Furniture Objects

Abstract

A variety of apparatuses are disclosed, including, in one embodiment, a sofa bed, that includes opposing arm rest sections, a back section, and a pull-out section, that includes a honeycomb structure disposed between the opposing arm rest sections, where the honeycomb structure of each pull-out section is configured to change between an extended and a non-extended position.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a nonprovisional of U.S. Provisional Patent Application No. 63/489,417 filed Mar. 9, 2023, which is incorporated by reference in its entirety.

BACKGROUND

Furniture may be used for sitting, lounging, and sleeping. Some furniture, i.e., pull-out beds, have dual function in that they can convert between living room furniture and beds. Such furniture is typically heavy, difficult to ship, and difficult to assemble. Professional movers are often needed to move heavy furniture. Lighter furniture is available but is often characterized as cheap and has poor durability.

SUMMARY

Disclosed herein is an example sofa bed, which may include opposing arm rest sections, a back section, and a pull-out section. Each pull-out section may include a honeycomb structure disposed between the opposing arm rest sections, configured to extend between an extended and non-extended position.

Further disclosed herein is an example puff bed, which may include front and back panels, side panels, and one or more honeycomb structures. The one or more honeycomb structures are disposed within an area bounded by the front, back, and side panels. At least one honeycomb structure is configured to convert the puff bed into an extended configuration.

Further disclosed herein is a sofa, which may include opposing arm rest sections, a frame, a divider, and a honeycomb structure. The frame includes a plurality of members extending between the opposing arm rest sections. The divider is disposed between the plurality of members. The honeycomb structure is disposed between the opposing arm rests.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory in nature and are intended to provide an understanding of the present disclosure without limiting the scope of the present disclosure. In that regard, additional aspects, features, and advantages of the present disclosure will be apparent to one skilled in the art from the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

These drawings illustrate certain aspects of some of the embodiments of the present invention and should not be used to limit or define the invention.

FIG. 1 illustrates a front view of a sofa bed in a non-extended configuration, in accordance with some embodiments of the present disclosure.

FIG. 2 illustrates pull-out sections of the sofa bed of FIG. 1, each in a non-extended configuration, in accordance with some embodiments of the present disclosure.

FIG. 3 illustrates the pull-out sections of the sofa bed of FIG. 2, each in an extended configuration, in accordance with some embodiments of the present disclosure.

FIG. 4 illustrates the pull-out sections of FIGS. 2 and 3 side-by side, with respective back sections of the sofa bed installed, in accordance with some embodiments of the present disclosure.

FIG. 5 illustrates the pull-out sections and respective back sections of FIG. 4, with arm rest sections of the sofa bed installed, in accordance with some embodiments of the present disclosure.

FIG. 6 illustrates the pull-out sections, respective back sections, and arm rest sections of the sofa bed of FIG. 5, with covers partially placed over the honeycomb structures, in accordance with some embodiments of the present disclosure.

FIG. 7 illustrates an angled view of the sofa bed of FIG. 1, comprising the various sections of FIGS. 2-6, and with pillow and sofa cushions disposed thereon, in accordance with some embodiments of the present disclosure.

FIG. 8 illustrates the sofa bed of FIG. 7, with the sofa cushions removed, and with the pull-out sections in the extended configuration of FIG. 3, in accordance with some embodiments of the present disclosure.

FIG. 9 illustrates the sofa bed of FIG. 8, with covers placed over the honeycomb in the extended configuration, in accordance with some embodiments of the present disclosure.

FIG. 10 illustrates the sofa bed of FIG. 9, with bed cushions partially placed over the covers, in accordance with some embodiments of the present disclosure.

FIG. 11 illustrates the sofa bed of FIG. 10, with the sofa bed cushions unfolded and placed over the covers and with pillow cushions disposed on the bed cushions, in accordance with some embodiments of the present disclosure.

FIG. 12 illustrates the sofa bed of FIG. 11, with one of the pull-out sections in a partially non-extended configuration, in accordance with some embodiments of the present disclosure.

FIG. 13 illustrates the sofa bed of FIG. 12, but with one of the pull-out sections in the extended configuration and the other in the non-extended configuration, in accordance with some embodiments of the present disclosure.

FIG. 14 illustrates a pull-out section of FIG. 1, in accordance with some embodiments of the present disclosure.

FIG. 15 illustrates a schematic view of the pull-out section of FIG. 14 in a non-extended position, in accordance with some embodiments of the present disclosure.

FIG. 16 illustrates the schematic view of the pull-out section of FIG. 15 but in an extended position, in accordance with some embodiments of the present disclosure.

FIG. 17 illustrates the schematic view of the pull-out section of FIG. 15, but with a folded bed cushion disposed thereon, in accordance with some embodiments of the present disclosure.

FIG. 18 illustrates the schematic view of the pull-out section in the extended position of FIG. 16, but with the bed cushion of FIG. 17 unfolded and spread out across a pull-out section, in accordance with some embodiments of the present disclosure.

FIG. 19A illustrates the schematic view of FIG. 16, but from another angle to show two screws and a bracket attached to a slider, in accordance with some embodiments of the present disclosure.

FIG. 19B illustrates a close-up view of the two screws, bracket, and slider of FIG. 19A, in accordance with some embodiments of the present disclosure.

FIG. 20 illustrates an exploded schematic view of a body of an armrest section, in accordance with some embodiments of the present disclosure.

FIG. 21 illustrates an armrest sponge draped over an armrest body, in accordance with some embodiments of the present disclosure.

FIG. 22A illustrates a schematic view of a pull-out section installed within a sofa bed by a plurality of clamps, in accordance with some embodiments of the present disclosure.

FIG. 22B illustrates a close-up view of the clamps shown in FIG. 22A, in accordance with some embodiments of the present disclosure.

FIG. 23 illustrates a schematic view of a clamp, in accordance with some embodiments of the present disclosure.

FIG. 24 illustrates a schematic top view of a sofa bed to show various placement locations of the clamps shown by FIGS. 22A, 22B, and 23, in accordance with some embodiments of the present disclosure.

FIG. 25A illustrates a schematic view of a frame of a sofa, in accordance with some embodiments of the present disclosure.

FIG. 25B illustrates a schematic view of the example connector shown in FIG. 25A, in accordance with some embodiments of the present disclosure.

FIG. 25C illustrates a close-up view of the connector of FIG. 25B over a divider of FIG. 25A, in accordance with some embodiments of the present disclosure.

FIG. 25D illustrates a cross-sectional view of the connector shown in FIG. 25C, attached to a frame by a hex bolt and wingnut, in accordance with some embodiments of the present disclosure.

FIG. 26A illustrates a schematic view of a frame of a sofa, in accordance with some embodiments of the present disclosure.

FIG. 26B illustrates a close-up view of an example connector, disposed under a divider, in accordance with some embodiments of the present disclosure.

FIG. 26C illustrates a close-up view of a connector, disposed above a divider, in accordance with some embodiments of the present disclosure.

FIG. 26D illustrates an exploded view of the connector of FIGS. 26B and 26C, in accordance with some embodiments of the present disclosure.

FIG. 26E illustrates a non-exploded view of the connector of FIG. 26D, in accordance with some embodiments of the present disclosure.

