Field of the invention

The invention relates to a method for manufacturing a furniture part. In particular, it relates to a method for manufacturing a panel for a piece of furniture.

Background

Articles of furniture, such as closets, chests of drawers, beds, and the like, are usually assembled from a number of individual furniture parts. Such parts can be, for example, panels, rods, bars, staves, or similar items. While the articles of furniture might be displayed as a whole in a store, it is impractical to transport them to a customer in an assembled state, especially if the articles are bulky. Thus, typically, the articles are transported to the customer in a disassembled state and then assembled from the individual parts on-site, either by trained personnel or by the customers themselves.

The individual furniture parts can be made from solid pieces of material, in particular from wood. However, for larger parts, e.g., panels to be used for side walls or front pieces of the article, this results in very heavy parts, making transport and assembly more difficult. Further, such parts are expensive due to the amount of material needed, and their machining can result in a large amount of wasted or unused material.

To address this problem, it is generally known in the art to manufacture such parts by connecting individual, comparatively thin, rods or bars together so that they form a hollow frame for the furniture part. Covering panels are subsequently attached the front side and the back side of the frame. This way, a furniture part is formed which is essentially hollow. As such, it is lighter than a corresponding solid part. Further, less material is used for the construction, reducing the price.

On the other hand, while a solid part can, e.g., be machined from a single piece of wood, the production of a frame as described above requires a larger number of individual pieces. For example, one rod might be needed for each side of the frame. Further, all of the pieces have to be carefully manufactured such that they fit together precisely. As such, producing and connecting the pieces requires more separate work steps than producing a solid part. Accordingly, it bears an associated higher risk for errors. Further, if a large number of identical frames is to be produced, the individual pieces should be identical for each frame, which can be difficult to achieve for large numbers.

Thus, it is the object of the invention to provide a method with which lightweight furniture parts can be mass-produced in an efficient and economic manner. Summary of the invention

This object is achieved with a method for manufacturing a furniture part according to claim 1. Preferred embodiments are specified in the dependent claims.

According to the invention, the method comprises the following steps:

(a) A hollow structure is provided which extends along a longitudinal direction. The hollow structure comprises a plurality of exterior walls, wherein each exterior wall extends parallel to the longitudinal direction. The hollow structure has a predetermined cross- sectional shape in a plane normal to the longitudinal direction.

(b) The hollow structure is cut transverse to the longitudinal direction, such that a first frame is formed. The first frame has the predetermined cross-sectional shape in a plane which is normal to the longitudinal direction.

(c) A first covering panel is attached to the front side of the first frame.

Here and in the following, for ease of understanding, a right-handed Cartesian coordinate system will be used as a reference system for directions.

In particular, the Y-axis is chosen to correspond to the longitudinal direction. The X- and Y-axes form the horizontal plane, and the Z-axis corresponds to the vertical direction. Here, horizontal and vertical refer to the positioning of the hollow structure during the cutting procedure, i.e., the horizontal plane is parallel to the surface the structure is resting on during this procedure. An X- Y-plane is any plane that is parallel to the plane formed by the X- and Y-axes; this applies analogously to X-Z- or Y-Z-planes. Using this reference frame, the predetermined cross-sectional shape lies in an X-Z-plane.

A frame can, of course, be oriented arbitrarily after it has been cut from the hollow structure. However, for the sake of convenience and clarity, the X-, Y-, and Z-directions are defined hereinafter for such a frame as corresponding to the respective directions of the hollow structure from which the frame is cut. In other words, the Y-direction of the frame coincides with the Y- direction of the hollow structure while the frame is being cut from the hollow structure; this applies analogously to the X- and Z- directions.

The“front”,“back”,“top”,“bottom”,“left� �� and“right” sides of an element refer to the respective sides of the element when it is looked at in positive Y-direction.

Per definition, the hollow structure extends from the front side of the structure along the longitudinal direction to the back side. The exterior walls extend between the front and back sides of the hollow structure. The term“cut transverse to the longitudinal direction” is to be understood such that, when looking at the hollow structure from the front, the cut starts on the left, right, top, or lower side of the hollow structure and proceeds across the entire hollow structure through the opposite side. It is to be understood that the cut crosses each of the plurality of exterior walls. In other words, the frame is completely separated from the remainder of the hollow structure after the cut is finished.

