Furniture frame with interlocking joints for use with multiple furniture members and mechanisms

Abstract

A furniture member frame includes a plurality of commercial grade plywood frame members connected to create a frame sub-assembly. A plurality of interlocking joints are defined by male extending members of first ones of the frame members and receiving apertures of second ones of the frame members. The interlocking joints operate when the male extending members of selected ones of the first ones of the frame members are received in the receiving apertures of the second frame members to temporarily connect the frame members. An adhesive applied to at least the interlocking joints fixedly connects the frame members of the first frame sub-assembly.

Description

FIELD

The present disclosure relates to furniture member frames adapted to separately receive a motion and/or footrest mechanism.

BACKGROUND

The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

Conventionally, reclining articles of furniture (i.e., chairs, sofas, loveseats, and the like) require a mechanism to extend, stow, and to bias a leg rest assembly in the extended and stowed positions. Known mechanisms commonly include a large number of moving parts that tends to increase the manufacturing time and costs associated with the furniture. A frame structure of the furniture member is adapted to receive the mechanism. Common furniture member frames are capable of receiving only a single mechanism design, therefore multiple frame designs are required for example to provide furniture members having different functions such as rocking vice gliding actions.

Most reclining and rocking furniture members include an upholstered chair frame supported from a stationary base assembly in a manner permitting the chair frame to “rock” freely with respect to the base assembly. In order to provide enhanced comfort and convenience, many rocking chairs also include a “reclinable” seat assembly and/or an “extensible” leg rest assembly. For example, combination platform rocking/reclining chairs, as disclosed in Applicant's U.S. Pat. Nos. 3,096,121 and 4,179,157, permit reclining movement of the seat assembly and actuation of the leg rest assembly independently of the conventional “rocking” action.

Common frame structures include hardwood material to accommodate loads applied by the'seating support members such as sinuous springs, and to allow fasteners to be inserted in any exposed side or face of the frame without tear-out, and further to provide a material which receives fasteners such as staples to attach padding and upholstery. Hardwood used in these applications can be cost prohibitive. Wood laminate materials (i.e., marine grade plywood) have been used to mimic the strength of hardwood, but are expensive, add weight to the frame, and do not have acceptable tear-out strength when fasteners are inserted in a direction parallel to the laminate layers. Common frame designs are frequently upholstered with the mechanism attached, which requires the upholsterer to handle the weight of both the frame and mechanism. When this combined weight is too great to be manually manipulated, lifting fixtures are required, which increase the construction costs.

SUMMARY

According to several embodiments of a furniture frame for use with and without a mechanism of the present disclosure, a furniture member frame includes a plurality of plywood members including at least one first member having at least one male extending member. At least one second member having a receiving aperture is adapted to receive the male extending member to operably interlock the first member to the second member without the use of a fastener. An adhesive applied between a contacting portion of each of the first member and the second member is operable to fixedly connect the first member to the second member to create a frame section.

According to other embodiments, a furniture member frame includes a plurality of commercial grade plywood frame members connected to create a first frame sub-assembly. A plurality of interlocking joints are defined by male extending members of first ones of the frame members and receiving apertures of second ones of the frame members. The interlocking joints operate when the male extending members of selected ones of the first ones of the frame members are received in the receiving apertures of the second frame members to temporarily connect the frame members. An adhesive applied to at least the interlocking joints fixedly connects the plurality of frame members of the first frame sub-assembly.

According to still other embodiments, a furniture member assembly includes a plurality of plywood frame members connected to create each of a first frame sub-assembly and a second frame sub-assembly. A plurality of interlocking joints defined by male extending members of first ones of the frame members are individually received within receiving apertures of second ones of the frame members to temporarily connect the plurality of frame members. An adhesive applied to at least the interlocking joints fixedly connects the plurality of frame members of the frame sub-assembly. A mechanism selected from a plurality of functionally different mechanisms is adapted to support each of the first and second frame sub-assemblies.

According to additional embodiments, a furniture member assembly includes a plurality of plywood frame members connected to create each of a first and second frame sub-assembly. A plurality of interlocking joints defined by male extending members of first ones of the frame members and receiving apertures of second ones of the frame members are operable when the male extending members are received in respective ones of the receiving apertures to temporarily connect the plurality of frame members of each of the first and second frame sub-assemblies. A mechanism is adapted to support the first frame sub-assembly and the second frame sub-assembly is connected to the mechanism independent of the first frame sub-assembly. The mechanism is operable to permit movement of the second frame sub-assembly with respect to the first frame sub-assembly.

According to still other embodiments, a method for constructing a furniture member frame is provided.

Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

FIG. 1 is a left front perspective view of a furniture member having a furniture frame and mechanism of the present disclosure;

FIG. 2 is a left front perspective view of a furniture member frame assembly of the furniture member of FIG. 1;

FIG. 3 is a front elevational view of the furniture member of FIG. 1;

FIG. 4 is a top plan view of the furniture member of FIG. 1;

FIG. 5 is a right side elevational view of the furniture member of FIG. 1;

FIG. 6 is a left front perspective view of a furniture member frame assembly modified from the furniture member frame assembly of FIG. 2;

FIG. 7 is a right rear perspective view of a high leg furniture member having a furniture frame and mechanism of the present disclosure;

FIG. 8 is a right rear perspective view of a furniture member frame assembly of the furniture member of FIG. 7;

FIG. 9 is a right front perspective view of the furniture member frame assembly of FIG. 8;

FIG. 10 is a right front perspective view of an upper frame sub-assembly of the furniture member of FIG. 7;

FIG. 11 is a side elevational view of the upper frame sub-assembly of FIG. 10;

FIG. 12 is a front elevational view of the upper frame sub-assembly of FIG. 10;

FIG. 13 is a right front perspective view of a completed upper frame assembly of the furniture member of FIG. 7;

FIG. 14 is a side elevational view of the completed upper frame assembly of FIG. 13;

FIG. 15 is a left front perspective view of another embodiment of a furniture member frame assembly of the present disclosure;

FIG. 16 is a perspective view of an upper seat pan of the furniture member frame assembly of FIG. 15;

FIG. 17 is a perspective view of a lower seat pan of the furniture member frame assembly of FIG. 15;

FIG. 18 is a right front perspective view of a motion sofa furniture member having a furniture frame and mechanism of the present disclosure;

FIG. 19 is a right rear perspective view of a left arm assembly of the furniture member of FIG. 18;

FIG. 20 is a rotated perspective view of the left arm assembly of FIG. 19;

FIG. 21 is a perspective view of a seat pan of the motion sofa furniture member of FIG. 18;

FIG. 22 is a right front perspective view of an arm/seat pan sub-assembly of the furniture member of FIG. 18;

