Recently, the demand for foldable futons has increased due to the flexibility of use in that these futons may function as either a sofa or a bed. The dual functionality of the foldable futons makes them both cost effective and space saving. Foldable futons abrogate the need to have a separate sofa and bed. To further decrease the cost of foldable futons, many are manufactured with easily workable and inexpensive materials. In this fashion, futons may be manufactured without the need for highly skilled labor. This further reduces the cost of futons, because they may be manufactured in under-developed countries in which the workers earn a lower annual wage than workers in more developed countries.
Currently, foldable futon frames are available in a variety of designs. For example, U.S. Pat. No. 5,303,432 to Fitts discloses a convertible futon frame that includes opposed end frames interconnected by front and back rails to define a rigid rectangular frame. Seat and back members are movably connected to the rectangular frame and to each other so that an individual can convert the frame between sitting and sleeping positions.
Typically, foldable futon frames are made from either metal or wood. Metal futon frames are typically more durable than wooden futon frames. On the other hand, wooden futon frames are often more appealing, aesthetically, than metal futon frames. However, wooden futon frames suffer another drawback in addition to reduced durability, when compared to metal frames.
As discussed above, foldable futon frames are often produced in under-developed countries resulting in the futons having to be transported over large distances. During transportation, foldable futons are often stacked several high. A foldable futon located near the bottom of a stack maybe subjected to several thousands pounds of weight. This produces cracks and splits in the wooden planks that form the wooden futon frames, as well as bending in the rails that form the metal futon frames. The failure rate, however, of wooden futon frames, due to transportation, often far exceeds the failure rate of metal futon frames. This often reduces the savings benefit derived from transporting the lighter wooden futon frames.
What is needed, therefore, is a foldable futon that is formed from wood and provides strength and durability comparable to a metal futon frame.