For the cutting, any suitable method or device can be used. It can, for example, be performed with a band saw, a cross-cutting saw or any other suitable type of saw. Alternatively, waterjet cutting or laser beam cutting can be used.

Preferably, the outer contour of the cross-sectional shape of the hollow structure corresponds, at least partly, to the outer contour of the furniture part. There is no principal restriction on the outer contour of the predetermined cross-sectional shape. It can be a regular rectangular shape. Alternatively, it can be a regular or irregular polygonal shape, such as a triangle, a pentagon, a hexagon etcetera. While it is preferable for ease of manufacturing that the contour consists of straight lines, the contour can also comprise curved lines.

The cross-sectional shape can be a symmetric shape. It can also be an asymmetric shape.

The first covering panel can be fixed to the front side of the frame by gluing or any other suitable method. The first covering panel and the frame can also be screwed or stapled together.

The exterior walls of the hollow structure are rigidly attached to one another. In particular, they can be glued together. The exterior walls can all be glued together in the same step. They can also be glued together sequentially. The step of gluing can involve applying glue to one or more portions of two or more exterior walls and then pressing the exterior walls together so that these portions overlap. In particular, a press can be used for to apply pressure to the exterior walls while they are being glued. In particular, the press can be at least partially shaped as a mould for at least a part of the hollow structure. This is advantageous if one of the sides of the hollow structure is comprised of more than one exterior wall.

Other methods of rigidly attaching the exterior walls to each other are also possible. The exterior walls can, for example, be attached to each other via screws or similar fixing means. Depending on the material, it might also be possible to solder, weld, or chemically bond them together.

Each exterior wall can comprise one board. It can also comprise more than one board. In particular, an exterior wall may comprise one primary board which forms the outer part of the exterior wall, and one or more secondary boards which are fixed to the inner side of the primary board, which will face the inside of the hollow structure after the exterior walls are attached to each other. In particular, the secondary boards can serve as reinforcement of the exterior wall and/or they may serve to provide material at places inside the frame once it is cut from the hollow structure. The material provided inside the frame by these secondary boards may, e.g., be used to provide mounting points for handles, hinges, or similar structural features of the final article of furniture. The primary boards and the secondary boards may comprise the same materials. They may also be made from different materials.

The method can further comprise repeating step (b) multiple times to obtain a plurality of frames having the p re-determined cross-sectional shape. In particular, step (b) can be repeated until the entire hollow structure has been cut into a plurality of frames having the predetermined cross- sectional shape in a plane which is normal to the longitudinal direction. Thus, a number of frames with identical cross-sectional shape can be manufactured in a convenient and fast manner.

In addition, the hollow structure can comprise interior walls located on the inside of the hollow structure. Here, an interior wall is to be understood as an element that extends between at least two other elements inside the hollow structure, thereby connecting them. In particular, the interior walls can extend along the longitudinal direction over the entire length of the hollow structure. In other words, each frame that is cut from the hollow structure having interior walls will comprise elements corresponding to the interior walls. For example, an interior wall can extend between two exterior walls. It can also extend between two secondary boards as described above. It can also extend between two other interior walls. In particular, an interior wall may connect two opposing exterior walls to each other. One or more of the interior walls can be connected to one another. In particular, one or more of the interior walls can be connected to one or more other interior walls, without being directly connected to an exterior wall. The interior walls can provide reinforcement to the hollow structure, and/or to the first frame and/or to the final furniture part. Further, the material provided inside the frame by these interior walls may be used, for example, to provide connection points for handles or other structural features of the final article of furniture.

The interior walls do not need to be solid walls. They can, e.g., have a honeycomb structure.

The method can further comprise the following step:

(d) A second covering panel is attached to the back side of the first frame.

The second covering panel can be fixed to the back side of the first frame in the same manner as described above for the first covering panel being fixed to the front side.

The plurality of exterior walls and/or the first covering panel and/or the second covering panel and/or the interior walls can comprise a wooden material, such as solid wood, plywood, high- density fiberboard (HDF), medium-density fiberboard (MDF), particleboard, cardboard, oriented strandboard (OSB), or other type of fiberboard. In particular, any or all of them can comprise HDF and/or MDF. These materials can be easily machined, and are structurally robust and light-weight. For the exterior walls of the hollow structure, MDF has been found to be particularly useful. However, any other material suitable for making furniture parts can be used alternatively or additionally. For example, light-weight metals or plastics are also suitable materials.