FIG. 23 is a left front perspective view of a movable frame sub-assembly of the furniture member of FIG. 18;

FIG. 24 is a rear perspective view of the movable frame sub-assembly of FIG. 23;

FIG. 25 is a left front perspective view of a base frame sub-assembly of a center section of the furniture member of FIG. 18;

FIG. 26 is a left front perspective view of an upper frame sub-assembly of the center section of the furniture member of FIG. 18;

FIG. 27 is a left front perspective view of a mechanism of the furniture member of FIG. 18;

FIG. 28 is a left side elevational view of the furniture member of FIG. 18;

FIG. 29 is a front elevational view of the furniture member of FIG. 18;

FIG. 30 is a right side perspective view of a furniture member having an extendable leg rest and rotatable back support section;

FIG. 31 is a right side perspective view of the furniture member of FIG. 30 showing the leg rest in a fully extended position;

FIG. 32 is a side perspective view of the furniture member of FIG. 31 further showing the back support section in a fully reclined position; and

FIG. 33 is a right side perspective view of the furniture member of FIG. 30 showing the back support section in a fully reclined position.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. It should also be understood that throughout the specification, the terms forward refers to the direction faced by an occupant seated in the furniture member and rearward refers the direction facing away from or behind the occupant. Right or right hand and left or left hand, generally refer to the right side or left side of an occupant facing forward in the furniture member.

Referring generally to FIG. 1, a furniture member 10 of the present disclosure in the form of a rocking, reclining chair, includes a frame assembly 12 including each of a lower frame sub-assembly 14 and an upper frame sub-assembly 16. A mechanism 18 (shown in phantom) is located within lower frame sub-assembly 14 to provide support and a rocking, reclining capability for lower frame sub-assembly 14 and frame assembly 12 in general. Mechanism 18 is in turn supported by a frame support section 20 which can be positioned on a planar surface such as a floor. Mechanism 18 is exemplary of a plurality of mechanisms that can be used in furniture member frames of the present disclosure, therefore the specific description of the features of mechanism 18 do not limit the scope of the furniture member frames of the present disclosure.

A plurality of sinuous wire members 22 are suspended over a cavity 23 created within a frame pan 24 of lower frame sub-assembly 14 and connected to mechanism 18. Sinuous wire members 22 provide vertical support for the weight of an occupant of furniture member 10. According to several embodiments, sinuous wire members 22 are made of a spring steel material. Upper frame sub-assembly 16 provides a back or back rest support for an occupant of furniture member 10.

Referring now to FIG. 2, frame assembly 12 can be constructed as shown prior to installation of mechanism 18 or connection to frame support section 20. Frame assembly 12 can therefore be upholstered prior to installation of mechanism 18. Frame assembly 12 and frame assemblies of the present disclosure in general are constructed to the maximum extent possible using a laminated wood material, particularly one of the commercial grades of plywood. Multiple joints used to assemble frame assembly 12 are controlled tolerance joints to promote self locking between the various frame members, stiffeners, and braces. The structural strength of frame assembly 12 derives from the various joints and the use of an adhesive between the members. Fasteners when used in the construction of frame assembly 12 (and for frame assemblies of the present disclosure in general) are generally in the form of staples, brads, and the like which function to hold various joints in place while the adhesive cures, but are not relied on for structural strength.

Frame assembly 12 includes each of a first arm section 26 defining a right arm section and a second arm section 28 defining a left arm section. First and second arm sections 26 and 28 can be mirror images of each other, therefore, the following discussion of second arm section 28 applies equally to first arm section 26. A forward post 30 and a middle post 32 have a lower brace 34 connected between the forward and rear posts 30, 32. A first pan arm 36 of frame pan 24 is joined to forward post 30 and middle post 32. A corner brace 38 is connected between first pan arm 36 and forward post 30. An arm rest member 40 is also connected to each of forward post 30 and middle post 32 and also extends rearwardly of middle post 32 to connect to a rear post 42.

An adhesive 21 such as a wood glue is applied as a film or bead to one or both of the frame members to be joined between opposed contacting faces or surfaces of the members. For example, a contacting face 23 of the present disclosure can include an outwardly directed face of forward post 30′ where it is notched to receive lower brace 34′. The opposing contacting face 25 can include an inwardly directed face of lower brace 34′ which is received in the notch of forward post 30′. The contacting faces can also be an edge of a frame member that abuts a face or edge of a corresponding frame member. Adhesive 21 and the joints described herein together provide the mechanical strength to support the weight or load of an occupant of the furniture member without the use of additional “structural” fasteners, which are relied on for their mechanical or structural strength to hold opposed members together under load.

Lower brace 34 is connected to forward post 30 using a lap joint 44 and is similarly connected to middle post 32 using a lap joint 44′. Corner brace 38 is connected to first pan arm 36 using a tongue 46 which mates within a tongue cavity 48 created in first pan arm 36. Similarly, a second tongue 46′ of corner brace 38 is received in a tongue cavity 49 created in forward post 30.

Arm rest member 40 is connected to forward post 30 using a tenon 50 extending from arm rest member 40 which is inserted entirely through a tenon cavity 52 of forward post 30. Similarly, a tenon 53 of middle post 32 is received in a tenon cavity of arm rest member 40. A mortise and tenon joint 54 is created where first pan arm 36 is joined to forward post 30. Through tenon 50 of arm rest member 40 carries vertical loads from arm rest member 40 to forward post 30, and a half-lap joint created proximate to tenon 53 is positioned directly under arm rest member 40 to carry vertical loads of arm rest member 40 through middle post 32. Rear post 42 is connected to lower frame sub-assembly 14 using a tenon 56 extending from first pan arm 36 which is received within a tenon cavity 57 created in rear post 42. Also, a tongue 58 of rear post 42 defines a portion of lap joint 44′. A tenon at each end of a cross brace 59 which is oriented transverse to frame pan 24 is also received proximate to tenon 56 of tenon through cavity 57.

Each of the joints described above used to assembly first and second arm sections 26 and 28 are created to allow the members to be hand-assembled and adhesively bonded without the use of fasteners except when the manufacturer uses fasteners for temporarily holding the joints in place to allow the adhesive to set. For example, the use of fasteners such as staples can be used when creating the joints at lap joints 44, 44′, tongues 46, 46′, and tongue 58, as well as through arm rest member 40 proximate to tenon 53.

Upper frame sub-assembly 16 includes first and second upper frame posts 60, 60′ which have respective first and second upper frame wings 61, 61′ connected thereto. An upper frame first cross member 62 and an upper frame second cross member 63 provide horizontal stiffness and cross support between the upper frame posts 60, 60′. Each of the upper frame posts 60, 60′ are connected to extending links of mechanism 18 using a fastener bracket 64 connected to each of the upper frame posts 60, 60′. Fasteners (not shown) are connected through fastener brackets 64 and fastened using fastener nuts 66. By connecting upper frame sub-assembly 16 to mechanism 18, upper frame sub-assembly 16 is rotatable with respect to lower frame sub-assembly 14 about an upper frame arc of rotation “A”.

