good balance between strength and light weight of the support frame.

[0070] Preferably, said primary and secondary ribs are respectively formed by hollow material protrusions with a primary material thickness comprised between 8 and 12 mm, and a secondary material thickness comprised between 4 and 6 mm.

[0071] According to a further or another embodiment, said primary and / or secondary ribs are oriented at a grid angle comprised between 30 and 60° with respect to a longitudinal direction of the support frame.

[0072] In the context of the present invention, the term "longitudinal direction" is to be interpreted as the longest dimension or axis of the support frame, which extends between two opposite sides or ends of the frame. In the context of the present invention, the term "grid angle" is to be interpreted as the angle that the ribs of the grid pattern form with the longitudinal direction of the support frame.

[0073] By positioning the primary and / or secondary ribs at a grid angle as described herein, the strength of the support frame, in particular for supporting pieces of furniture with a rectangular or square underside, can be further improved.

[0074] Preferably, said primary and / or secondary ribs are oriented at a grid angle comprised between 40 and 50° with respect to a longitudinal direction of the support frame. Even more preferably, said primary and / or secondary ribs are oriented at a grid angle of 45° with respect to a longitudinal direction of the support frame. Even more preferably, said primary and secondary ribs are oriented at a grid angle comprised between 30 and 60° with respect to a longitudinal direction of the support frame, still more preferably between 40 and 50°, most preferably 45°.

[0075] According to a further or another embodiment, adjacent openings are positioned with a spacing comprised between 30 and 60 mm with respect to each other.

[0076] In the context of the present invention, the term "spacing (between the openings)" is to be interpreted as the distance measured between the edges of adjacent openings in the upper surface of the support frame.

[0077] The spacing as described herein ensures good air circulation through the support frame, and thus good ventilation of the supported piece of furniture. However, the material present across the spacing contributes to the good strength of the support frame as a whole and contributes to the good support of the supported piece of furniture, since the material across the various spacings forms a substantial portion of the upper surface of the support frame.

[0078] Preferably, adjacent openings are positioned with a spacing between 40 and 50 mm from each other.

[0079] According to a further or another embodiment, said openings have a maximum diameter comprised between 3 and 15 cm, preferably comprised between 4 and 12 cm, more preferably comprised between 5 and 10 cm. Within the range described herein, the openings provide a balance between a good strength and weight distribution of the support frame, as well as good ventilation.

[0080] The various embodiments as described herein allow a good balance to be obtained between strength, weight distribution, and ventilation of the support frame. The support frame is extremely suitable for the stand-alone support of a mattress and / or functions as an ideal base for supporting a superstructure, in particular a fixed superstructure. According to some embodiments, such a fixed superstructure comprises a plurality of Bonnell springs, a plurality of pocket springs, or a combination thereof.

[0081] In the context of the present invention, the term "superstructure" is to be interpreted as the entirety of layers and materials that are located on top of the support frame, in the case of, for example, a box spring. The superstructure is in this case responsible for the direct comfort and support provided to the user, while the support frame provides the structural base. In the context of the present invention, the term "Bonnell springs" is to be interpreted as a spring system wherein the springs are manufactured in an hourglass shape and are connected to each other by a wire structure. This type of spring system provides uniform support because the springs react to pressure as a single unit but offers less individual pressure distribution and adaptation to specific pressure points.

[0082] Within the framework of the present invention, the term "pocket springs" is understood as a spring system wherein each spring is individually packaged in an individual fabric bag (pocket), whereby the springs can move independently of each other. This provides for personalized support, wherein the springs follow specific pressure points, and minimizes motion transfer between different parts of the piece of furniture.

[0083] According to a further or another embodiment, the upper surface has a material thickness comprised between 3 and 12 mm.

[0084] In the context of the present invention, the term "material thickness of the upper surface" is to be interpreted as the thickness of the material from which the upper surface of the support frame is formed, measured perpendicular to the upper surface.

[0085] Preferably, the upper surface has a material thickness comprised between 6 and 10 mm, even more preferably, comprised between 6 and 8 mm.