FIG. 27 illustrates a partially exploded schematic view of a partially assembled sofa, with a honeycomb structure disposed within, in accordance with some embodiments of the present disclosure.

FIG. 28 illustrates a clip for clipping together respective ends of two separate honeycomb structures of the sofa of FIG. 27, in accordance with some embodiments of the present disclosure.

FIG. 29 illustrates the clip of FIG. 28, installed in the sofa of FIG. 27, in accordance with some embodiments of the present disclosure.

FIG. 30A illustrates a schematic view of base padding disposed on the sofa of FIG. 27 in accordance with some embodiments of the present disclosure.

FIG. 30B illustrates an exploded schematic view of the base padding of FIG. 30A, in accordance with some embodiments of the present disclosure.

FIG. 30C illustrates the base padding of FIG. 30B affixed to a sofa with a hex bolt and wing nug, in accordance with some embodiments of the present disclosure.

FIG. 31 illustrates an exploded schematic view of a front panel for a sofa, in accordance with some embodiments of the present disclosure.

FIG. 32 illustrates an exploded view of back padding for a sofa, in accordance with some embodiments of the present disclosure.

DETAILED DESCRIPTION

Disclosed herein are methods and apparatuses relating to furniture which includes, but are not limited to, sofas and sofa beds. More particularly, disclosed herein is furniture including an expandable and collapsible honeycomb material, which may be made from paper.

Advantageously, the furniture may be foldable, collapsible, and expandable, in some examples, without significant losses to structural reliability. Further, the honeycomb material may simplify assembly by eliminating or reducing the need for special tools and may be lightweight and portable. In some examples, instruction manuals may be eliminated entirely or at least simplified due to the elimination of complicated assembly processes. Other advantages may include low shipping costs of the furniture, as well as ergonomic retrieval and storage using a small amount of space.

Some embodiments of the present disclosure are directed to honeycomb-based furniture and methods of formation of said furniture. The honeycomb structure can be used to make furniture objects such as a sofa, sofa bed, puff, for example, to be individually described in detail. In examples, utility of a portable foldable furniture object may be measured according to the following criteria: the weight of a furniture object; the volume of a furniture object when it is folded; the time required to fold/unfold a furniture object; the bearing capacity of a furniture object; the time of assembly and disassembly; and any combination thereof.

In some examples, a furniture object may comprise honeycomb paper. The bearing capacity of such furniture objects may be at least 40 tons/m². For example, from about 40 tons/m² to about 80 tons/m², in some examples, depending on the type of glue, dimensions of individual cells, choice of material, etc.

In some examples, a whole furniture piece can be provided for delivery folded in one or more carton boxes. The structure can be either a seat, love seat, sofa, etc., as examples, or other furniture objects, for one to three people or more. When a furniture object is made to be a sofa for three people, the foldable volume of a furniture object may be at least 50% less than comparable fixed furniture objects (e.g., sofas/flat pack sofas) in the market. For example, from about 80% or less of an original volume, or any ranges therebetween, in a disassembled and collapsed “shipping” configuration. The decrease in volume may vary depending on the design of a given furniture object, however, a furniture object may be from about 5% to about 80% an original volume in a collapsed configuration as opposed to an expanded configuration, in many examples. The weight of a furniture object may be at least 50% less than the counterpart sofas on the market. Alternatively, from about 50% to about 200%, or any ranges therebetween, in some examples.

The honeycomb structure of a furniture object may be used to make a sofa bed. In some example, the quality of a foldable sofa bed may also be measured according to the following criteria: the weight of the sofa bed; the volume of the sofa bed when it is folded; the time required to fold/unfold the sofa bed; and the bearing capacity of the sofa bed. In some examples, the weight of a foldable sofa bed is about 6 kg to about 12 kg, or about 7.5 kg to about 10 kg of honeycomb paper, or any ranges therebetween. The amount of honeycomb may be even heavier, for example, if smaller cell sizes and more sheets are used. For example, the weight of honeycomb in a sofa bed may be 3 kg or higher, in some examples. In some embodiments, the weight of a foldable sofa bed is about 8.5 kg of honeycomb paper. In some example, the time required to fold/unfold the sofa bed is less than 5 minutes, less than 2 minutes, or less than 1 minute. In some examples, the bearing capacity of the sofa bed is at least 2 tons/m². In some examples, the weight of a foldable sofa bed is less than 15 kg depending on the hexagonal cell size and the number of layers. In some examples, the bearing capacity of an extended structure can carry a weight of more than 1000 kg. For example, from about 1 kg to about 1500 kg, or any ranges therebetween. In some examples, more layers added in the same area may increase the bearing capacity of a furniture object in that area.

In some examples, a furniture object is more than 25% lighter than a comparable furniture object (e.g., without the honeycomb) in the market. For example, from about 5% to about 80%, or any ranges therebetween, of a comparable furniture object of roughly an equivalent size and for a similar purpose. In one example, the volume of a folded sofa bed is roughly half the volume of a classic counterpart piece of furniture.

In some examples, a furniture object may comprise cellulose fiber sheets made from recyclable materials. This may make a sofa or sofa bed, or subcomponent thereof (e.g., a honeycomb structure thereof) more “green” and environmentally friendly. For example, a sofa bed (e.g., sofa bed 100 of FIGS. 1-24) or sofa (e.g., sofa 2500 of FIGS. 25-32), or subcomponent thereof (e.g., honeycomb sections 202a, 202b of FIG. 2), can be recycled again in a closed loop.

The weight and the dimensions of a furniture object can make it shippable easily by air freight couriers. The shipping of the sofa bed may be, for example, at least 25% lower CO2 footprint than other normal sofa beds in the market. For example, from about 25% to about 300% lower, or any ranges therebetween. The flexibility of the one or more honeycomb structures in the furniture objects makes these versatile and multi-functional.

In some examples, the fast operation of expanding and folding the sofa bed makes the user experience more efficient and hence more convenient than other foldable sofa beds in the market. For example, converting a sofa bed or puff (e.g., pull-out section 106 of sofa bed 100 of FIGS. 1-24) between extended and non-extended configurations may be ergonomic and simple, such as by pulling on a tab (e.g., tab 204 of FIG. 2) to gently expand a honeycomb section (e.g., honeycomb section 202b of FIG. 16) to an extended configuration.

The present disclosure may overcome the difficulty of transportation and installation and also add convenience in buying, moving in, and moving out big pieces of furniture like a sofa bed or a sofa.

As used herein, a corrugated sheet may comprise, without limiting to any single embodiment, A-flute, B-flute, C-flute, BC-flute, E flute, other standard cardboard sizes, combinations (e.g., layers) thereof, or the like.

In an embodiment, a sofa bed is disclosed of which at least the base can be comprised purely of paper with the sofa bed being foldable or collapsible and expandable. The honeycomb structure is like an accordion that can be folded and unfolded easily. The honeycomb structure may include a plurality of hexagonal shapes, i.e., “cells” that can be expanded manually to make a longer structure.

One advantage is sustainability of the product that comes from recyclable materials. The paper can be virgin or recycled for both the honeycomb structure and the corrugated sheets. Also, the foldability of the structure saves space in shipping, handling, storing and makes it easy for the final consumer to assemble it alone.