Referring to FIG. 3, frame support section 20 includes each of a first leg 68 and a second leg 70. A rear brace member 72 and a front brace member 74 provide horizontal stabilization of first and second legs 68, 70. One or more feet 76 can also be connected to a bottom or floor facing surface of each of first and second legs 68, 70. Feet 76 are made of a resilient material to resist slipping between first and second legs 68, 70 and a smooth floor surface.

To provide a planar surface for attachment of upholstery, a brace outer face 78 of tongue 46′ and a brace outer face 80 of lower brace 34 are positioned substantially co-planar with or recessed with respect to a planar edge surface 82 of forward post 30. A similar arrangement is provided for forward post 30′.

Referring to FIG. 4, a drive rod longitudinal axis 84 is positioned as shown when furniture member 10 is in its static position prior to rocking either forward or backwards. As viewed in FIG. 4, rocking motion of furniture member 10 will appear to displace drive rod longitudinal axis 84 either upwards or downwards from the position shown. The frame assembly joints and construction of the frame assemblies of the present disclosure allow mechanism 18 to be assembled independently of frame assembly 12. Frame assembly 12 is subsequently positioned over and supported by contact of frame pan 24 with each of support surfaces 78, 78 ′ of mechanism 18. Fasteners inserted through extension portions 67, 67′ of frame pan 24, and through corresponding apertures (not shown) of mechanism 18 fixedly connect frame assembly 12 to mechanism 18. When assembled, furniture member 10 has a frame first width “B” which according to several embodiments is greater than a frame second width “C”. Frame first width “B” can also be substantially equivalent to or smaller than frame second width “C” in other embodiments of the present disclosure.

Referring now to FIG. 5, furniture member 10 has several motions with respect to first and second legs 68, 70. Starting when furniture member 10 is positioned substantially in an upright and “non-rocked” position defined by a central axis 85, a rocking member 87 is supported by a leg upper surface 86 of both first and second legs 68, 70. From this position, furniture member 10 can rock forward about a forward arc of rotation “D” to a forward rocking limit 88. Furniture member 10 can also rock rearward in a rearward arc of rotation “E” to a rearward rocking limit 90. Independent of either of the rocking motions for furniture member 10 upper frame sub-assembly 16 can be rotated about a seat back arc of rotation “F” from the position shown to an upper frame rearward rocking limit 92.

Referring now to FIG. 6, a frame assembly 94 is modified from frame assembly 12 to provide a brace member 96 connected between each of the extension portions 67, 67′ using a first bracket 98 and a second bracket 100. Brace member 96 can also be a homogeneous extension of frame pan 24 of frame assembly 12 and in this embodiment first and second brackets 98, 100 are omitted. Use of brace member 96 can inhibit the rocking motion for this embodiment where a non-rocking or gliding mechanism is desired for a furniture member of the present disclosure. Use of brace member 96 also eliminates upholstery connection member 25 shown in FIG. 1 which must be independently connected to mechanism 18. Brace member 96 also provides for additional stiffness between first pan arms 36, 36′.

Referring now to FIG. 7, a furniture member 102 which is commonly referred to as a high leg chair includes each of an upper frame assembly 104 and a base frame assembly 106. A first rear leg 108 and a second rear leg 110 extend downwardly from a rear section of furniture member 102. A first front leg 112 and a second front leg 114 (not clearly shown in this view) extend downwardly from a forward portion of furniture member 102.

Referring to FIG. 8, base frame assembly 106 includes a right side arm assembly 116 and a left side arm assembly 118 which are substantially mirror images of each other. Right side arm assembly 116 includes a right arm support member 120, having a mounting flange 122 adhesively attached and fastened thereto, and a right arm piece 124 adhesively attached and fastened to right arm support member 120. Right side arm assembly 116 further includes a right arm post 126 which is connected using a half lap joint 128 to a base pan 130 created from a plywood sheet. A first base pan tongue 132 is connected to first rear leg 108 using a tongue joint 134. A second base pan tongue 136 is connected to first front leg 112 using a second tongue joint 138. Right arm support member 120 is connected to an upper portion of first rear leg 108 using a half lap joint 140.

Left side arm assembly 118 includes a left arm support member 142 having a second mounting flange 144 adhesively and fastenably secured thereto. A left arm piece 146 is also adhesively and fastenably connected to left arm support member 142. A left arm post 148 is connected to second front leg 114 using a half lap joint similar to half lap joint 128.

Base pan 130 includes a plurality of clearance apertures and cavities which are provided for clearance to various components of a mechanism 224 shown and described in better detail in reference to FIG. 17. A first clearance aperture 150 and a second clearance aperture 152 are provided in the rearward portion of base pan 130. A clearance cavity 154 is created at a forward facing end of base pan 130 to provide clearance for a moveable leg rest extension portion of the mechanism.

With reference now to FIG. 9, a tongue 156 of right arm support member 120 is used to create a partial tongue joint 158 joining right arm support member 120 to right arm post 126. A tongue 160 of right arm piece 124 is similarly used to create a partial tongue joint 162 joining right arm piece 124 to right arm post 126. Similar joints are shown which are used to join left arm support member 142 and left arm piece 146 to left arm post 148.

Referring now to FIG. 10, an upper frame sub-assembly 164 includes a right frame member 166 and a left frame member 168 both generally having an L-shaped configuration. A right shoulder board 170 extends outwardly from right frame member 166 and, similarly, a left shoulder board 172 extends outwardly from left frame member 168. A top cross member 174 connects to both right and left shoulder boards 170, 172. A spacer block 176,176′ is used to connect, and provide a predetermined spacing between, right and left shoulder boards 170, 172 and right and left frame members 166, 168. A crown brace 178 is connected to top cross member 174 to further stiffen top cross member 174 and add an additional level of detail for upholstering. A rear lower corner of upper frame sub-assembly 164 is created using an upright cross brace 180 having a tenon 182 at opposing ends to mate with each of the right and left frame members 166, 168. A horizontal cross brace 184 is positioned in abutment with upright cross brace 180 and oriented substantially traverse to upright cross brace 180.

A tenon 186 extending from opposite ends of horizontal cross brace 184 abuts with the corresponding tenon 182 of upright cross brace 180 to collectively create a mortise and tenon joint 188 in each of right and left frame members 166, 168. Forward directed legs 190, 190′ of right and left frame members 166, 168 have an interconnecting horizontal stiffening member 192. Additionally, a brace member 194 abuts each of right and left frame members 166, 168 at opposed ends of brace member 194 and is adhesively (and fastenably if desired) connected to horizontal stiffening members 192. A tongue 196 extending from opposite ends of horizontal stiffening member 192 is used to create a half lap joint 198 with each of right and left frame members 166, 168.