[0086] According to a further or another embodiment, the support frame comprises at least one side surface that extends between opposite edges of the lower surface and the upper surface, wherein said side surface is at least partially provided with reinforcement zones.

[0087] In the context of the present invention, the term "reinforcement zones" is to be interpreted as specific areas of the support frame that are provided with extra material thickness, ribs, or other structural elements to increase the strength and stiffness of the frame.

[0088] These reinforcement zones are provided to offer extra resistance against load, deformation, or forces that are exerted on the support frame. Preferably, the support frame comprises at least two opposite side surfaces, which extend between opposite edges of the lower surface and the upper surface, wherein said side surfaces are at least partially provided with reinforcement zones.

[0089] More preferably, the support frame is beam-shaped, wherein the support frame comprises four side surfaces that each extend between the opposite edges of the lower surface and the upper surface, and wherein said side surfaces are at least partially provided with reinforcement zones. Even more preferably, said side surfaces are provided with reinforcement zones for at least three-quarters of their length.

[0090] According to a further or another embodiment, the support frame comprises three or more leg connection zones.

[0091] In the context of the present invention, the term "leg connection zones" is to be interpreted as specific areas on the lower surface of the support frame that are designed and / or reinforced for the attachment of legs. These zones may be provided with structural elements such as thickenings, screw inserts, or hollow recesses to ensure a firm and durable connection with the legs of the piece of furniture.

[0092] Preferably, said leg connection zones are positioned at the lower surface. More preferably, the upper surface of the support frame is provided with at least three reinforcement zones opposite each of the three leg connection zones of the lower surface.

[0093] According to a further or another embodiment, the support frame is beam-shaped, wherein the lower surface has four corners, and wherein the support frame comprises four leg connection zones which are positioned at said four corners. Preferably, the upper surface of the support frame is provided with four reinforcement zones opposite each of the four leg connection zones of the lower surface.

[0094] According to some embodiments, it is however possible that one or more leg connection zones are provided at locations other than the four corners of the lower surface of a beam-shaped support frame. Thus, additional leg connection zones can be present along one or more sides of the lower surface, preferably substantially in the middle of a side, between two corners. According to a further or another embodiment, the support frame comprises at least one frame connection zone. The frame connection zones are suitable for connecting two or more support frames to each other, in particular next to each other.

[0095] In the context of the present invention, the term "frame connection zones" is to be interpreted as specific areas on the support frame that are designed and reinforced to couple multiple support frames laterally to each other.

[0096] According to some embodiments, these zones are provided with fastening means, such as slots or hollow recesses. In these slots or hollow recesses, inserts can be clamped, snap-fitted, or combinations thereof, which inserts provide a firm connection between adjacent frames, whereby a larger structural unit is formed. According to some embodiments, said frame connection zones allow for two or more support frames to be connected in their width direction. According to some embodiments, said frame connection zones allow for two or more support frames to be connected in their longitudinal direction.

[0097] Preferably, said frame connection zone is positioned at the lower surface. More preferably, the upper surface of the support frame is provided with at least one reinforcement zone opposite the frame connection zone.

[0098] According to a further or another embodiment, the support frame is beam-shaped, wherein the lower surface has four sides, and wherein the support frame comprises at least two frame connection zones which are positioned at two opposite sides of said four sides. Preferably, the support frame comprises four frame connection zones which are positioned at two opposite sides of said four sides of the lower surface. More preferably, the support frame comprises six frame connection zones which are positioned at two opposite sides of said four sides of the lower surface. Most preferably, said frame connection zones are positioned at two opposite long sides of said four sides of the lower surface.

[0099] In the context of the present invention, the term long sides' is to be interpreted as the two opposite sides of a rectangular support frame, the length of which is greater than that of the other two opposite sides (the "short sides"). The long sides form the greatest distance between the corners of the rectangular frame and determine the longitudinal axis of the support frame. According to some embodiments, frame connection zones are provided on all sides of the lower surface.

[0100] According to a further or another embodiment, the support frame comprises at least four textile connection zones.