The honeycomb structure may be like an accordion that can be folded and unfolded easily. It may include a plurality of hexagonal shapes called “cells” that can be expanded manually to make a longer structure (e.g., expanded and non-expanded configurations of FIGS. 2, 3). A honeycomb structure may be glued to panels of the sofa bed so it can be expanded from 2 inches to 80 inches. Alternatively, so it can be expanded from about 0.5 inches to any length needed (e.g., about 120 inches, 300 inches, or more), or any ranges therebetween, depending on the number of layers. More layers of honeycomb correlates to a greater expansion capability. Panels may be divided into multiple sections (e.g., 2) that may be connected by metal connectors.

Here, normal wooden slates commonly that would normally be used to construct a sofa bed may be replaced by honeycomb paper structure that folds and unfolds easily. The honeycomb structure (e.g., honeycomb section 202a of FIG. 2) may be glued to one or more panels (e.g., side panels 302, 304 or front panel 206 of FIG. 3). Gluing a honeycomb structure to one or more panels may give the ability to fold and unfold the structure easily, such as from 2 inches to 80 inches or the alternate ranges disclosed. When expanded, front and end panels (e.g., front pane 206 of FIG. 3) may be connected to sides (e.g., side panels 302, 304 of FIG. 3) by one or more metal connector. In some examples, the size of a front or end panel may be selected from any of a comparable standard for sofa bed sizes.

One or more panels (e.g., side panels 302, 304 of FIG. 3) may be divided into two (or more) pieces that are connected together. So, four small parts of the side boards can be disassembled, folded, and packed together in a smaller box, for example. By dividing panels into multiple pieces, volume, storage, and shipping cost may be reduced, in some examples. Where used, connection between divided panels can be metal, any other material, or be based on an interlocking feature (e.g., tongue and groove) of panels themselves. In some examples, a wooden board may be inserted in between divided panels, for example, when these are connected to support a center of a sofa of sofa bed.

In another embodiment a foldable puff is disclosed that can expanded to a bed using honeycomb structure. A “foldable puff” is a piece of furniture that can be folded down to smaller size, then expanded and fixed to make a puff. “Fixing” may be achieved, for example, using any suitable connector (e.g., metal hooks) to temporarily lock, latch, or set the puff in an extended configuration. When needed, the puff can be expanded to a sofa bed using honeycomb structure. The honeycomb structure is like an accordion that can be folded and unfolded easily. It includes hexagonal shapes called cells that can be expanded manually to make a longer structure.

The honeycomb structure puff (e.g., pull-out section 106 of FIGS. 1-19B) can include multiple panels (e.g., front and back panels 206, 208 of FIG. 15). These may be made from wood, engineered wood, or other suitable material, and may be glued to a honeycomb structure that is made of paper, plastic, aluminum, or any other materials. A honeycomb structure itself can be folded down to 2 inches or less and open up to 80 inches or more when it gets expanded, as discussed. Other dimensions are possible, such as the structure folded down to between 0.2 inches and 7 inches, and expanded to between 35 inches and 120 inches, and any ranges therebetween. Front and back panels may be connected to side panels (e.g., particle boards, plywood or MDF) by sliders (e.g., slider 300 of FIGS. 15, 16).

The honeycomb structure has several layers that can be expanded, e.g., to either a puff (e.g., pull-out section 106 of FIGS. 1-19B) of 40 inches or a sofa bed of 80 inches. Other ranges are possible, such as between 20 inches to about 70 inches for a puff, or about 60 inches to about 120 inches for a sofa bed, or any ranges therebetween. They are separated by a wooden board that may connect to the sides using metal connectors.

In some examples, wooden sides may have a drawer slider (e.g., slider 300 of FIG. 3) that can be expanded, e.g., up to 40 inches. Alternatively, from about 15 inches to about 100 inches, or any ranges therebetween. In some examples, these sliders may be fixed to wooden sides (e.g., side panels 302, 304 of FIG. 15), such as one on each side. When sides are connected to a main body (e.g., front and back panels 206, 208 of FIG. 15) that has the honeycomb structure (e.g., honeycomb section 202a), drawer sliders may be fixed to a front panel (e.g., front panel 206), e.g., by screws (e.g., screws 1900 of FIG. 19A, 19B).

In some examples, foam may be folded into two pieces (e.g., upper and lower sections 702, 704 of FIGS. 7, 14) and can be opened into a full length of the sofa bed when needed. These may be folded back and closed, e.g., by zippers or other suitable device. The size of a foam may be, for example, about 40 inch when folded to be a cushion for the puff. Alternatively, from about 15 inches to about 150 inches, or any ranges therebetween. Where used, foam may be open to make the full size of the sofa bed, such as about 80 inches). Alternatively, from about 40 inches to about 120 inches, or any ranges therebetween.

When the puff is assembled, an armrest and a back rest can be connected to it to make half sofa. Both armrest and backrest can be connected to the puff using a U-shape connector that has a screw for fixation as per the drawing. When it is finished, the whole structure can be linked to another structure making a sofa. The two parts can be expanded to a sofa bed making this piece of furniture a sofa/sofa bed piece. Everything can be unfolded to smaller boxes that will save in shipping and materials.

This piece of furniture is sustainable since it does not need to use the amount of wood and packages that is used of traditional furniture.

A glue may comprise starch with acrylic additives. The glue that can be used includes starch or any other glue like PVA, resins, acrylic or any other glue. The glue can be water based or solvent based. PVA (An aliphatic rubbery synthetic polymer with the formula (C4H6O2)n may have good elasticity and low cost. It belongs to the polyvinyl ester family, with the general formula [RCOOCHCH2].

The material used in this structure may comprise paper but can be any flaccid materials like, but not limited to, plastic, non-woven fabric, or synthetic paper. The paper used can be treated to be water resistant and/or fire retardant. The thickness of paper can vary from 10 micron to 15 mm. Other materials can be used to give the hexagonal shapes. Plastic, felt, non-woven fabric can also be used. Any flaccid materials can be used to give the same function.

For paper, paper density can vary from 40 grams to 500 grams per meter square. Paper also can be engineered to have better edge burst strength of 800 kPa to 900 kPa.

The paper (or other material) used can be treated and sprayed by coloring materials, i.e., with pigments, or dyed in coloring chemicals. Spraying materials can be for any purpose from coloring or adding feature and/or function to the structure like being water proof, or/and fire retardant, changing flexibility, changing color, or changing physical or chemical properties of the paper or other structural material as examples.

In some examples, an advantage of these embodiments is that the structure can be divided into zones with one or more zones having reduced cell size to give more support to the points of stresses of a sleeping person. The cell size can be larger in the areas that will not carry more load.

A honeycomb structure may be flexible, which may be a result of a determined cell size and glue size. The cell side is determined by the space between the glue lines in the honeycomb core machine. The width of the glue line is also a factor in giving flexibility to the honeycomb structure. The improvement was done on the machine to increase the length between the glues from 2-3 cm to 7-10 cm. The glue width also decreased from 10 mm to 2 mm. The glue width can go down to 1 mm. The smaller the glue line and the bigger the width between the glue lines gives higher flexibility.