Referring now to FIG. 11, exemplary locations for a plurality of fasteners such as staples are shown which are used to temporarily hold the various members of upper frame sub-assembly 164 together while the adhesive which binds the various members cures. These fasteners include a first fastener group 200 used to join an upper portion of right shoulder board 170 to crown brace 178. A second fastener group 202 can be used to join right shoulder board 170 to spacer block 176 (not clearly visible in this view). A third fastener group 204 can be used to fasten right frame member 166 to upright cross brace 180. A fastener 206 can be used to fasten right frame member 166 to horizontal cross brace 184 (not clearly visible in this view). A fastener 208 can be used to fasten right frame member 166 to horizontal stiffening member 192, and a fastener 210 can be used to fasten right frame member 166 to brace member 194. Similar fastener groups can be used when assembling left frame member 168.

Referring to FIG. 12, each of a fourth and a fifth fastener group 212, 214 are shown which can be used to join right frame member 166 to spacer block 176, and to join left frame member 168 to spacer block 176′, respectively. Each of right and left shoulder boards 170, 172 are spaced from their respective right or left frame member 166, 168 by a shoulder board clearance dimension “G”. Shoulder board clearance dimension “G” increases the overall width of upper frame sub-assembly 164 in the shoulder area of an occupant.

Referring now to FIG. 13, when upper frame sub-assembly 164 is complete, additional components and hardware are added to create upper frame assembly 104. These include a plurality of back support sinuous wire members 216 shown as sinuous wire members 216, 216′, 216″. Each of the sinuous wire members 216 are joined to respective ones of right and left frame members 166, 168 using a clip 218 which retains opposed ends of sinuous wire members 216 in contact with one of the right or left frame members 166, 168. A plurality of seat support sinuous wire members 220 are similarly connected by clips 218′, 218″ to horizontal cross brace 184 and horizontal stiffening member 192 respectively. Each of the sinuous wire members 220 span a cavity 222 created between horizontal cross brace 184 and horizontal stiffening member 192 and between each of right and left frame members 166, 168. Cavity 222 is provided to permit occupant clearance to and motion of various component parts of a mechanism 224. Similar to each of the furniture members described herein, mechanism 224 can be one of a plurality of mechanism types, allowing for leg rest extension, rocking motion, a gliding motion, seat back rotation, and member rotation, and the like. An exemplary mechanism 224 is shown and described in U.S. Issued Pat. No. 5,503,453 to Saul et al. commonly assigned to the assignee of the present disclosure, the subject matter of which is incorporated herein by reference. A portion of mechanism 224 is shown connected to left frame member 168.

Referring to FIG. 14, in an un-loaded or non-deflected condition, sinuous wire members 220 define an upwardly curved shape as shown. This shape provides additional clearance below sinuous wire members 220 to accommodate deflection from the weight of an occupant while providing sufficient clearance between the occupant and mechanism 224 for operation of mechanism 224. According to several embodiments, mechanism 224 includes each of a foot rest support link 226 and a plurality of pantograph links 228 which are used by mechanism 224 to extend or retract foot rest support link 226. A fully retracted position of foot rest support link 226 is shown.

As best seen in FIG. 15, a base frame assembly 230 is modified from base frame assembly 106 but retains the capability to fixedly receive upper frame assembly 104. Base frame assembly 230 includes a right side arm assembly 232 and a left side arm assembly 234. Right and left side arm assemblies 232, 234 are substantially a mirror image of each other. Right side arm assembly 232 includes a right front leg 236 and a right arm post 238 connected to right front leg 236. A right arm inner support member 240 and a right arm outer support member 242 are connected between right arm post 238 and a right rear leg post 244. Right rear leg post 244 includes a homogenously extending right rear leg member 246. Right arm inner support member 240 is connected to right rear leg post 244 using a half lap joint 248.

Similar to right side arm assembly 232, left side arm assembly 234 includes a left front leg 250 connected to a left arm post 252. A left arm inner support member 254 and a left arm outer support member 256 are connected between left arm post 252 and a left rear leg post 258. A left rear leg member 260 defines a homogenous extension of left rear leg post 258. A half lap joint similar to half lap joint 248 is also used to connect left arm inner support member 254 to left rear leg post 258. According to several embodiments, all of the component parts of base frame assembly 230 are created from a commercially available grade of plywood, except right front leg 236 and left front leg 250, which can also be made from a hardwood material due to their geometry, or from a composite material.

A left pan support member 262 is connected between left front leg 250 and left rear leg member 260. A similar support member 262′ (not clearly visible in this view) is provided between right front leg 236 and right rear leg member 246. In addition to bracing the respective arm posts 238, 252 to the rear leg members 246, 260, left and right pan support members 262, 262′ also support an upper seat pan 264 which in several embodiments can be created from a single sheet of plywood. A lower seat pan 266 connected to upper seat pan 264 acts to increase the overall thickness and therefore the stiffness and weight-carrying capacity of upper seat pan 264. Upper seat pan 264 is supported to right front leg 236 using an overlap joint 268. A similar overlap joint 268′ is used to join upper seat pan 264 to left front leg 250. First and second tongues 270, 270′ extend front a rearward facing side of upper seat pan 264. Each of the tongues 270, 270′ are received in notches created in right and left rear leg members 246, 260 to create tongue joints 272, 272′. A clearance cavity 274 is created by removing material from each of upper and lower seat pans 264, 266. Clearance cavity 274 provides operating clearance to a mechanism such as mechanism 224 (not shown). To provide clearance for operation of or access to components of the mechanism a plurality of apertures are provided. These include first clearance apertures 276, 276′ and second clearance apertures 278, 278′.

Referring now to FIG. 16, upper seat pan 264 can also include a plurality of clearance notches 280, 280′ in addition to the above noted clearance apertures for additional clearance for moving components of the mechanism. Upper seat pan 264 has a seat pan thickness “H” corresponding to a commercially available thickness of plywood material. Clearance cavity 274 is created by removing sufficient material from upper seat pan 264 to define a major support section 282 having a major support section depth “J”. Major support section depth “J” maintains the structural integrity of upper seat pan 264 to accommodate an occupant's weight on the furniture member, while also providing clearance for actuation and operation of the lower positioned mechanism.