[0101] In the context of the present invention, the term "textile connection zones" is to be interpreted as specific areas on the support frame that are designed for the attachment or tensioning of textiles, such as fabric or upholstery, as is customary for a box spring. These zones can be provided with fastening means such as slots, hooks, or clamping systems, which ensure that the textile is fastened tightly and firmly to the frame, or can be suitable for receiving staples with which the textile is fastened to the frame.

[0102] According to a further or another embodiment, the support frame is beam-shaped, wherein the lower surface has four sides, and wherein the support frame comprises at least four textile connection zones which are positioned at said four sides of the lower surface.

[0103] According to a further or another embodiment, the textile connection zone comprises a slot which is arranged along the edges of the lower surface, and which allows textile to be clamped, for example via a clamping system in said slot.

[0104] According to some embodiments, the support frame is upholstered with textiles without a superstructure. According to some embodiments, the support frame is covered with a superstructure.

[0105] According to some embodiments, the support frame has a length of 140 mm, 160 mm, 180 mm, 190 mm, 200 mm, 210 mm, or 220 mm. According to some embodiments, the support frame has a width of 70 mm, 80 mm, 90 mm, or 100 mm. Preferably, the support frame has a width of 70 mm and a length of 190 mm or 200 mm. Further preferably, the support frame has a width of 80 mm and a length of 190 mm, 200 mm, 210 mm, or 220 mm. Further preferably, the support frame has a width of 90 mm and a length of 190 mm, 200 mm, 210 mm, or 220 mm. Further preferably, the support frame has a width of 100 mm and a length of 140 mm, 160 mm, 180 mm, 200 mm, 210 mm, or 220 mm.

[0106] According to some embodiments, larger dimensions can be obtained by means of connecting two or more support frames together by means of connecting the respective frame connection zones. For example, connecting two support frames with a width of 100 mm and a length of 210 mm can thus form a total size with a width of 200 mm and a length of 210 mm.

[0107] It is noted that the support frame as described in any of the preceding embodiments can also serve as a headboard, in particular when the support frame is used in a bed. In such a case, a larger-sized support frame can serve as a lying surface, and a smaller- sized support frame can serve as a headboard. Both support frames can be coupled to each other by means of headboard connection zones provided for that purpose. In particular, a support frame with a width of 100 mm and a length of 140 mm, 160 mm, 180 mm, 200 mm, or 220 mm is best suited for use as a headboard.

[0108] According to some embodiments, the support frame comprises at least two headboard connection zones which are each shaped to fasten a bracket therein. The bracket allows the support frame serving as a headboard to be coupled to an end of the support frame serving as a lying surface. In particular, according to some embodiments, said headboard connection zones are configured as slots or recesses, in which said bracket can be fastened, preferably slid, clamped, clicked, or combinations thereof. According to some embodiments, said headboard connection zones are located at at least one short side of the lower surface. According to some embodiments, said headboard connection zones are located at the two short sides of the lower surface.

[0109] According to a further or alternative embodiment, the support frame comprises at least two lying surface connection zones each configured to connect a bracket. In particular, according to some embodiments, said lying surface connection zones comprise one or more screw points.

[0110] As described herein, according to some embodiments, said headboard connection zones and lying surface connection zones of the support frame are thus configured for connecting a support frame serving as a lying surface by means of its headboard connection zones to a support frame serving as a headboard by means of its lying surface connection zones, using said bracket.

[0111] The various embodiments as described herein allow a support frame serving as a headboard to be coupled to a support frame serving as a lying surface at different height positions, and a distinction can also be made between a standing or a floating connection. According to a further or another embodiment, said support frame is configured for improved stacking of a plurality of support frames on top of each other. According to some embodiments, the support frame comprises one or more protrusions for this purpose.

[0112] According to some embodiments, the support frame is manufactured from a plastic material.

[0113] According to some embodiments, the plastic material is a homopolymer.

[0114] In the context of the present invention, a "homopolymer" is defined as a polymer that is composed of repeating units of only one type of monomer. This means that all monomers in the polymer chain are identical.