There are two kinds of foldability for the bed of a furniture object. Horizontal foldability: a furniture object can be folded to be 2 cm and extended to be anything from 2 cm up to 10,000 cm depending on the number of layers glued to each other. Vertical foldability: a furniture object itself can be cut into two or more pieces then be attached to each other vertically with a hinge or any other connector. This allows the structure to be folded into two halves or more.

A particular honeycomb structure may be designed to minimize the amount of used material to reach a minimal weight and minimal material cost. For example, the geometry of honeycomb structures can vary widely but the common feature of all such structures is an array of hollow cells formed between thin vertical walls. These cells are often columnar and hexagonal in shape. A honeycomb shaped structure may provide a material with minimal density and relative high out-of-plane compression properties and out-of-plane shear properties.

The honeycomb technology in a furniture object may use one or more gluing machines to glue the paper (or analogous flexible materials) in parallel glue lines. In examples, lines may be laid down and in preparation for placement of a subsequent paper sheet. Glue may be done in a staggered way for one paper to another. Paper sheets may go through two glue stations. For example, glue lines may be applied on a first and second paper layers parallel to each other. When applying glue lines on a third paper layer, for example, these may be placed somewhere between (e.g., in the middle of) glue lines of the first and second layers. Likewise, for a fourth layer, glue lines may be laid in the same location as in the first and second layers. In a fifth layer, glue may be laid on the same location as in a third layer, and so forth. If glue lines were all placed on the same location for all layers, a honeycomb structure formed from the layers would not open (no hexagonal cells would be shaped). Hence, glue lines should alternate between layers to provide a hexagonal cell shape. However, these specific manufacturing techniques disclosed should not limit the honeycomb structure to any specific example.

With continued reference to example techniques for making a honeycomb structure, first and second sheets may be glued together by applying parallel glue lines at a first station. Third and fourth sheets may have the same glue lines applied thereto at the same (first) station. At a second glue station, new glue lines may be applied to surfaces of first and second sheets, for example, in a space formed between glue lines applied at station one. In some examples, this allows first and second sheets to be glued to third and fourth sheets. So, each of a plurality of single sheets may have parallel glue lines on front and back surfaces, but offset so as not to be exactly superimposed, in some examples. Hence, a “staggered” glue application may ensure, in some examples, that a hexagonal shape of the honeycomb cells is formed to enable the desired expansion. A stack of layers may constitute a “block,” e.g., of paper layers. Thus, the staggered gluing may provide a hexagonal shape constituting the honeycomb structure.

These layers may then be cut to the size of the bed by various cutting methods. For example, a cut block may be attached to opposing panels (e.g., front and back panels 206, 208 of FIG. 2) by glue, a hardware fixture, or any other suitable connection means. The hexagonal shape of a honeycomb structure may have the property of being expandable manually to a desired length. However, the limit of expansion for a honeycomb structure may depend on the number of paper layers. Likewise, the design of the hexagonal structure of each cell, the distance between the glue lines, and the width of the glue lines together, may also affect the expansion parameters of the honeycomb structure, and may make it easier or more difficult for an assembler to expand and/or collapse a furniture object.

Following cutting, honeycomb may be permanently attached to one or more pieces of a furniture object. For example, panels or side boards may be inserted to keep the honeycomb structure in place once the given furniture object is assembled.

The honeycomb material of a furniture object may comprise, for example, paper or a thin-wood based material. In some examples, such may comprise, or be formed of, cellulose fiber. Cellulose fiber may comprise, for example, white kraft pulp of high brightness and formed of virgin fibers. Such brightness may be useful for observing the presence of defects and may also give the appearance of durability and value. “Virgin fibers” are pure fibers sourced from tree fiber (e.g., from one or more Nordic forests) and may be free or essentially free of recycled paper fiber. This may ensure good strength and the durability of the honeycomb core. In some examples, using Virgin fibers may allow a major part of the material of a given honeycomb structure to be sourced from renewable forests, which may result in higher quality, i.e., improved pulp specifications. In the alternative or in addition, however, the honeycomb material can be formed of additional materials, such as but not limited to aluminum and plastics and/or other papers.

When paper and/or wood are used, the density may be, for example, at least 140-170 grams/m², or ranges therebetween, to ensure adequate strength. The paper used may have a weight greater than 140 grams/m². For example, from about 140 grams/m² to about 300 grams/m², or any ranges therebetween. If less than this weight is used, the honeycomb structure may be affected and hence the durability of the product may be reduced. Where less than 140 grams/m² is used in making the honeycomb structure, more layers may be necessary to compensate for the reduced strength of the lighter weight paper.

In some examples, the material is approved by the German Institute for Risk Management (BfR) and the FDA as a safe material for human contact.

In some examples, an individual cell of a honeycomb structure may have, in expanded form, dimensions of 10 cm from vertex to vertex. Alternatively, between 5 cm and 20 cm, or any ranges therebetween.

Each unit in the honeycomb when expanded may form a hexagonal prism. Except for edges, each side of each hexagonal prism may abut a side of another hexagonal prism. Sides may be attached by glue. That is, each of the six sides may be attached to a different abutting hexagonal prism along one side using glue. A single glue type may be used, such as elastic glue. In some examples, PVA glue having a solid content of 40%, plus or minus 2%, for example, may be used. Viscosity of a glue may be about 3000, plus or minus 1000 centipoise, for example. Specific gravity of glue may be about 1.1, for example. A pH of glue may be between 5-6, for example.

Each of the individual honeycombs may have a thickness of material ranging from 0.5 mm to 2 mm.

When used to form a sofa or bed, the honeycomb hexagons may form hexagonal-prism-based sheets, whereby the honeycomb hexagons are glued together to form a sheet along a common side, and then the sheet is cut to size. In expanded form, the dimension of a sheet may be, e.g., 174 cm long and/or wide. Alternatively, from about 40 cm to about 300 cm long and/or wide, or any ranges therebetween. A sheet may be longer or shorter based on the design of a particular furniture object and a desired expansion parameter. In one example, a sheet may be about 60 cm×92.5 cm when expanded, such as for a sofa (e.g., sofa bed 100 of FIGS. 1-24 or sofa 2500 of FIGS. 25A-32).

Building a stack (three dimensional construction) of sheets to form a honeycomb structure may involve attaching sheets to one another. To do this, cells may be aligned one with another, but alternatively may be offset from one another; that is, hexagon sheets may not align exactly one over another.

In one example, vertexes of the hexagons in a hexagon sheet may be aligned with the center points of the hexagons in the next sheet and so on.

In general, when expanded, each hexagon has a length, thereby each one forms a regular hexagonal prism when expanded.

In attaching sheets to one another, honeycomb sheets may each be expanded for attachment. In this case, the same glue may be used as previously discussed. Glue may be applied with glue rollers having protruding glue rings, e.g., with equal spaces. Spaces may differ from one product to another. In some examples, as many as 300 sheets can be stacked together, or more. The total thickness of a honeycomb structure or section thereof may depend on the type or styles of furniture (e.g., chair, sofa, bed, etc.).