Referring to FIG. 17, lower seat pan 266 is reduced in overall size compared to upper seat pan 264. First clearance notches 286, 286′ correspond in location to second clearance apertures 278, 278′ of upper seat pan 264. Second clearance notches 288, 288′ correspond in location to first clearance apertures 276, 276′ of upper seat pan 264. Lower seat pan 266 has a seat pan thickness “K” which can be substantially equal to, less than, or greater than seat pan thickness “H” of upper seat pan 264. A major support section 284 has a major support section depth “L” which is less than the major support section depth “J” of upper seat pan 264.

Referring now to FIG. 18, a furniture member 290 according to several embodiments defines a multi-section motion sofa, which can include each of a left side reclining portion 292, a fixed center section 294, and a right side reclining portion 296 (shown in phantom). Right side reclining portion 296 is removed for clarity to better illustrate each of a first track member 298 and a second track member 300, which according to several embodiments are L-shaped metal channels which extend under each of left side reclining portion 292, center section 294, and right side reclining section 296. Each of the sofa portions are fixedly connected to first and second track members 298, 300. Center section 294 is fixedly connected to first and second track members 298, 300 using a plurality of L-brackets 302 and a plurality of fasteners 304. Center section 294 includes each of a base frame sub-assembly 306 and an upper frame sub-assembly 308 which is connected to base frame sub-assembly 306 using a plurality of connecting members.310 and fasteners (not shown). Center section 294 also includes a fixed front panel 312. According to several embodiments, upper frame sub-assembly 308 is fixedly connected to base frame sub-assembly 306 and is unable to move relative to base frame sub-assembly 306.

Left side reclining portion 292 and right side reclining portion 296 are substantially a mirror image configuration of each other, therefore the following discussion of components used for left side reclining portion 292 applies also to right side reclining portion 296. Left side reclining portion 292 includes a base frame sub-assembly 314. A mechanism 316 is provided, such as the mechanism disclosed in U.S. patent application Ser. No. 11/328,772 entitled “Wall Proximity Reclining Chair With In-Line Linkage Mechanism”, filed Jan. 10, 2006, and commonly owned by the assignee of the present disclosure, the subject matter of which is incorporated herein by reference. A foot rest panel 318 is extendable by operation of mechanism 316. Base frame sub-assembly 314 is connected to a left side arm sub-assembly 320 and fixed with respect to base frame sub-assembly 314. A left side moveable frame sub-assembly 322 is connected to mechanism 316 for rotation from the upright position shown to a reclined position (not shown). One or more mechanism connection links 324 are used to fastenably connect mechanism 316 and thereby base frame sub-assembly 314 and left side arm sub-assembly 320 to each of the first and second track members 298, 300 using one or more L-channels 326. L-channels 326 are oriented substantially transverse to each of first and second track members 298, 300.

Base frame sub-assembly 314 also includes a seat pan assembly 328 which has a seat pan member constructed of a single homogenous piece of plywood. A cavity created in seat pan assembly 328 provides operating clearance for mechanism 316. It is noted that mechanism 316 can be modified from the mechanism shown within the scope of the present disclosure.

Referring now to FIG. 19, left arm assembly 330 is constructed similar to the previously discussed frame assemblies and sub-assemblies using plywood material throughout. A front post 332, a center post 334, and a rear post 336 are each cut from one or a minimum number of sheets of plywood. A left arm piece 338 is connected to front post 332 and center post 334. A left arm support member 340 is connected to each of front post 332, center post 334, rear post 336, and left arm piece 338. A brace member 342 similar to left arm support member 340 is connected to each of front post 332, center post 334, and rear post 336. A tongue 344 extending from left arm piece 338 is connected to center post 334 defining a lap joint 346. An end 348 of a curved member portion 350 of left arm support member 340 is connected to rear post 336 defining a lap joint 352. A lap joint 354 is created between center post 334 and brace member 342. A tongue 356 extending from brace member 342 is connected to rear post 336 defining a lap joint 358.

Multiple slots and through apertures are created in various ones of the front post 332, center post 334, and rear post 336 which are adapted to engage portions of seat pan assembly 328. A first slot 360 is created in front post 332. A second slot 362 is created in center post 334. A third slot 364 is created in rear post 336. Each of a first and second through aperture 366, 368 are also created in front post 332. It is noted that each of the members used to create left arm assembly 330 are assembled and fixedly connected using an adhesive such as glue and optionally fastened for example using staples to hold the assembly together while the adhesive cures.

Referring now to FIG. 20, additional features of left arm assembly 330 include a tenon 370 extending from left arm support member 340 which is inserted into front post 332 defining a mortise and tenon joint 372.

Referring now to FIG. 21, with the exception of fastener receiving nuts 373 made of a metal adapted to receive fasteners used for attaching seat pan assembly 328 to a mechanism, seat pan assembly 328 components can be created entirely from a commercial grade of plywood material. A plywood panel 374 defines a major surface of seat pan assembly 328. An attachment brace 376 also acts as an upholstery attachment member at a forward facing side of seat pan assembly 328. A stiffening brace 378 is positioned below plywood panel 374 and attachment brace 376. A spacer member 380 is positioned under a left facing side of plywood panel 374. A rear stiffening brace 382 is positioned under plywood panel 374 at a rearward facing end of seat pan assembly 328. Plywood panel 374 also includes each of a horizontal elongated slot 384, a narrow slot 386, and a corner notch 388 which are created in a left arm assembly facing side 390. A mechanism clearance and seat suspension cavity 392 are created by removing material from plywood panel 374. It is noted that material removed to create mechanism clearance and seat suspension cavity 392 can be used to manufacture various ones of the components of furniture member 290. The slots and notch created in side 390 are used to subsequently attach seat pan assembly 328 to left arm assembly 330 which will be described in better reference to FIG. 26.

Referring to FIG. 22, an arm/seat-pan sub-assembly 394 is created by joining seat pan assembly 328 to left arm assembly 330. A corner brace 396 is positioned between a lower surface of plywood panel 374 and abutted to a rearward facing surface of front post 332. At this time, a first tenon 398 of corner brace 396 is extended through first through aperture 366 of front post 332 to create a mortise and tenon joint 400. At the same time, a second tenon 402 of corner brace 396 is inserted through second through aperture 368 of front post 332 to create a mortise and tenon joint 404. A lap joint 406 is created between plywood panel 374 and center post 334 using narrow slot 386 shown in FIG. 25. Similarly, a lap joint 408 is created between plywood panel 374 and rear post 336 using corner notch 388 shown in FIG. 25. Similar to other joints created for furniture members of the present disclosure, each of the joints of arm/seat-pan sub-assembly 394 are joined using an adhesive, with the optional use of fasteners such as staples if desired.