[0115] Preferably, the plastic material is a homopolymer selected from the group consisting of polypropylene (PP), polyethylene (PE), polyamide (PA), polyethylene terephthalate (PET), polylactide (PLA), polyvinyl chloride (PVC), or combinations thereof. According to some embodiments, polyethylene (PE) comprises high-density polyethylene (HDPE) or low-density polyethylene (LDPE). More preferably, the plastic material is polypropylene (PP).

[0116] According to a further or another embodiment, the plastic material is a copolymer. According to some embodiments, the plastic material is a block copolymer or a random copolymer.

[0117] In the context of the present invention, the term "copolymer" should be understood as a polymer that is composed of at least two different types of monomers, which are polymerized together. The monomers can be arranged in different sequences or segments in the polymer chain. The specific arrangement of the monomers can vary. For example, the monomers can occur in blocks, which is referred to as a "block copolymer", or as alternating units, or be arranged in a random order, which is referred to by the term "random copolymer".

[0118] Preferably, the plastic material is a copolymer selected from the group consisting of polypropylene (PP) copolymers, polyethylene (PE) copolymers, polyamide (PA) copolymers, polyethylene terephthalate (PET) copolymers, polylactide (PLA) copolymers, polyvinyl chloride (PVC) copolymers, acrylonitrile butadiene styrene (ABS), or combinations thereof. More preferably, the plastic material is a polypropyleneethylene copolymer. Even more preferably, the plastic material is a polypropyleneethylene block copolymer or random copolymer.

[0119] According to some embodiments, the plastic material comprises no fillers. Preferably, the plastic material is polypropylene (PP) without fillers.

[0120] According to a further or another embodiment, the plastic material comprises one or more fillers, such as mineral fillers.

[0121] Preferably, the plastic material comprises between 5 and 50 percent by weight (wt.%) of fillers. More preferably, the plastic material comprises between 5 and 10 percent by weight (wt.%) of fillers, between 10 and 20 percent by weight (wt.%) of fillers, between 20 and 30 percent by weight (wt.%) of fillers, between 30 and 40 percent by weight (wt.%) of fillers, or between 40 and 50 percent by weight (wt.%) of fillers.

[0122] According to some embodiments, said filler is talc. According to some embodiments, the plastic material comprises between 5 and 20 percent by weight (wt.%) of talc. Preferably, the plastic material is a polypropylene (PP) copolymer comprising between 5 and 20 percent by weight (wt.%) of talc, more preferably between 15 and 20 percent by weight (wt.%) of talc.

[0123] According to some other embodiments, said filler is glass fiber. According to some embodiments, the plastic material comprises between 5 and 20 percent by weight (wt.%) of glass fiber. Preferably, the plastic material is polypropylene (PP) comprising between 5 and 20 percent by weight (wt.%) of glass fiber, more preferably between 15 and 20 percent by weight (wt.%) of glass fiber.

[0124] The various embodiments of said support frame allow the frame to be optimally suited for circular use. In particular, this implies that the support frame is suitable for complete take-back, whereby the support frame can be reused in its entirety as a raw material.

[0125] A further advantage from an environmental standpoint is that the various embodiments of the support frame make it possible for the overall height of the support frame and any superstructure to be lower than existing products, thereby allowing more products to be transported. This therefore leads to a reduced ecological footprint.

[0126] A second aspect of the present invention relates to a mold assembly for manufacturing a support frame for pieces of furniture, wherein the mold assembly comprises an internal cavity for forming said support frame, wherein this mold assembly comprises at least one central mold, two axial molds, and two transverse molds, and wherein said support frame comprises an upper surface and a lower surface, wherein the upper surface comprises a plurality of openings in the material, and wherein the support frame comprises a plurality of primary and secondary ribs, wherein said primary and secondary ribs are formed by hollow material protrusions which extend from the upper surface to the lower surface of the support frame, and wherein the primary ribs have a height and / or width that is equal to, or greater than, the height and / or width of the secondary ribs.