We use a stacking machine that glues certain type of cellulose fiber sheets layer by layer. The machine provides the glue in parallel lines that provides the shape of hexagonal structure. In some examples, the distance between the glue lines is 10 cm. A furniture object may comprise, for example, between 50 and 150 layers of sheets, or any ranges therebetween. For example, about 80 layers, or 100 layers, for a sofa and bed, respectively. Layers may then be cut to the shape of the desired furniture piece, such as but not limited to either a sofa, seat, ottoman, bed, or corner unit. Cuts may be made manually using a saw machine or performed automatically. When expanded, the structure may bear a vertical load of at least 1 ton/m2.

Cellulose fiber sheets of 140-170 g/m² may be produced from very pure, white kraft pulp of high brightness, and each sheet may include entirely of virgin fibers. The long and strong fibers from the Nordic's slowly growing softwood forests may give the paper its inherent strength.

The cellulose sheets may be produced from a mill. In some examples, a mill may have been certified in accordance with ISO 9001, ISO 14001, ISO 50001, FSC® CoC (FSC-C020000) and PEFC™ COC (PEFC/05-33-136).

The honeycomb structure may be comprised of, for example, up to 180 layers of cellulose or hexagon sheets. Sheets may be divided (e.g., using one or more dividers) into a plurality of sections (e.g., two 90 layer sheet sections). A middle support, typically formed of plywood or another durable light weight material (e.g., having a height of 24 cm), may be glued between each of a plurality of sections of honeycomb sheets, in some examples. Panels (e.g., front panel 206, back panel 208, and side panels 302, 304, referring to FIGS. 2, 3) may be made out of a frame of wood that is laminated with 3 mm MDF board to be covered, for example. A layer of 1 cm foam may be glued to a panel. Fabric may be added to cover foam where foam is used, and may be permanently attached (e.g., stapled) to the back side of each panel. Glue may be used to attach the honeycomb structure to front and back panels (e.g., front panel 206 and back panel 208 of FIG. 3), such as by using a white or clear glue (such as PVA) and pressing these under a pressing machine for 10-15 minutes.

In some examples, a white glue Poly Vinyl Acetate (PVA) (commonly known as wood glue or White glue), or equivalent, may be used to glue sheets together to make the honeycomb structure. An aliphatic rubbery synthetic polymer with the formula (C4H602)n, it belongs to the polyvinyl ester family, with the general formula RCOOCHCH2.

Advantages of the present disclosure may include, without limitation, space efficiency. Unlike more traditional furniture which typically requires assembly and may not be easily moved, furniture objects which include the honeycomb structure as presently disclosed can be folded down to a fraction (e.g., less than 70%, less than 50%, less than 30%, less than 20%, or ranges therebetween), making them ideal for smaller spaces (e.g., apartments, dorm rooms) or venues where storage space is limited. Furthermore, the furniture objects may have improved portability. For example, due to the inherent collapsibility of the honeycomb structure, the furniture objects may be much easier to transport than traditional furniture, resulting in improved convenience for more transient dwellers (e.g., those who live in temporary housing). The furniture objects are also more customizable than traditional furniture. Modular designs may allow users to customize and configure furniture to suit individual needs. This flexibility particularly benefits users who frequently rearrange living spaces or who have specialized requirements for their furniture layout. In addition, the furniture objects that include the honeycomb structure are durable and long-lasting and are able to withstand regular use and retain their structure overtime. The furniture objects may also be environmentally friendly by virtue of both their materials and reduced C.

FIG. 1 illustrates a front view of a sofa bed 100 in a non-extended configuration, in accordance with some embodiments of the present disclosure. A sofa bed 100 may include arm rest sections 102 that bookend a pair of pull-out sections 106 and a pair of back sections 104. Together, the arm rest sections 102, back sections 104, and pull-out sections 106 may form a structure that support the weight of sofa bed cushions 110, pillow cushions 108, and any personnel disposed thereon.

FIG. 2 illustrates pull-out sections 106 of the sofa bed 100 of FIG. 1, each in a non-extended configuration, in accordance with some embodiments of the present disclosure. As shown, pull-out sections 106 may each comprise one or more, e.g., in this example, first and second honeycomb sections 202a, 202b, comprising the honeycomb structure. A tab 204 may facilitate pulling out the pull-out section 106. In use, a person can grab the tab 204 and pull on the pull-out section 106 away from the sofa bed 100 (e.g., referring to FIG. 1) causing second honeycomb section 202b to expand to the extended configuration of FIG. 3. In the non-extended configuration, first honeycomb section 202a may be extended while second honeycomb section 202b is not extended. In alternative configurations, such as when pull-out section 106 comprises a single honeycomb structure, opening and closing may result in extension and collapse of a single honeycomb structure, e.g., extending between opposite front and back panels 206, 208 of pull-out section 106.

FIG. 3 illustrates the pull-out sections 106 of the sofa bed 100 of FIG. 2, each in an extended configuration, in accordance with some embodiments of the present disclosure. This Figure shows second honeycomb section 202b in an extended configuration. As compared to FIG. 2, the length of an extended configuration may be many times the length of the non-extended configuration, for example, at least 5, 6, 7, 10, or 15 times the length of the non-extended configuration. This Figure also shows sliders 300 which may be disposed on either side of the honeycomb sections 202a, 202b. Sliders 300 may comprise, for example, a metal track, a drawer slider, wheels, the like, or any suitable mechanism to guide second honeycomb section 202b between the extended and non-extended configurations. In this example, first honeycomb section 202a is bounded on three sides by respective panels 302a, 302b, 302c which may comprise, for example, wood, plastic, fiber, etc., or any suitable material. As will be shown schematically in later figures (e.g., referring to FIGS. 15, 16, 19, and 20), sliders 300 may be permanently attached to front panel 206 and side panels 302, 304. Front panel 206 may temporarily attach to part of sofa bed 100 (e.g., to side panels 302, 304), such as via one or more connectors (e.g., hook and loop fastener, clips, metal hook, latch, magnet, etc.) so that the pull-out section 106 remains in the non-extended configuration when desired.

FIG. 4 illustrates the pull-out sections of FIGS. 2 and 3 side-by side, with respective back sections 104 of the sofa bed 100 (e.g., referring to FIG. 1) installed, in accordance with some embodiments of the present disclosure. Back sections 104 may be coupled to pull-out sections 106, such as by one or more U connectors (e.g., referring to FIG. 23). Pull-out sections 106 may likewise be coupled together, to prevent them from migrating away from each other during use. This Figure also shows honeycomb sections 202a, 202b.

FIG. 5 illustrates the pull-out sections 106 and respective back sections 104 of FIG. 4, with arm rest sections 102 of the sofa bed 100 installed, in accordance with some embodiments of the present disclosure. Arm rest sections 102 may, in some examples, be identical to back sections 104. Further, arm rest section 102 may correspond to what is schematically shown in FIG. 21, in some examples.

FIG. 6 illustrates the pull-out sections 106, respective back sections 104, and arm rest sections 102 of the sofa bed 100 of FIG. 5, with covers 600a, 600b partially placed over the honeycomb structures 202, in accordance with some embodiments of the present disclosure. Covers 600a, 600b may comprise any suitable material or fabric. Covers 600a, 600b may serve to provide a layer between sofa bed cushions 110 (e.g., referring to FIGS. 1 and 7) that protects the honeycomb structures 202 from becoming damaged, e.g., when sofa bed cushions 110 are removed.