In one embodiment, step (b) can precede step (c). In other words, the frame can first be cut from the hollow structure, and then the first covering panel can be attached to the front side of the frame.

In an alternative embodiment, step (c) can precede step (b). In this case, the first covering panel is attached to the front side of the hollow structure, and then the frame is cut off. This can be advantageous if the exterior walls of the hollow structure are thin; in that case, the first covering panel provides support to the hollow structure during the cutting process. Thus, deformations of the hollow structure caused by, e.g., the operation of the saw, can be avoided. Analogously, this sequence of steps may be preferable if the piece that is to be cut off, i.e., the frame, is thin. Then, the covering panel can provide support to the frame while it is being cut off, reducing the risk of the frame breaking or being otherwise damaged during the cutting. It is to be understood that it is also possible, and that it provides the same effect, that the sequence of the steps is (d) - (b) - (c). In this case, the second covering panel is attached to the front side of the hollow structure before the cutting.

The method can further comprise filling the hollow structure with a support material and/or structure prior to step (b). The support material can comprise wood or paper, in particular in the form of a honeycomb structure. It can also comprise a foam, in particular a polyurethane foam. The filling can serve to increase the stability of the hollow structure during the cutting process, thereby avoiding or reducing deformations of the hollow structure, which would lead to deformations of the frame. Alternatively, the first frame may be filled with such a support material after step (c) and before step (d). The support material can serve to increase the stability of the furniture part.

The method may further comprise mounting inserts to the frame after step (c). These inserts may, for example, be connection element interfaces, e.g. with metric nuts or plastic“click” elements, for connection of the final article of furniture to handles, knobs, drawers, hinges, other furniture panels etc. The inserts may also be electronic modules such as circuit boards, inductive chargers, components of so-called“smart-home” devices, and the like.

The method can further comprise machining of the first frame and/or the first covering panel and/or the second covering panel. In particular, the machining can comprise milling. In particular, the machining can comprise machining of the outer shape of the first frame and/or the first covering panel and/or the second covering panel. Thus, the contour of the predetermined cross- sectional shape can be slightly different from the contour of the furniture part. For example, even if the furniture part should have rounded corners, the hollow structure, and consequently the frame, may have angular corners. The angular corners can then be milled to provide rounded corners. This makes the manufacture of the hollow structure easier, since boards shaped in a regular rectangular form can be used for the construction of the exterior walls, such boards being easy to produce and readily available.

Further, the machining can comprise the provision of recesses inside the first frame and/or the first covering panel and/or the second covering panel. This way, mounting points for structural features of the final article of furniture, such as hinges or handles, can be provided.

The transverse cutting can be performed such that it results in a cut surface that includes an angle with an X-Z-plane. Alternatively or additionally, the cut surface may be curved and/or comprise irregularities. In other words, the intersection line of the cut surface with a Y-Z-plane and/or an X- Y-plane may have a shape that is not linear. In the following, such an intersection line is also referred to as a path of a cut. In particular, the path may be curved. It may also have a sawtooth like form. It may also have a step-like form.

This way, the face of the frame that results from the cut, i.e., the front and/or back side of the frame can have a cross-sectional profile that is curved and/or angled and/or step-like in an X-Y- plane and/or a Y-Z-plane. Thus, the front and/or back face of the frame can have a three- dimensional structure as required for the furniture part. Further, the paths of the cut can be alternated or mirrored for subsequent cuttings. This way, complementary frames can be manufactured easily.

For example, the cutting of a first frame can follow a path that is linear, but comprises an angle with the Y-direction in an X-Y-plane. The resulting first frame will have a planar front face that is parallel to the X-Z-plane, while the back surface is planar and includes the angle with the X-Z- plane. When a second frame is subsequently cut using a cutting that follows a path that is normal to the Y-direction, it will have a planar front face comprising the corresponding angle with the X- Z-plane and a planar back face that is parallel to the X-Z-plane.