[0127] The construction of the mold assembly as described herein allows a variety of support frames to be manufactured, in particular a wide variety of sizes, by means of a combination of different sizes of the axial molds and the transverse molds with the central mold. According to some embodiments, the mold assembly as a whole forms the negative image of the support frame to be manufactured.

[0128] According to some embodiments, the two transverse molds comprise an internal cavity for forming the short sides of the support frame. According to some embodiments, the central mold comprises an internal cavity for forming a central portion of the support frame. According to some embodiments, the two axial molds comprise an internal cavity for forming the long sides of the support frame. According to some embodiments, the transverse molds comprise an internal cavity for forming the short sides of the support frame.

[0129] According to a further or another embodiment, each of the axial molds has a length which is equal to the length of the central mold. According to a further or another embodiment, each of the transverse molds has a width which is equal to the sum of the width of the central mold and the width of two adjacent axial molds.

[0130] Molds as described herein preferably comprise two mold halves, which allow the mold to be opened and closed.

[0131] According to a further or another embodiment of the mold assembly according to the second aspect of the present invention, the support frame is a support frame according to the embodiments from the first aspect.

[0132] A third aspect of the present invention relates to a method for manufacturing a support frame for a piece of furniture, comprising the steps of: providing a mold or the mold assembly, wherein the mold or the mold assembly comprises an internal cavity for forming a support frame, injecting a plastic material into the internal cavity of the mold or the mold assembly, forming the support frame from the plastic material in the internal cavity of the mold or the mold assembly, cooling the formed support frame, and removing the formed support frame from the internal cavity of the mold or the mold assembly, wherein said support frame comprises an upper surface and a lower surface, wherein the upper surface comprises a plurality of openings in the material, and wherein the support frame comprises a plurality of primary and secondary ribs, characterized in that said primary and secondary ribs are formed by hollow material protrusions which extend from the upper surface to the lower surface of the support frame, and that the primary ribs have a height and / or width that is equal to, or greater than, the height and / or width of the secondary ribs.

[0133] Preferably, the step of injecting the plastic material into the internal cavity of the mold or the mold assembly comprises prior melting of the plastic material and injecting the plastic material under high pressure into the internal cavity of the mold or the mold assembly.

[0134] More preferably, the step of forming the support frame from the plastic material in the internal cavity of the mold or the mold assembly comprises maintaining said high pressure, whereby the plastic material is compressed.

[0135] According to some embodiments, the plastic material is a homopolymer.

[0136] Preferably, the plastic material is a homopolymer selected from the group consisting of polypropylene (PP), polyethylene (PE), polyamide (PA), polyethylene terephthalate (PET), polylactide (PLA), polyvinyl chloride (PVC), or combinations thereof. According to some embodiments, polyethylene (PE) comprises high-density polyethylene (HDPE) or low-density polyethylene (LDPE). More preferably, the plastic material is polypropylene (PP).

[0137] According to a further or another embodiment, the plastic material is a copolymer. According to some embodiments, the plastic material is a block copolymer or a random copolymer. Preferably, the plastic material is a copolymer selected from the group consisting of polypropylene (PP) copolymers, polyethylene (PE) copolymers, polyamide (PA) copolymers, polyethylene terephthalate (PET) copolymers, polylactide (PLA) copolymers, polyvinyl chloride (PVC) copolymers, acrylonitrile butadiene styrene (ABS), or combinations thereof. More preferably, the plastic material is a polypropyleneethylene copolymer. Even more preferably, the plastic material is a polypropyleneethylene block copolymer or random copolymer.

[0138] According to some embodiments, the plastic material comprises no fillers. Preferably, the plastic material is polypropylene (PP) without fillers.

[0139] According to a further or another embodiment, the plastic material comprises one or more fillers, such as mineral fillers.

[0140] Preferably, the plastic material comprises between 5 and 50 percent by weight (wt.%) of fillers. More preferably, the plastic material comprises between 5 and 10 percent by weight (wt.%) of fillers, between 10 and 20 percent by weight (wt.%) of fillers, between 20 and 30 percent by weight (wt.%) of fillers, between 30 and 40 percent by weight (wt.%) of fillers, or between 40 and 50 percent by weight (wt.%) of fillers.