FIG. 7 illustrates an angled view of the sofa bed of FIG. 1, comprising the various sections 102, 104, 106, of FIGS. 2-6, and with pillow and sofa cushions 108, 110 disposed thereon, in accordance with some embodiments of the present disclosure. Sofa bed cushions 110 may be disposed on top of covers 600a, 600b. A seam 700 may divide upper and lower sections 702, 704 of a given sofa bed cushion 110. Upper and lower sections 702, 704 may be folded outward to form a bed cushion (e.g., bed cushion 110 of FIGS. 10, 11).

FIG. 8 illustrates the sofa bed of FIG. 7, with the sofa bed cushions 110 (e.g., referring to FIG. 7) removed, and with the pull-out sections 106 in the extended configuration of FIG. 3, in accordance with some embodiments of the present disclosure. Also visible in this Figure is honeycomb section 202b of each pull-out section 106.

FIG. 9 illustrates the sofa bed 100 of FIG. 8, with covers 600a, 600b placed over the honeycomb section 202b (e.g., referring to FIG. 8) in the extended configuration, in accordance with some embodiments of the present disclosure. Like sofa bed cushion 110 of FIG. 7, covers 600a, 600b may be folded in half in FIG. 6a and unfolded to achieve the full length shown in this Figure. In a full length, covers 600a, 600b may extend from back sections 104 all the way up to front panels 206 of pull-out sections 106.

FIG. 10 illustrates the sofa bed 100 of FIG. 9, with sofa bed cushions 110 partially placed over the covers 600, in accordance with some embodiments of the present disclosure. A person may pull on the tabs 204 (e.g., referring to FIG. 2) to achieve the extended configuration and then unfold sofa bed cushions 110 so that it achieves the desired length.

FIG. 11 illustrates the sofa bed 100 of FIG. 10, with the sofa bed cushions 110 unfolded and placed across the full length of the pull-out sections 106 in the extended configurations, (e.g., over the covers 600 of FIG. 6). This Figure also shows how pillow cushions 108 may be disposed on the sofa bed cushions 110 and used as pillows, in accordance with some embodiments of the present disclosure.

FIG. 12 illustrates the sofa bed 100 of FIG. 11, with one of the pull-out sections 106 in a partially non-extended configuration, in accordance with some embodiments of the present disclosure. FIG. 13 illustrates the sofa bed 100 of FIG. 12, but with one of the pull-out sections 106 in the extended configuration and the other in the non-extended configuration, in accordance with some embodiments of the present disclosure. This Figure shows how a sofa bed cushion 110a that is folded may be taller than a sofa bed cushion 110b that is unfolded.

FIG. 14 illustrates a pull-out section 106 of FIG. 1, in accordance with some embodiments of the present disclosure. Also visible in this Figure is seam 700 dividing upper and lower sections 702, 704. Pull-out section 106 may be characterized as a “puff bed,” in some examples. In some examples, a puff bed may be a standalone piece of furniture separate and apart from sofa bed 100 of FIGS. 1-13 or may be included as a modular subcomponent thereof.

FIG. 15 illustrates a schematic view of the pull-out section 106 of FIG. 14 in a non-extended position, in accordance with some embodiments of the present disclosure. As illustrated, pull-out section 106 may comprise a first honeycomb section 202a bounded by front and back panels 206, 208 and side panels 302, 304. A second honeycomb section 202b (e.g., referring to FIG. 16) may also be included within a gap 1500 formed between a divider 1502 and front panel 206, but is omitted in this Figure for clarity. Sliders 300 are also shown in this figure as being disposed between first honeycomb section 202a and side panels 302, 304, and extend past gap 1500 to attach to front panel 206. In the non-extended position, front panel 206 may seat against corresponding surfaces of side panels 302, 304 when second honeycomb section 202b (e.g., referring to FIG. 16) is compressed. This Figure also shows protrusions 1504 which may alternatively be, for example, wheels. Protrusions 1504 may seat against the floor and may prevent front panel 206 from touching the floor. This allows opening/closing of pull-out sections 106 with minimal resistance and without touching the floor.

FIG. 16 illustrates the schematic view of the pull-out section 106 of FIGS. 15 but in an extended position, in accordance with some embodiments of the present disclosure. As illustrated, sliders 300 are fully extended and second honeycomb section 202b is also extended. Divider 1502, in this example, has the same axial position along the length of side panels 302, 304 in both the extended and non-extended positions (e.g., referring to both FIGS. 15 and 16).

FIG. 17 illustrates the schematic view of the pull-out section 106 of FIG. 15, but with a sofa bed cushion 110 in a folded configuration and disposed thereon, in accordance with some embodiments of the present disclosure. Also visible in this Figure are seam 700, upper section 702, and lower section 704.

FIG. 18 illustrates the schematic view of the pull-out section 106 in the extended position of FIG. 16, but with the bed cushion of FIG. 17 unfolded and spread out across pull-out section 106, in accordance with some embodiments of the present disclosure. As illustrated, upper section 702 may be disposed on one side of pull-out section 106, and lower section 704 may be disposed on an opposite side. Seam 700 may thus be disposed at an axial distance about halfway between either end of pull-out section 106 in the extended configuration.

FIG. 19A illustrates the schematic view of FIG. 16, but from another angle to show two screws 1900 and a bracket 1902 to attach to a slider 300 and front panel 206, in accordance with some embodiments of the present disclosure. FIG. 19B illustrates a close-up view of the two screws 1900, bracket 1902, slider 300, and front panel 206 of FIG. 19A, in accordance with some embodiments of the present disclosure.

FIG. 20 illustrates an exploded schematic view of a body of an armrest section 102, in accordance with some embodiments of the present disclosure. As illustrated, an armrest section 102 may comprise any suitable number (e.g., 6) of pieces including, for example, front and back pieces 2102a, 2102b, side pieces 2100a, 2100b each supported by support strips 2106a, 2106b, as well as a top piece 2104 and bottom piece (not shown). Each side may comprise one or more layers of a suitable material (e.g., wood, plastic, corrugated sheets, etc.). For example, side pieces 2100a, 2100b may comprise wood, and support strips 2106a, 2106b may comprise corrugated sheets. In some examples, a length by height by width of armrest section 102 may be about 925 mm by 600 mm by 170 mm. Alternatively, a length between 700 mm and 1500 mm, a height between 300 mm and 1200 mm, and a width between 100 mm and 500 mm, or any ranges therebetween. One or more (e.g., all) dimensions of armrest section 102 may be shared by back section 104 (e.g., referring to FIG. 22A). Advantageously, this may allow for interchangeability between an armrest section 102 and a back section 104, in some examples.

FIG. 21 illustrates an armrest sponge 2200 draped over an armrest section 102, in accordance with some embodiments of the present disclosure. Also visible in this Figure are top piece 2104, front piece 2102a, and side piece 2100b. Armrest sponge 2200 may comprise any suitable number of layers and may provide cushioning to sofa bed 100.

FIG. 22A illustrates a schematic view of a pull-out section installed within a sofa bed by a plurality of clamps 2300, in accordance with some embodiments of the present disclosure. Clamps 2300 are shown as clamping together side panel 304 to armrest section 102 as well as back panel 208 to back section 104. In some examples, one or more clamps 2300 may also be used to clamp together two or more pull-out sections 106 (e.g., referring to FIG. 15-20). This Figure also shows an end 2302 of honeycomb section 202a which may seat against back panel 208 when sofa bed 100 is assembled. FIG. 22B illustrates a close-up view of two clamps 2300 shown in FIG. 22A, in accordance with some embodiments of the present disclosure. Also visible in this Figure is slider 300.