The method according to the invention can further comprise applying a coating to the first frame and/or the first covering panel and/or the second covering panel. The coating can comprise a paint. It can also comprise a lacquer. Such a coating can be applied to the first frame and/or the first covering panel and/or the second covering panel by any suitable method. It can, for example, be applied by spray painting or spray coating as, for example, described in international patent application WO 2018/030944 A1. Additionally or alternatively, the coating can also be applied manually and/or automatically with a brush, a paint roller, or a similar tool. It can also be performed by powder coating. The coating can additionally or alternatively comprise a foil. The foil can, for example, be applied to the first frame and/or the first covering panel and/or the second covering panel by gluing and/or stapling.

The method can further comprise, prior to step (b), applying a coating to the plurality of exterior walls of the hollow structure. In other words, the exterior walls may be provided with a coating. This may happen before or after the exterior walls are rigidly attached to each other. Applying the coating to the exterior walls directly may result in less wasted paint when, e.g., a spray painting process is used.

The method can further comprise providing a three-dimensional structure on an outer surface of the first and/or the second covering panel. The three-dimensional structure can be provided by milling the first and/or second covering panel. Alternatively or additionally, the first and/or second covering panel can be press-molded such that they comprise the three-dimensional pattern. Such a three-dimensional structure can, e.g., increase the structural stability of the covering panels.

The method can further comprise the following steps:

(e) A hollow structure, preferably the same hollow structure from which the first frame has been cut, is cut transverse to the longitudinal direction, such that at least one second frame having a predetermined cross-sectional shape in a plane normal to the longitudinal direction is formed.

(f) The first frame is attached to at least one of the at least one second frames in a side-by-side arrangement.

Here, the term“side-by-side arrangement” means that a side of the first frame is attached to a complementary side of a second frame. Here, the term“complementary” is to be understood to refer to the two sides of the first and the second frame that share the same dimensions, but are located on opposite sides of the respective frame. Examples of complementary sides are the top side of the first frame and the bottom side of the second frame, and vice versa. Further examples of complementary sides are the left side of the first frame and the right side of the second frame, and vice versa. A“side-by-side arrangement” of multiple frames also encompasses arrangements where two or more frames are arranged next to each other in a first direction, and two or more frames are arranged next to each other in a second direction. The first direction may, e.g., be the X-direction, and the second direction may, e.g., be the Z-direction.

By using two or more frames obtained by cutting the same hollow structure, and by combining them, a furniture part which has outer dimensions that are a multiple of the outer dimensions of the frame can easily be manufactured. For example, closets or wardrobes often have several compartments of different height or width, but are designed such that the dimensions of the compartments share a common factor. For example, a closet might comprise several drawers, all having the same height and width, and it might additionally comprise a compartment that has the same width as each drawer, but a height that is a multiple of the height of one drawer. For example, the larger compartment could have twice the height of one drawer. In this case, one frame could be used for the front of each drawer and two frames could be used to form the front for the larger compartment. It is to be noted that the final furniture part used for the front of the larger compartment can have different and/or additional structural features than the final furniture parts used for the fronts of the drawers. For example, the front of the door could comprise recesses used for mounting a handle, which are nor present in the fronts of the drawers.

In other words, multiple frames that are cut from the hollow structure can be used to modularly manufacture furniture parts.

The first frame may be attached directly to a second frame. However, it is also possible to attach the first frame via one or more spacing elements to the second frame. The spacing elements can, for example, be rods or boards. The use of such spacing elements is particularly advantageous in the case that a first furniture part and a second furniture part share one dimension, for example their width, and that the second dimension, e.g. the height, of the second furniture part is different from an integer multiple of the second dimension of the first part. For example, using the above example of a dresser comprising drawers and a large compartment with a door, the door may have a height that is larger than twice, for example 2.1 times, the height of the drawers while having the same width. In this case, the door could be manufactured using two frames of the same type as used for the drawer fronts, with spacing elements provided between the two frames to provide the additional height.

It is to be noted that the invention is not restricted to the use of a first and one or more second frames that have been cut from the same hollow structure. In particular, it is possible to combine a first frame, which has been cut from a first hollow structure, with one or more second frames that have been cut from one or more second hollow structures. This way, frames with different outer dimensions and/or cross-sectional shapes can be combined to form furniture parts as required for a final furniture part.