[0141] According to some embodiments, said filler is talc. According to some embodiments, the plastic material comprises between 5 and 20 percent by weight (wt.%) of talc. Preferably, the plastic material is a polypropylene (PP) copolymer comprising between 5 and 20 percent by weight (wt.%) of talc, more preferably between 15 and 20 percent by weight (wt.%) of talc.

[0142] According to some other embodiments, said filler is glass fiber. According to some embodiments, the plastic material comprises between 5 and 20 percent by weight (wt.%) of glass fiber. Preferably, the plastic material is polypropylene (PP) comprising between 5 and 20 percent by weight (wt.%) of glass fiber, more preferably between 15 and 20 percent by weight (wt.%) of glass fiber.

[0143] According to a further or another embodiment of the method according to the third aspect of the present invention, the obtained support frame is a support frame according to the embodiments from the first aspect. According to a further or another embodiment of the method according to the third aspect of the present invention, the support frame is formed by means of a mold assembly according to embodiments from the second aspect.

[0144] According to an alternative embodiment of the method according to the third aspect of the present invention, the support frame is formed by means of a mold, in particular a mold comprising two mold halves, each of these mold halves being formed from a single piece.

[0145] A further aspect of the invention relates to a mold, in particular a mold comprising two mold halves, each of these mold halves being formed from a single piece, for manufacturing a support frame for pieces of furniture, wherein said support frame comprises an upper surface and a lower surface, wherein the upper surface comprises a plurality of openings in the material, and wherein the support frame comprises a plurality of primary and secondary ribs, wherein said primary and secondary ribs are formed by hollow material protrusions which extend from the upper surface to the lower surface of the support frame, and wherein the primary ribs have a height and / or width that is equal to, or greater than, the height and / or width of the secondary ribs.

[0146] A further aspect of the invention relates to an insert suitable for connecting two or more support frames according to the first aspect by means of their respective frame connection zones. Preferably, said insert comprises two protrusions which are complementary to slots or recesses of said frame connection zones of the support frames. The two said protrusions are connected to each other by means of a bridge connection. Said protrusions are preferably configured for clamping, clicking, or combinations thereof into said slots or recesses of said support frames.

[0147] Yet a further aspect of the invention relates to a bracket suitable for connecting a support frame that serves as a lying surface and a support frame that serves as a headboard, by means of their respective headboard connection zone and lying surface connection zone, wherein both support frames are support frames according to the first aspect of the invention. Preferably, said bracket comprises a first end that is complementary to slots or recesses of said headboard connection zone of the support frame that serves as a lying surface. Said first end is preferably configured for sliding, clamping, clicking, or combinations thereof into said slots or recesses of the headboard connection zone. According to a further or another embodiment, said bracket comprises a second end that is complementary to screw points of said lying surface connection zone of the support frame that serves as a headboard. Said second end is preferably configured for screwing to the screw points of said lying surface connection zone.

[0148] In what follows, the invention will be described by way of non-limiting examples illustrating the invention, and which are not intended to and should not be interpreted as limiting the scope of the invention.

[0149] EXAMPLES

[0150] Figures 1 and 2 show a three-dimensional view of a support frame 1 according to an embodiment of the present invention, seen from the underside and the top side, respectively. Figures 3 and 4 show a bottom view and a top view, respectively, of a support frame 1 according to an embodiment of the present invention. The depicted support frame 1 is suitable for standalone use, i.e., for supporting a mattress, as well as for supporting a superstructure, for example comprising Bonnell springs or pocket springs, as in a box spring, and is manufactured by means of injection molding, whereby it forms a single piece of material. In particular, the depicted support frame has a length of 200 mm and a width of 100 mm. The support frame comprises an upper surface 2 and a lower surface 3, wherein the upper surface 2 comprises a plurality of openings 4 in the material, and wherein the support frame comprises a plurality of primary 5 and secondary ribs 6, wherein said primary 5 and secondary ribs 6 are formed by hollow material protrusions 7 which extend from the upper surface 2 to the lower surface 3 of the support frame 1, which is clearly visible in Figure 2. The primary ribs 5 in this case have a height and / or width that is equal to, or greater than, the height and / or width of the secondary ribs 6. In particular, a support frame 1 is shown wherein the height of the primary ribs 5 and the height of the secondary ribs 6 are in a ratio of between 3:2 and 3: 1. The width of the primary ribs 5 and the secondary ribs 6 as shown is approximately equal, but may be in a ratio of between 3:3 and 3: 1.