Referring to FIG. 23, left side moveable frame sub-assembly 322 also includes framing components made from plywood material. These include a frame member 410 connected to each of a first frame side 412 and second frame side 414. A frame brace 416 is connected between the bottom ends of both first and second frame sides 412, 414 defining a lap joint 418, 418′ at opposed ends of frame brace 416. A mortise and tenon joint 420 is created to join second frame side 414 to frame member 410. A similar mortise and tenon joint (shown in FIG. 28) is used to connect first frame side 412 to frame member 410. An extended frame side 422 is connected using a butt joint 424 to a freely extending end of frame member 410 which extends beyond first frame side 412. A spacer block 426 is connected between each of extended frame side 422 and first frame side 412. A butt joint 428 is created between spacer block 426 and first frame side 412 which can be through-fastened from an opposing face of first frame side 412 if desired. A cavity 430 created in frame member 410, similar to other cavities used in the present disclosure, can also serve as a source of material for individual parts of the various assemblies.

Referring now to FIG. 24, mortise and tenon joint 420 is created from a tenon 432 extending from second frame side 414 which is received in a mortise aperture 434 of frame member 410. Similarly, a mortise and tenon joint 436 is created from a tenon 438 of first frame side 412 extending through a similar mortise aperture of frame member 410. A tenon 440 extending outwardly from spacer block 426 is used to create a mortise and tenon joint 442 to connect spacer block 426 to frame member 410.

Referring now to FIG. 25, base frame sub-assembly 306 is shown in its installed position with reference to first and second track members 298, 300. Base frame sub-assembly 306 includes a first frame wall 444 and an oppositely positioned second frame wall 446. First and second frame walls 444, 446 are substantially a mirror image of each other. A stiffening brace 448 connects first and second frame walls 444, 446 and is positioned proximate to and partially over fixed front panel 312. An upholstery attachment member 450 is connected to an upper facing side of stiffening brace 448 and acts to receive fasteners used when attaching upholstery to base frame sub-assembly 306. A rear stiffening brace 452 is connected between first and second frame walls 444, 446 similar to stiffening brace 448. A brace support member 454 is oriented substantially transverse to rear stiffening brace 452 and is connected to each of rear stiffening brace 452 and first and second frame walls 444, 446. Lap joints 456, 456′ are used to join stiffening brace 448 to each of first and second frame walls 444, 446. Similarly, lap joints 458, 458′ are used to join rear stiffening brace 452 to first and second frame walls 444, 446. A plurality of clips 460 are fastened to each of stiffening brace 448 and rear stiffening brace 452. Clips 460 will subsequently create attachment points for a plurality of sinuous wire members (not shown) which are subsequently connected to base frame sub-assembly 306 to provide support for an occupant.

With reference now to FIG. 26, upper frame sub-assembly 308 is constructed from a plurality of plywood frame members including a first frame sidewall 462 and an opposing second frame sidewall 464. An upper brace 466, a middle brace 468, and a lower brace 470 are each connected between and to first and second frame sidewalls 462, 464, respectively defining each of an upper lap joint pair 472, 472′, a middle lap joint pair 474, 474′, and a lower lap joint pair 476, 476′. Corner braces 478 can also be installed where upper ends of first and second frame side walls 462, 464 join upper brace 466, to minimize twisting of these members.

Referring now to FIG. 27, mechanism 316 is representative of a plurality of mechanisms which can be used in the furniture members of the present disclosure. For example mechanism 316 provides L-channels 326, 326′ which are fastened to each of first and second track members 298, 300 when creating furniture member 290. Mechanism 316 can also include a first foot rest support member 480, and a second foot rest support member 482 which are extended using a pantograph linkage set 484 to allow the foot rest (not shown) to be extended from a stowed to a fully extended position. Mechanism 316 can also provide both a first frame support member 486 and a second frame support member 488 on opposed sides of the mechanism. First and second frame support members 486, 488 include apertures adapted to receive fasteners (not shown) to fixedly connect seat pan assembly 328 to mechanism 316 before or after upholstery is applied to seat pan assembly 328.

Referring now to FIG. 28, when furniture member 290 is assembled as shown, a side wall 490 is connected to foot rest panel 318 defining a standoff distance “Z” between front post 332 and foot rest panel 318. As also shown, left side moveable frame sub-assembly 322 can be rotated about an arc of rotation “M” by clearance provided between a curved surface 492 of extended frame side 422 and a corresponding curved surface 494 of curved member portion 350.

Referring to FIG. 29, a clearance dimension “N” is created between center section 294 and left side reclining portion 292 to both provide for space for applied upholstery, and to allow subsequent rotation of left side moveable frame sub-assembly 322. A clearance dimension “P” is also provided between fixed front panel 312 and foot rest panel 318 to both provide for space for the applied upholstery, and to allow displacement of foot rest panel 318.

Referring now to FIGS. 30 through 33, a furniture member 496 includes a plywood frame sub-assembly 498 having a homogenous, one piece brace/seat pan 500. In FIG. 30 a handle 502 is attached to a mechanism which is operable when rotated to extend a leg rest 504 away from or to return the leg rest 504 back to a leg rest stowed position shown, and a backrest sub-assembly 506 is shown in a fully upright position. As shown in FIG. 31, handle 502 is fully rotated in a counterclockwise direction which extends the leg rest 504 to a fully extended position. As shown in FIG. 32, the leg rest 504 is in the fully extended position and the backrest sub-assembly 506 is shown rotated to a fully reclined position. As shown in FIG. 33, only the backrest sub-assembly 506 is rotated to its fully reclined position.

Referring back to each of FIGS. 6, 8, and 22, each of items 36, 130, and 328 define a plywood deck or pan member which according to several embodiments provides a central support member for the entire frame or frame assembly. The plywood deck or pan member a seat pitch angle, provides a substantially flat surface for a seat suspension (including sinuous wire members and clips), and provides a face laminate for attachment of a mechanism which supports the pan member and thereby the frame. In several embodiments, threaded fasteners can be inserted through the face laminate, thereby eliminating the need for secondary attachment devices such as tee nuts.

Each of the tenons and tongues described herein define male extending members of a first frame member received in “close tolerance” receiving apertures, slots, or notches of a second (or more) frame member(s) which together define an interlocking joint. Close tolerance apertures, slots, or notches (collectively referred to as receiving apertures) as described herein refer generally to apertures which are sized to receive the male extending member with an interference fit, a sliding fit, or a lap fit which temporarily interlocks the members to allow the joined frame members to remain together for a time period to allow an adhesive to cure which bonds the two (or more) frame members without the use of fasteners. The male extending members of the present disclosure can maximize joint strength by orienting the male extending members to receive applied loads from an occupant of the furniture member transverse to the overlapped layers of material. Fasteners including staples and brads described herein which optionally aid in assembly of the various frame members during the application of adhesives are “non-structural” fasteners, meaning the fastener is not subsequently relied on for its structural strength to hold the frame members together when an occupant weight or load is applied to the furniture member. The capability to hold the frame members together is provided by the combination of the joints provided and the use of adhesive(s) between contacting portions of the frame members.