The length of the hollow structure can be in between 0.5 m and 10 m, preferably in between 2 m and 6 m. Here the length denotes the dimension of the hollow structure along the longitudinal direction Y. The width of the hollow structure may be in between 80 mm and 2.4 m, preferably in between 0.1 m and 0.8 m. The height of the hollow structure may be in between 80 mm and 2.4 m, preferably in between 0.1 m and 0.8 m. A hollow structure with these dimensions can be easily manufactured from exterior walls that are monolithic, since boards of this size are typically easily available and/or manufactured.

The thickness of a frame, i.e. its extension in the Y-direction, may be in between 5 mm and 200 mm, preferably 5 mm to 50 mm. This way, a large number of individual frames can be cut from a hollow structure of the above-given length.

The above-disclosed methods have several advantages:

In the prior art methods for producing a hollow frame, if the frame to be manufactured should have n sides, then in order to produce m frames, n x m individual pieces, e.g. rods, have to be provided and assembled. In contrast, with the method according to the invention, only n parts, namely the sidewalls of the hollow structure, have to be provided and assembled.

Further, the cutting can easily be automated. For example, the hollow structure can be placed on a conveyor belt, which can move the structure along the longitudinal direction. To the side of the conveyor belt, a saw can be provided. The structure can be moved by a defined amount of length past the saw and then be stopped, whereupon the saw can perform the transverse cut. The resulting frame can be removed from the belt, and the structure can be moved a second time by the defined amount of length. Then, a second transverse cut can be performed. This procedure can be repeated until the entire hollow structure has been cut into individual frames.

All these frames are nearly identical, having been cut from the same hollow structure.

The invention further provides a furniture part, in particular manufactured according to one of the methods described above. The furniture part comprises a frame, wherein the frame has been obtained by transverse cutting of a hollow structure, which extends in a longitudinal direction and comprises a plurality of exterior walls, wherein each exterior wall is parallel to the longitudinal direction, and wherein the hollow structure has a predetermined cross-sectional shape in a plane normal to the longitudinal direction. The furniture part further comprises a first covering panel attached to the front side of the frame.

The furniture part can further comprise a second covering panel attached to the back side of the frame.

The first and/or the second covering panel can comprise a three-dimensional pattern. The furniture part can further comprise at least one second frame, wherein the at least one second frame has been obtained by transverse cutting of the hollow structure, wherein the first frame is attached to at least one of the at least one second frames in a side-by-side manner.

Advantageous embodiments will now be described in combination with the enclosed figures.

Brief description of the drawings

Figure 1 schematically shows a hollow structure in explosion view;

Figure 2 schematically shows a hollow structure;

Figures 3a to 3c schematically show the cutting of a frame from a hollow structure;

Figure 4 schematically shows a path for a cut and the resulting frame;

Figure 5 schematically shows a path for a cut and the resulting frame;

Figure 6 schematically shows a path for a cut and the resulting frame;

Figure 7 schematically shows the assembly of a part of a hollow structure;

Figure 8 schematically shows the assembly of a furniture part;

Figure 9 schematically shows an exemplary furniture part;

Figures 10a and 10b schematically show the assembly of a furniture part, and a furniture part, respectively; and

Figure 1 1 schematically shows a piece of furniture using furniture parts manufactured according to the invention.

Detailed description of the invention

Figure 1 shows an explosion view of a hollow structure 101 , which extends along its length in a longitudinal direction, which in the illustrated case corresponds to the Y-direction. The height and width of the hollow structure 101 extend in the Z- and X-direction, respectively. It can be seen that the cross-sectional shape 103 of the hollow structure 101 in an X-Z-plane does not change along the Y-direction, i.e., it remains constant.

In the embodiment shown in Figure 1 , the hollow structure 101 is formed by a plurality of exterior walls 102 such that it has the shape of a rectangular tube, which has a groove in its top surface. The groove runs along the entire length of the tube. Therefore, the contour of the cross-sectional shape 103 in an X-Z-plane forms a rectangle with a recess in its upper side.

It can be seen that each exterior wall 102 comprises one primary board 104. In the embodiment shown in Figure 1 , the left and right exterior walls 102 of the hollow structure 101 also comprise secondary boards 105. The secondary boards 105 can serve to provide stability to the hollow structure 101. They also can provide mounting points for handles, hinges, or similar structural features of the final article of furniture at a later stage of manufacture. The secondary boards 105 are optional. While Figure 1 illustrates the case that the left and right exterior walls 102 comprise secondary boards 105, it goes without saying that each exterior wall 102 can comprise one or more secondary boards 105.