[0151] In Figures 1 and 3, it can be seen that said primary ribs 5 form a primary grid pattern 8a of cells 9a, wherein the primary ribs 5 are orthogonally arranged and form a primary grid pattern 8a of square cells 9a. The secondary ribs 6 as shown also form a secondary grid pattern 8b of cells 9b, wherein the secondary ribs 6 are orthogonally arranged and form a secondary grid pattern 8b of square cells 9b. The cells 9a of the primary grid pattern 8a herein each enclose four cells 9b of the secondary grid pattern 8b, as far as they are completely formed within the volume of the support frame. The cells 9b of the secondary grid pattern 8b herein each enclose four openings 4 of the upper surface 2, as far as they are completely formed in the upper surface of the support frame. The primary 5 and secondary ribs 6 are oriented at a grid angle of 45° with respect to a longitudinal direction of the support frame. Adjacent openings 4 are positioned with respect to each other with a spacing of between 30 and 60 mm.

[0152] Although not explicitly shown, said primary 5 and secondary ribs 6 are respectively formed by hollow material protrusions 7 with a primary material thickness of between 6 and 12 mm, and a secondary material thickness of between 3 and 6 mm. The upper surface 2 has a material thickness of between 3 and 12 mm.

[0153] As shown, the support frame is beam-shaped, wherein the support frame 1 comprises four side surfaces 10 that each extend between the opposing edges of the upper surface 2 and the lower surface 3, and wherein said side surfaces 10 are at least partially provided with reinforcement zones 11. The support frame furthermore comprises, at its four corners 12 of the lower surface 3, four leg connection zones 13. On the side of the upper surface 2, four corresponding reinforcement zones 11 are formed. The leg connection zones comprise recesses 14 which allow for legs to be fastened by means of screws. Also visible are the frame connection zones 15, which are positioned at at least two opposing sides of the lower surface 3, in this case at all four sides of the lower surface 3. Also shown are the textile connection zones 16, which are positioned at said four sides of the lower surface 3, and which are configured as a slot along the edges of the lower surface 3.

Claims

CLAIMS1. A support frame for a piece of furniture, such as a bed or sofa, wherein said support frame is manufactured by means of injection molding, and wherein said support frame forms a single piece of material, wherein said support frame comprises an upper surface and a lower surface, wherein the upper surface comprises a plurality of openings in the material, and wherein the support frame comprises a plurality of primary and secondary ribs, characterized in that said primary and secondary ribs are formed by hollow material protrusions which extend from the upper surface to the lower surface of the support frame, and in that the primary ribs have a height and / or width that is equal to or greater than the height and / or width of the secondary ribs.

2. The support frame according to claim 1, characterized in that said primary ribs form a primary grid pattern of cells, preferably wherein the primary ribs are orthogonally arranged and form a primary grid pattern of rectangular cells.

3. The support frame according to claim 1 or 2, characterized in that said secondary ribs form a secondary grid pattern of cells, preferably wherein the secondary ribs are orthogonally arranged and form a secondary grid pattern of rectangular cells.

4. The support frame according to any one of the preceding claims 1-3, characterized in that said primary ribs form a primary grid pattern of cells and that said secondary ribs form a secondary grid pattern of cells, wherein said cells of the primary grid pattern each enclose at least two cells of the secondary grid pattern.

5. The support frame according to any one of the preceding claims 1-4, characterized in that said primary ribs are orthogonally arranged and form a primary grid pattern of square cells, and that said secondary ribs are orthogonally arranged and form a secondary grid pattern of square cells, wherein said cells of the primary grid pattern each enclose at least four cells of the secondary grid pattern.