Commercial grade plywood referred to herein is commonly identified as grade “CDX” type plywood, having no sanded or finished faces. Commercial grade plywood does not include “marine grade” plywood which is known in some furniture member applications because it can approximate the holding strength of a hardwood or softwood member when a fastener is received parallel to a plane defined between any joined pairs of the material plies. Marine grade plywood can be substituted for the furniture frame members of the present disclosure, but is not defined herein as commercial grade plywood.

The use of plywood for the frame members of the present disclosure also offers the advantage of material use efficiency. Many of the individual frame members such as the braces, corner braces, and stiffener members are made from material cut from the aperture or cavity areas of items such as the seat pan. Also, by nesting the various parts, it is possible to cut the individual frame members for a single frame from approximately a single 4×8 foot (1.22×2.44 m) sheet of plywood. It is further noted that seat pan thickness “H” can be a common thickness for all frame members of a frame or frame sub-assembly of the present disclosure. All frame members can therefore be cut from a single thickness of plywood, which permits a plywood sheet having a single inventory part number to be delivered to a work station for manufacture of the frame. This feature obviates the common practice to inventory and gather multiple parts with multiple inventory part numbers from a warehouse to manufacture a furniture frame.

The interlocking joints or features of the present disclosure permit the frame assemblies to be constructed without the use of ancillary fixtures to hold the parts. The frame therefore acts as its own fixture during assembly. Specialized assembly training for assembly personnel is therefore eliminated, and a reduced number of assemblers can be used to assemble frames of the present disclosure, further reducing construction costs.

Furniture members of the present disclosure offer several advantages. By using a commercial grade of plywood for substantially all framing components, the cost of the furniture member frames are reduced compared to commonly used materials such as hardwood and metal. By assembling the frames of the present disclosure using interlocking joints and adhesive, the frames of the present disclosure can be assembled without fasteners if desired, and connect using the advantageous overlapped strength provided by multiple, overlapped layers of the plywood material without fastening into the ends of the plies where tear-out strength of the plywood material is reduced. The all-plywood, interlocked frames of the present disclosure are also adapted to be upholstered before the frames are connected to a mechanism, which minimizes the weight of the frame assembly which must be manipulated during the upholstery phase. This further reduces handling complexity and cost of the resulting furniture member. Frames of the present disclosure are also adapted to receive multiple mechanism designs, permitting a single frame assembly to be used in multiple applications such as rocking/reclining members, rocking only members, leg rest extendable members, and the like. The mechanism when used in a furniture member sub-assembly of the present disclosure can be selected from a plurality of functionally different mechanisms, therefore furniture members of the present disclosure can support multiple furniture member platforms or types. The functionally different mechanisms can include but are not limited to rocking, reclining, rotating, fixed, leg rest extending, fixed leg panel, gliding, backrest fixed, and backrest rotatable designs, and the like. The furniture member types which are supported include but are not limited to chairs, love seats, sofas, ottomans, and the like.

Claims

1. A furniture member frame, comprising:

a plurality of plywood members, including: at least one first member having at least one male extending member; at least one second member having a receiving aperture adapted to receive the male extending member to operably interlock the first member to the second member without the use of a fastener;

an adhesive applied between a contacting portion of each of the first member and the second member being operable to fixedly connect the first member to the second member to create a frame section.

2. The furniture member frame of claim 1, wherein the at least one second member further comprises first and second post members having the first member connected to each of the first and second post members.

3. The furniture member frame of claim 2, further comprising:

a second frame section defining a mirror image of the first frame section; and

first and second brace members operable to interconnect the second frame section to the first frame section.

4. The furniture member frame of claim 3, further comprising a third member defining a pan member partially received in at least one second receiving aperture created in each of the first and second frame sections.

5. The furniture member frame of claim 4, wherein the first frame section defines a substantially vertically oriented right arm section and the second frame section defines a substantially vertically oriented left arm section, the pan member positioned in a substantially horizontal position and adapted to fixedly connect the first and second frame sections.

6. The furniture member frame of claim 5, further comprising a third brace member connected to each of the first and second post members using a lap joint created between respective ones of the first and second post members and opposed ends of the brace member.

7. The furniture member frame of claim 5, further comprising:

a first frame sub-assembly including the first and second frame sections and the pan member;

a second frame sub-assembly having second ones of the first and second frame posts and at least one brace connecting the second ones of the first and second frame posts;

a bracket fixedly connecting the second frame sub-assembly to the first frame sub-assembly operable to prevent relative motion between the first and second sub-assemblies.

8. The furniture member frame of claim 5, wherein each of the first and second post members further comprise homogenously extending leg members extending below the seat pan to operably raise the seat pan above a floor surface.

9. The furniture member frame of claim 1, wherein the plywood members comprise a material selected from only a commercial grade plywood.

10. A furniture member frame, comprising:

a plurality of commercial grade plywood frame members connected to create a first frame sub-assembly;

a plurality of interlocking joints defined by male extending members of first ones of the frame members and receiving apertures of second ones of the frame members operable when the male extending members of selected ones of the first ones of the frame members are received in respective receiving apertures of the second ones of the frame members to temporarily connect the plurality of frame members; and

an adhesive applied to at least the interlocking joints to fixedly connect the plurality of frame members of the first frame sub-assembly.

11. The furniture member frame of claim 10, further comprising a second frame sub-assembly defining a mirror image of the first frame sub-assembly.

12. The furniture member frame of claim 11, further comprising a plywood brace member fixedly connecting the first frame sub-assembly to the second frame sub-assembly.

13. The furniture member frame of claim 12, further comprising a homogenous plywood pan member partially received in a receiving aperture created in one of the frame members of both the first and second frame sub-assemblies.

14. The furniture member frame of claim 13, further comprising:

a plurality of sinuous spring members having opposed ends connected to the pan member and spanning a cavity created in the pan member; and

a clip connected to each of the opposed ends operable to connect to the pan member.

15. The furniture member frame of claim 10, further comprising a frame support section operable to rotatably support the first frame sub-assembly for a motion of the first frame sub-assembly with respect to the frame support section.

16. The furniture member frame of claim 10, wherein the plurality of interlocking joints include at least one mortise and tenon joint.

17. The furniture member frame of claim 10, wherein the plurality of interlocking joints include at least one lap joint.

18. The furniture member frame of claim 10, wherein the plurality of interlocking joints include at least one tongue joint.

19. The furniture member frame of claim 10, wherein the plurality of interlocking joints include each of a mortise and tenon joint, a lap joint, and a tongue joint.