The exterior walls 102 of the hollow structure are rigidly attached to one another. Preferably, they are glued together. The gluing process can, e.g., be similar to the process described with reference to Figure 7 further below. The exterior walls 102 can also be screwed and/or stapled to one another.

Figure 2 schematically shows a hollow structure, which further comprises a plurality of interior walls. In the illustrated embodiment, the hollow structure comprises six interior walls 107a - 107f. It can be seen that interior walls 107a, 107b, 107c, and 107d are connected to both the bottom exterior wall 102a and the top exterior wall 102b of the hollow structure. In other words, the interior walls 107a - 107d connect the bottom exterior wall 102a and the top exterior wall 102b. This way, they reinforce the hollow structure 101 in the Z-direction. Interior walls 107e and 107f are both attached to each of interior walls 107b and 107c, connecting those walls along the X-direction. Thus, interior walls 107e and 107f reinforce the hollow structure along the X-direction. All of the interior walls 107a - 107f also serve to reinforce a frame that is cut from the hollow structure 101. Furthermore, the interior walls 107a-107f may also provide support to one or more covering panels attached to the frame, as described hereinafter. The interior walls 107a-107f also provide material inside such a frame that can be used to provide mounting points for structural elements such as handles.

The interior walls 107a - 107f can be glued to the exterior walls 102a and 102b, and to one another. The gluing process can be similar to the process described with reference to Figure 7 below.

It is to be noted that it is not necessary that all interior walls 107a - 107f connect the bottom exterior wall 102a and the top exterior wall 102b to each other. For example, it could be possible that interior walls 107b and 107c only extend upward from the bottom exterior wall 102a until they connect with interior wall 107e. Such an arrangement may be advantageous if the stability of the hollow structure in Z-direction does not need to be reinforced. In this case, interior walls 107b, 107c, 107e, and 107f would still provide material inside a frame that is cut from the hollow structure, but less material would be needed to manufacture the hollow structure.

Figures 3a - 3c schematically show the process of cutting a frame 201 from a hollow structure 101. The hollow structure 101 can, for example, correspond to the hollow structure 101 illustrated in Figure 1. Figure 3a shows the situation before the cutting starts. A circular saw 106 is positioned to the left side and a short distance behind the front face of the hollow structure 101. In Figure 3b, it can be seen that the circular saw 106 has cut into the hollow structure 101 from the left side and has completely cut through the left exterior wall of the hollow structure 101. The cut proceeds in X-direction through the hollow structure 101. In Figure 3c, the circular saw 106 has passed through the entire hollow structure 101 , thereby separating frame 201 from the hollow structure 101. While the cut is performed by circular saw 106, it can, naturally, also be performed by any other suitable means, such as, for example, a band saw, water beam cutting, or laser cutting.

It is immediately evident from Figure 3c that the frame 201 has the same cross-sectional shape 103 in any X-Z-plane as the hollow structure 101.

The cut illustrated in Figures 3a to 3c results in a frame 201 that has a planar front side and a planar back side, both of which lie in an X-Z-plane. As such, the intersection line of the cut surface with an X-Y-plane, i.e. the path of the cut in an X-Y-plane, and the intersection line of the cut surface with a Y-Z-plane, i.e. the path of the cut in a Y-Z-plane, are both normal to the longitudinal direction Y.

Figure 4 shows, on the top, a close-up view of an alternative cutting process of a hollow structure 101 in more detail. The hollow structure can correspond to the hollow structure 101 illustrated in Figure 1. The dashed line indicates the path of the cut in an X-Y-plane. The path is linear, and it includes an angle a with the Y-axis, the angle a being different from 90°, for example the angle a could be 60° to 89°. In the lower part of Figure 4, the frame 201 resulting from this cut can be seen. The frame 201 has a planar front side, which lies in an X-Z-plane. The back side of the illustrated frame 201 is also planar, but it includes the angle a with any X-Z-plane.