FIG. 23 illustrates a schematic view of a clamp 2300, in accordance with some embodiments of the present disclosure. Clamp 2300 may comprise a body 2304, a wing nut 2306, and a clamping member 2308. In operation, adjacent sections (e.g., a pull-out section and an armrest section) may be clamped together by tightening wing nut 2306 to press clamping pressure thereto via clamping member 2308. Other connection/attachment devices are possible as alternatives to clamp 2300, however, an advantage posed by Clamp 2300 is its ability to allow sofa bed 100 to be modular and to be easily disassembled and reassembled. Also, this makes moving (e.g., shipping, installing, etc.) of sofa bed 100 easier. E.g., clamp 2300 may be characterized as a “temporary U clamp” in some examples.

FIG. 24 illustrates a schematic top view of a sofa bed 100 to show various placement locations of the clamps 2300 shown by FIGS. 22A, 22B, and 23, in accordance with some embodiments of the present disclosure. This Figure shows 10 clamps 2300. However, any suitable number may be used (e.g., 8, 9, 10, 12, 15, 20, etc.). Moreover, the placement locations of clamps 2300 may be modified to adjust a specific application. Advantageously, placement of the clamps 2300 in these locations may securely form the structure of sofa bed 100 from modular components.

FIG. 25A illustrates a schematic view of a frame of a sofa 2500, in accordance with some embodiments of the present disclosure. Frame of sofa 2500 may comprise a plurality (e.g., 4 or more) members 2502 extending laterally between opposite arm rest sections 2504. Members 2502 may comprise, for example, any suitable support structure such as rods, hollow steel frames, wooden beams, the like, or any suitable material (e.g., engineered wood, cardboard, plastic, carbon fiber, etc.) capable of maintaining a structure of sofa 2500. In some examples, connectors 2508 may be used to connect members 2502 together, such as at a midpoint between arm rest sections 2504, as shown. A divider, e.g., divider, may be used to support frame of sofa 2500. A profile of divider may be adapted, such as at respective corners, to allow members 2502 to pass therethrough and/or rest thereon or may otherwise conform to frame of sofa 2500. While specific types of connectors 2508 are herein disclosed, various alternatives are also possible. In some examples, connectors 2508 and/or divider are not needed, and members 2502 have sufficient strength to withstand weight when it is applied to a sofa 2500. FIG. 25B illustrates a schematic view of the example connector 2508 shown in FIG. 25A, in accordance with some embodiments of the present disclosure. As illustrated, a connector 2508 may comprise a body 2510 (e.g., rectangular) having one or more apertures 2512 disposed therein, and a u-shaped track 2514 to help guide divider to the appropriate lateral configuration within sofa 2500. This may ensure that a honeycomb structure (e.g., honeycomb structure 2700 of FIG. 27) is evenly distributed across a length of sofa 2500, by ensuring that an amount of the honeycomb structure is equal on either side, in some examples. FIG. 25C illustrates a close-up view of the connector 2508 of FIG. 25B over a divider 2506 of FIG. 25A, in accordance with some embodiments of the present disclosure. Divider 2506 may serve to divide various honeycomb sections of a honeycomb structure (e.g., honeycomb structure 2700 of FIG. 27). Divider 2506 may also, in some examples, help to structurally support a frame of sofa 2500. As illustrated, one or more bolts 2516 (e.g., hex bolts) may be used to secure connector 2508 to members 2502 while u-shaped track 2514 aligns with divider 2506. Alignment may be achieved by resting u-shaped track 2514 on an aperture 2518 of divider, as shown. FIG. 25D illustrates a cross-sectional view of connector 2600 shown in FIG. 25C, attached to a member 2502 by a bolt 2516 and wingnut 2520, in accordance with some embodiments of the present disclosure. As illustrated, the end of member 2502 may rest against a stop 2522 of connector 2508. Stop 2522 may allow an assembler to limit over-insertion of member 2502 in connector 2508 while aiding in signaling to an assembler when member 2502 is fully inserted (thereby also preventing under-insertion).

FIG. 26A illustrates a schematic view of a frame of sofa 2500, with another example of a connector 2600, and with arm rest sections 2504 omitted for reference, in accordance with some embodiments of the present disclosure. This Figure also shows how multiple dividers 2506 (e.g., 2, 3, 4, 5, 6, or more) may be used, as well as how a profile of a divider 2506 may vary, in some examples. A profile of a honeycomb structure disposed within sofa 2500 may conform with a profile of dividers 2506, in some examples, as illustrated. FIG. 26B illustrates a close-up view of connector 2600, disposed under a divider 2506, in accordance with some embodiments of the present disclosure. This Figure also shows a dowel 2606 which may limit over-insertion of connector 2508, in some examples. FIG. 26C illustrates a close-up view of a connector 2600, disposed above a divider 2506, in accordance with some embodiments of the present disclosure. In this example, connector 2508 may comprises a hinge 2602. Rotation of hinge 2602 is limited by an overhanging portion 2604 of connector 2508. This may facilitate compact shipping without sacrificing structural stability of sofa 2500. An assembler may unfold member 2502 at hinge 2602 and then slide an outer body 2608 of connector 2600 over hinge 2602 until outer body 2608 meets dowel 2606 (e.g., referring to FIG. 26B). FIG. 26D illustrates an exploded view of the connector 2600 of FIGS. 26A-26C, in accordance with some embodiments of the present disclosure. FIG. 26E illustrates a non-exploded view of the connector of FIG. 26D, in accordance with some embodiments of the present disclosure. Dowel 2606 (e.g., referring to FIG. 26B) is omitted in this view.

FIG. 27 illustrates a partially exploded schematic view of a partially assembled sofa 2500, with a honeycomb structure 2700 disposed therein, in accordance with some embodiments of the present disclosure. Members 2502 may be omitted from sofa 2500, in some examples, however, apertures 2518 in dividers 2506 may allow such members 2502 to pass therethrough to form a frame, as previously shown (e.g., referring to FIGS. 25A, 26A). Two assembler may, in some examples, standing at opposite sides of sofa 2500, pull apart the honeycomb structure by tugging on arm rest sections 2504 until sofa 2500 reaches a desired length. Dividers 2506 separating one or more honeycomb sections of honeycomb structure 2700 and may conform generally to a shape thereto. In the illustrated example, divider 2506 has a recessed portion (e.g., be bowed inwards) to accommodate for comfortably sitting, for example.

FIG. 28 illustrates a clip for clipping together respective ends of two separate sections of honeycomb structure 2700 of the sofa bed of FIG. 27, in accordance with some embodiments of the present disclosure.

FIG. 29 illustrates the clip 2800 of FIG. 28, installed in the sofa 2500 of FIG. 27, in accordance with some embodiments of the present disclosure. An end 2802 may flare outwards slightly to facilitate easy assembly. One or more clips 2800 may be used to connect multiple dividers 2506 together at various locations along an outer periphery 2900 of a cross-sectional section of two dividers 2506 (e.g., referring to FIG. 27) of honeycomb structure 2700. This may allow multiple sections of honeycomb structure 2700 to be securely coupled together to form a uniform structure capable of bearing the weight of multiple people.