20. A furniture member assembly, comprising:

a plurality of plywood frame members connected to create each of a first frame sub-assembly and a second frame sub-assembly;

a plurality of interlocking joints defined by male extending members of first ones of the frame members individually received within receiving apertures of second ones of the frame members operable to temporarily connect the plurality of frame members;

an adhesive applied to at least the interlocking joints to fixedly connect the plurality of frame members of the frame sub-assembly; and

a mechanism selected from a plurality of functionally different mechanisms and connected to each of the first and second frame sub-assemblies.

21. The furniture member assembly of claim 20, further comprising a third sub-assembly positioned proximate to both the first and second sub-assemblies.

22. The furniture member assembly of claim 21, further comprising first and second tracks having the mechanism and the third sub-assembly independently connected to the first and second tracks.

23. The furniture member assembly of claim 22, wherein the third frame sub-assembly is fixed to the first and second tracks having at least the second sub-assembly moveable with respect to the third frame sub-assembly.

24. The furniture member assembly of claim 20, further comprising a support structure adapted to support the mechanism.

25. The furniture member assembly of claim 20, wherein the second frame sub-assembly is connected to the mechanism independent of the first frame sub-assembly for rotational motion of the second frame sub-assembly independent of the first frame sub-assembly.

26. The furniture member assembly of claim 20, wherein each of the first and second frame sub-assemblies are independently connected to the mechanism allowing independent motion of each of the first and second frame sub-assemblies.

27. The furniture member assembly of claim 20, wherein the mechanism includes an extendable leg rest.

28. The furniture member assembly of claim 20, wherein the plywood frame members comprise a material selected from only a commercial grade plywood.

29. A furniture member assembly, comprising:

a plurality of plywood frame members connected to create each of a first and second frame sub-assembly;

a plurality of interlocking joints defined by male extending members of first ones of the frame members and receiving apertures of second ones of the frame members operable when the male extending members are received in respective ones of the receiving apertures to temporarily connect the plurality of frame members of each of the first and second frame sub-assemblies; and

a mechanism adapted to support the first frame sub-assembly and having the second frame sub-assembly connected to the mechanism independent of the first frame sub-assembly;

wherein the mechanism is operable to permit movement of the second frame sub-assembly with respect to the first frame sub-assembly.

30. The furniture member assembly of claim 29, further comprising an adhesive applied to at least the interlocking joints to fixedly connect the plurality of frame members of each of the first and second frame sub-assemblies.

31. The furniture member assembly of claim 29, wherein the plywood frame members comprise a material selected from only a commercial grade plywood.

32. The furniture member assembly of claim 29, further comprising a leg rest connected to the mechanism wherein the mechanism is operable to permit movement of the leg rest with respect to the first frame sub-assembly.

33. The furniture member assembly of claim 29, wherein the second frame sub-assembly defines a back rest including a plurality of sinuous sire members, the back rest movable from a fully upright position to a fully reclined position.

34. A furniture member frame, comprising:

a first plurality of commercial grade plywood frame members connected to create a first frame sub-assembly;

a second plurality of commercial grade plywood frame members connected to create a second frame sub-assembly;

a first plurality of interlocking joints defined by male extending members of first ones of the frame members and receiving apertures of second ones of the frame members operable when the male extending members of selected ones of the first ones of the frame members are received in respective receiving apertures of the second ones of the frame members to temporarily connect the plurality of frame members of each of the first and second frame sub-assemblies;

at least one of the first plurality of interlocking joints defining a mortise and tenon joint;

a plywood member pan assembly having a plurality of apertures adapted to be slidingly interlocked with corresponding receiving apertures of both the first and second frame sub-assemblies, the plurality of apertures and the plurality of receiving apertures defining a second plurality of interlocking joints when the pan assembly is connected and oriented substantially transverse to the first and second frame sub-assemblies; and

an adhesive applied to at least the interlocking joints to fixedly connect the plurality of frame members and the pan assembly.

35. The furniture member frame of claim 34, further comprising at least one brace member positioned between each of a first and second post member of the first and second frame sub-assemblies.

36. The furniture member frame of claim 35, wherein the pan assembly further comprises:

a plywood member having a portion removed defining a cavity; and

a plywood stiffening member connected at least at a first end of the plywood member.

37. The furniture member frame of claim 36, further comprising an leg member homogenously connected to and extending from each of the first and second post members, each leg member positioned to elevate the pan assembly above a floor surface.

38. A method for constructing a furniture member frame, the frame including a plurality of plywood frame members, a plurality of interlocking joints defined by male extending members of first ones of the frame members and receiving apertures of second ones of the frame members, the method comprising:

connecting selected ones of the male extending members into respective ones of the receiving apertures to create the plurality of interlocking joints of a frame sub-assembly; and

applying an adhesive to at least the interlocking joints to fixedly connect the plurality of frame members of the first frame sub-assembly without the use of structural fasteners.

39. The method of claim 38, further comprising shaping selected ones of the male extending members as a tenon.

40. The method of claim 39, further comprising creating selected ones of the receiving apertures as mortise apertures adapted to slidably receive individual ones of the tenons.

41. The method of claim 38, further comprising shaping selected ones of the male extending members as a tongue.

42. The method of claim 38, further comprising creating selected ones of the receiving apertures as a tongue aperture adapted to slidably receive individual ones of the tongues.

43. The method of claim 38, further comprising connecting the male extending members to respective ones of the receiving apertures to create a plurality of lap joints.

44. The method of claim 38, further comprising repeating the inserting and applying steps to create a second frame sub-assembly.

45. The method of claim 44, further comprising fixedly connecting the first and second frame sub-assemblies to each other.

46. The method of claim 44, further comprising movably connecting the first and second frame sub-assemblies with respect to each other.

47. The method of claim 44, further comprising selecting each of the plywood members from only a commercial grade plywood.

48. A method for constructing a furniture member frame, the frame including a plurality of plywood frame members, the method comprising:

assigning a single inventory part number to an individual sheet of plywood;

withdrawing the individual sheet of plywood and forwarding the individual sheet to an assembly area;

cutting a plurality of frame members from the individual sheet operable to be assembled in a single furniture member frame, each frame member having at least one of a male extending member and a receiving aperture; and

interlocking the plurality of frame members using the male extending members received in respective ones of the receiving apertures to assemble the frame, without the use of fasteners.

49. A method for constructing a furniture member frame, the frame including a plurality of plywood frame members, the method comprising:

orienting a plywood pan member defining a central support member for the frame having a seat pitch angle;

connecting a seat suspension system to a substantially flat surface of the pan member; and

attaching a mechanism directly to a face laminate of the pan member wherein the mechanism operably supports the pan member and the frame.

50. The method of claim 49, further comprising inserting a plurality of threaded fasteners through the face laminate to fastenably connect the mechanism to the pan member.