Figure 5 shows, on the top, a close-up view of the cutting of a hollow structure 101 according to another embodiment of the invention. As in Figure 4, the dashed line indicates the path of the cut which proceeds in an X-Y-plane. Unlike in Figure 4, the path is not linear, but curved. As such, the resulting frame 201 has a curved surface, which in the illustrated case is the back side of the frame 201 , as shown in the lower part of Figure 5. The embodiment of Figure 5 is suitable when a furniture panel is to be manufactured that has a rounded face, for example a rounded outer face. Figure 6 shows, on the top, a close-up view of the cutting of a hollow structure 101 according to another embodiment of the invention. The dashed line indicates the path of the cut in a Y-Z-plane. The path is linear, and it includes an angle b with the Z-direction, the angle b being different from 0°, for example the angle b could be 1 ° to 30°. In the lower part of Figure 6, the frame 201 resulting from this cut can be seen. The frame 201 has a planar front side which lies in an X-Z-plane. The back side of the illustrated frame 201 is also planar, but it includes the angle b with any Y-Z-plane.

It is to be understood that the embodiments shown in Figures 4 to 6 can be freely combined and are not limited to the exemplary shapes of the illustrated paths. In other words, the cutting can proceed along a first path in an X-Y-plane that has any arbitrary shape, only being restricted by it being transverse to the Y-direction. At the same time, the cutting can proceed along a second path in a Y-Z-plane, which has arbitrary shape, which is only restricted by being transverse to the Y-direction.

Figure 7 shows the assembly of a part 109 of a hollow structure 101 in more detail. The part 109 can correspond, for example, to the top part of the hollow structure 101 illustrated in Figure 1. It can be seen that the part 109 comprises five separate boards 104. In order to attach the boards 104 to one another, glue is applied to those places of each board 104 that will overlap the respective neighboring boards, as illustrated in the upper picture of Figure 7. Then, as illustrated in the upper picture of Figure 7, the boards 104 are pressed together in order to form a strong adhesion. In the illustrated case, this is done with a press, which comprises a lower press part

601 and an upper press part 602. It can be seen that the shape of the two press parts 601 and

602 complements the outer shape of the part 109, i.e., the press forms a mould for the part 109. The resulting part 109 can be seen in the lower picture of Figure 7. It can be seen that the part 109 comprises a recess 108.

Figure 8 illustrates the assembly of a furniture part according to an embodiment of the invention. It can be seen that a first covering panel 202 is attached to a first side of a frame 201. The frame 201 can, for example, correspond to the frame 201 illustrated in Figure 1. Further, a second covering panel 203 is attached to a second side of the frame 201. The covering panels 202 and

203 can be attached to the respective sides of the frame 201 by gluing or any other suitable means.

It can further be seen in Figure 8 that the frame 201 comprises two support elements 204 on its inner left and right sides. Preferably, the support elements 204 result from the cutting of a hollow element 101 that comprises exterior walls 102 with secondary boards 105 and/or interior walls 107 as described with reference to Figures 1 and 2 above. Alternatively, the support elements

204 can be separate elements that are attached to the frame 201 after the cutting. Figure 8 further shows that the frame 201 comprises a recess 108 on the top side of the frame. The recess 108 can, for example, correspond to the recess 108 formed in the part 109 illustrated in Figure 7.

The frame 201 can correspond to any of the frames described above. In case the frame 201 has one side which is not planar, the covering panel to be attached to that side may be machined to fit to the form of that non-planar side of the frame prior to attaching.

In an alternative embodiment, the first covering panel 202 may be attached to the front side of the hollow structure 101 before cutting. This can serve to provide stability to the hollow structure 101 and the frame 201 during the cutting procedure. In particular, this is useful in case that the exterior walls 102 of the hollow structure 101 are thin, and/or if the thickness of the frame 201 is small.

Figure 9 illustrates a furniture part 100 manufactured according to an embodiment of the invention. It may correspond to the furniture part manufactured according to the principles illustrated in Figure 8. This furniture part 100 may, for example, be a drawer front for a drawer of a chest of drawers. After the frame 201 (not visible in Figure 9) and the first covering panel 202 and the second covering panel 203 (not visible in Figure 9) have been attached to each other, the resulting piece can be machined, in order to obtain the final geometry of the furniture piece 100. For example, in the illustrated case, the frame 201 , the first covering panel 202 and the second covering panel 203 have been machined to form a top recess 207. This top recess may correspond to the recess 108 formed in the part 109 as illustrated in Figure 7. The top recess 207 in the upper side of the furniture piece 100 can, e.g., serve as a handle part of the drawer front. Further, it can be seen that the corners 206 have been machined to provide them with a curvature of defined radius.