6. The support frame according to any one of the preceding claims 1-5, characterized in that the cells of the secondary grid pattern each enclose at least two openings of the upper surface, preferably enclose at least four openings of the upper surface.

7. The support frame according to any one of the preceding claims 1-6, characterized in that the height of the primary ribs and the height of the secondary ribs are in a ratio of between 4:3 and 4: 1, preferably between 3:2 and 3: 1.

8. The support frame according to any one of the preceding claims 1-7, characterized in that the width of the primary ribs and the width of the secondary ribs are in a ratio of between 3:3 and 3: 1.

9. The support frame according to any one of the preceding claims 1-8, characterized in that said primary and secondary ribs are respectively formed by hollow material protrusions with a primary material thickness of between 6 and 12 mm, and a secondary material thickness of between 3 and 6 mm.

10. The support frame according to any one of the preceding claims 1-9, characterized in that said primary and / or secondary ribs are oriented at a grid angle of between 30° and 60° with respect to a longitudinal direction of the support frame.

11. The support frame according to any one of the preceding claims 1-10, characterized in that adjacent openings are positioned with respect to each other with a spacing of between 30 and 60 mm.

12. The support frame according to any one of the preceding claims 1-11, characterized in that the upper surface has a material thickness of between 3 and 12 mm.

13. The support frame according to any one of the preceding claims 1-12, characterized in that the support frame comprises at least one side surface that extends between the opposing edges of the lower surface and the upper surface, wherein said side surface is at least partially provided with reinforcement zones.

14. The support frame according to any one of the preceding claims 1-13, characterized in that the support frame is beam-shaped, wherein the lower surface has four corners, and wherein the support frame comprises four leg connection zones which are positioned at said four corners of the lower surface.

15. The support frame according to any one of the preceding claims 1-14, characterized in that the support frame is beam-shaped, wherein the lowersurface has four sides, and wherein the support frame comprises at least two frame connection zones which are positioned at two opposing sides of said four sides of the lower surface.

16. The support frame according to any one of the preceding claims 1-15, characterized in that the support frame is beam-shaped, wherein the lower surface has four sides, and wherein the support frame comprises at least four textile connection zones which are positioned at said four sides of the lower surface.

17. A mold assembly for manufacturing a support frame for a piece of furniture, wherein the mold assembly comprises an internal cavity for forming said support frame, wherein this mold assembly comprises at least one central mold, two axial molds, and two transverse molds, characterized in that said support frame comprises an upper surface and a lower surface, wherein the upper surface comprises a plurality of openings in the material, and wherein the support frame comprises a plurality of primary and secondary ribs, characterized in that said primary and secondary ribs are formed by hollow material protrusions which extend from the upper surface to the lower surface of the support frame, and in that the primary ribs have a height and / or width that is equal to or greater than the height and / or width of the secondary ribs.

18. The mold assembly according to claim 17, characterized in that the support frame is a support frame according to any one of claims 1-16.

19. A method for manufacturing a support frame for a piece of furniture, method for manufacturing a support frame for a piece of furniture, comprising the steps of: providing a mold or the mold assembly, wherein the mold or the mold assembly comprises an internal cavity for forming a support frame, injecting a plastic material into the internal cavity of the mold or the mold assembly, forming the support frame from the plastic material in the internal cavity of the mold or the mold assembly, cooling the formed support frame, and removing the formed support frame from the internal cavity of the mold or the mold assembly, characterized in that said support frame comprises an upper surface and a lower surface, wherein the upper surface comprises a plurality of openings in thematerial, and wherein the support frame comprises a plurality of primary and secondary ribs, characterized in that said primary and secondary ribs are formed by hollow material protrusions which extend from the upper surface to the lower surface of the support frame, and in that the primary ribs have a height and / or width that is equal to or greater than the height and / or width of the secondary ribs.

20. The method according to claim 19, characterized in that the obtained support frame is a support frame according to any one of claims 1-16.

21. The method according to claim 19 or 20, characterized in that the support frame is formed by means of a mold assembly according to any one of claims 17 or 18.

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