FIG. 30A illustrates a schematic view of base padding 3000 disposed on a sofa 2500 in accordance with some embodiments of the present disclosure. FIG. 30B illustrates an exploded schematic view of the base padding 3000 of FIG. 30A, in accordance with some embodiments of the present disclosure. Base padding 3000 may comprise one or more layers of sheets, fabric, hook and loop fasteners, or the like, to provide cushion between the honeycomb structure and a person and/or sofa cushion, for example. In the example shown, strips of fabric 3002 are arranged along an outer edge of base padding 3000. Top layer 3004 may comprise a hook and loop fastener, in some examples. In one example, middle layer 3006 may have one or more metal rings (not shown) disposed therein. FIG. 30C illustrates the base padding 3000 of FIG. 30B affixed to a beam 3008 of a sofa 2500 with a bolt 2516 and wingnut 2520, in accordance with some embodiments of the present disclosure.

FIG. 31 illustrates an exploded schematic view of a front panel 3100 for a sofa 2500 (e.g., referring to FIGS. 27 and 30A), in accordance with some embodiments of the present disclosure. Front panel 3100 may comprise one or more layers, such as a rear layer 3102, a middle layer 3104, and a front layer 3106. A layer may comprise, for example, lining, fabric, wood, fiber, corrugated sheets, or the like. A piece 3108 may comprise wood and may brace front panel 3100. A strip 3110 may comprise a hook and loop fastener.

FIG. 32 illustrates an exploded view of back padding 3200 for a sofa 2500 (e.g., referring to FIGS. 27 and 30A), in accordance with some embodiments of the present disclosure. Back padding 3200 may comprise one or more layers, such as a top layer 3202, a lower layer 3204, and a back layer 3206. A layer may comprise, for example, lining, fabric, a sponge, fiber, corrugated sheets, and combinations thereof. Piece 3208 may comprise wood and may brace lower layer 3204 and back layer 3206. A beam 3210 may be disposed between top layer 3202 and lower layer 3204.

Although this invention has been disclosed in the context of certain embodiments and examples, it will be understood by those skilled in the art that the invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. In addition, while several variations of the embodiments of the invention have been shown and describe the sofa bed in detail, other modifications, which are within the scope of this invention, including, but not limited to, the substitutions of equivalent features, materials, or parts, will be readily apparent to those of skill in the art based upon this disclosure without departing from the spirit and scope of the invention.

Although specific embodiments have been described above, these embodiments are not intended to limit the scope of the present disclosure, even where only a single embodiment is described with respect to a particular feature. Examples of features provided in the disclosure are intended to be illustrative rather than restrictive unless stated otherwise. The above description is intended to cover such alternatives, modifications, and equivalents as would be apparent to a person skilled in the art having the benefit of this disclosure. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms “a”, “an”, and “the” include singular and plural referents unless the content clearly dictates otherwise. Furthermore, the word “may” is used throughout this application in a permissive sense (i.e., having the potential to, being able to), not in a mandatory sense (i.e., must). The term “include,” and derivations thereof, mean “including, but not limited to.” The term “coupled” means directly or indirectly connected. If there is any conflict in the usages of a word or term in this specification and one or more patent or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted for the purposes of understanding this invention.

For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.

The scope of the present disclosure includes any feature or combination of features disclosed herein (either explicitly or implicitly), or any generalization thereof, whether or not it mitigates any or all of the problems addressed herein. Various advantages of the present disclosure have been described bed herein, but embodiments may provide some, all, or none of such advantages, or may provide other advantages.

Claims

1. A sofa bed, comprising:

opposing arm rest sections;

a back section; and

a pull-out section, comprising: a honeycomb structure disposed between the opposing arm rest sections, wherein the honeycomb structure of each pull-out section is configured to change between an extended and a non-extended position.

2. The sofa bed of claim 1, wherein the honeycomb structure comprises at least a first and a second section of the honeycomb structure, wherein the second section of each pull-out section is configured to expand and collapse between the extended and the non-extended positions.

3. The sofa bed of claim 1, wherein each pull-out section is attached to at least one back section and at least one of the opposing arm rest sections by a plurality of u-shaped clamps.

4. The sofa bed of claim 3, wherein at least ten of the u-shaped clamps are disposed at respective intersections along the opposing arm rest sections, the back section, and the pull-out section, wherein each of the opposing arm rest sections, the back section, and the pull-out section are modular, and wherein an armrest sponge draped over each of the opposing arm rest sections.

5. The sofa bed of claim 1, further comprising a sofa cushion disposed on the pull-out section, wherein the sofa cushion comprises upper and lower sections folded along a seam and configured to unfold to form a bed cushion spanning a length of the pull-out section in the extended position.

6. The sofa bed of claim 1, wherein the honeycomb structure is disposed within an area bounded by front, back, and side panels of the pull-out section.

7. The sofa bed of claim 1, wherein the pull-out section comprises one or more sliders configured to expand and collapse the honeycomb structure between the extended and non-extended positions.

8. A puff bed, comprising:

front and back panels;

side panels; and

one or more honeycomb structures disposed within an area bounded by the front, back, and side panels, wherein at least one honeycomb structure is configured to convert the puff bed into an extended configuration from a non-extended configuration.

9. The puff bed of claim 8, wherein the puff bed comprises sliders attached to the side panels to allow the puff bed to extend into the extended configuration, wherein the puff bed in the extended configuration is about twice a length of the puff bed in the non-extended configuration.

10. The puff bed of claim 9, further comprising:

a cushion disposed above the one or more honeycomb structures; and

a tab attached to the front panel to enable sliding along the sliders to convert between the extended configuration and a non-extended configuration,

wherein the cushion comprises upper and lower sections that unfold to conform with a length of the puff bed in the extended configuration.

11. A sofa, comprising:

opposing arm rest sections;

a frame comprising a plurality of members extending between the opposing arm rest sections;

a divider disposed between the plurality of members; and

a honeycomb structure disposed between the opposing arm rests.

12. The sofa of claim 11, wherein the sofa is configured such that assembly comprises expanding the honeycomb structure by pulling apart, in opposite directions, the opposing arm rest sections.

13. The sofa of claim 11, further comprising a connector for attaching the plurality of members together at a midpoint of the frame.

14. The sofa of claim 13, wherein the connector comprises a u-shaped guide track that seats the divider.

15. The sofa of claim 14, wherein the connector further comprises a hinge and a dowel.

16. The sofa of claim 12, further comprising one or more clips to clip together dividers corresponding to separate honeycomb sections of the honeycomb structure, wherein each clip flares outwardly at an end to facilitate assembly.

17. The sofa of claim 11, further comprising base padding disposed above the honeycomb structure.

18. The sofa of claim 11, further comprising a front panel attached to the sofa.

19. The sofa of claim 11, further comprising back padding attached to the sofa.

20. The sofa of claim 11, wherein the plurality of members extends through respective apertures of the divider, and wherein a profile of the honeycomb structure generally conforms to a profile of the divider.