Additionally, the first covering panel 202 and the frame 201 have been machined to provide recesses 205 to serve as connection points to other furniture parts at the inner side of the furniture part 100. In particular, the recesses 205 have been formed after the first covering panel 202 has been attached to the frame 201 , i.e., the recesses 205 have been machined into the first covering panel 202 and the frame 201 at the same time. This way, it can be ensured that the positioning of the recesses 205 in the first covering panel 202 and the first frame 201 matches with a high accuracy. The recesses 205 can, for example, be formed by drilling or milling.

Alternatively, the first frame 201 and the first covering panel 202 can be machined individually before assembly to provide the recesses 205.

In a further step, the frame 201 , the first panel 202, and the second panel 203 can be, e.g., powder-coated (not shown). They can also be coated by any other suitable method. This can take place before or after the parts have been attached to each other. In particular, it is possible to paint or coat the outside of the hollow structure 101 before the cutting takes place. This can be more efficient and economical for certain methods of coating like, e.g., powder coating or spraypainting. It is, however, also possible to coat the furniture part 100 after the individual parts have been attached to each other and machining as described above has been performed.

Figures 10a and 10b schematically show the assembly of a furniture part 400 according to another embodiment of the invention. It can be seen that a first frame 201 and a second frame 301 have the same cross-sectional shape in an X-Z-plane. Preferably, the first frame 201 and the second frame 301 have been cut from the same hollow structure 101. The cutting can have been performed by the method described with reference to Figure 3 above. The top side of the first frame 201 is attached, for example by gluing, to the bottom side of the second frame 301 , thereby connecting the two frames 201 and 301 to each other in a side-by-side arrangement as illustrated in Fig. 10a. This way, a frame 401 with twice the height of and the same width as the first frame 201 is formed. It is also possible to attach three or more frames in a side-by-side arrangement, for example, in order to manufacture a furniture part of correspondingly larger width or height.

After the first frame 201 and the second frame 301 have been attached to one another, a first covering panel 402 is attached to the front side of the resulting frame 401 , and a second covering panel 403 is attached to the back side of the frame 401. After this, the assembled pieces can be machined as described above with reference to Figure 9. They can, e.g., be machined to provide recesses for connecting to other furniture parts, to provide a top recess serving as a handle part, and providing curved corners with a defined radius.

Figure 10b schematically shows the finished furniture part 400 after the assembly and machining as described above. In the illustrated case, the furniture part 400 can, for example, be twice the height and the same width as the furniture part 100. The finished furniture part 400 can, for example, be a door for a cabinet.

It will be appreciated that for more complicated structures in furniture parts it is also possible to combine two or more frames that do not have the same cross-sectional shape in X-Z-plane. Said two or more frames may originate from to two hollow structures of different cross-sections.

Figure 1 1 illustrates how furniture parts manufactured according to the invention can be used for the construction of a piece of furniture. Figure 1 1 shows a frontal view of a chest of drawers 500. It can be seen that the chest of drawers comprises, on its left side, two drawers 501 located above one another. Each of these drawers comprises, as its front part, a furniture part 100. The furniture parts 100 can, e.g., correspond to the furniture part 100 illustrated in Figure 9. On its right side, the chest of drawers comprises one door 502, which has twice the height of one of the drawers 501 and which covers a cabinet part of the chest of drawers 500. The door 502 comprises a furniture part 400 mounted to hinges (not shown). The furniture part 400 can, e.g., correspond to the furniture part 400 illustrated in Figure 10b. Preferably, all of the furniture parts 100 and 400 have been manufactured using the same hollow structure 101 , as described above. It is possible to make the furniture part 400 higher than two times the height of the frame 201. For example, spacing elements could be provided between the two frames 201 , 301 of the furniture part 400 to provide the desired additional height.

Although the previously discussed embodiments and examples of the present invention have been described separately, it is to be understood that some or all of the above-described features can also be combined in different ways. The above discussed embodiments are particularly not intended as limitations, but serve as examples, illustrating features and advantages of the invention.