Furniture Unit with Moisture Barrier and Method

A furniture unit, comprising:

• a planar support panel having a generally rectangular configuration including a central portion, and opposing side portions and opposing end portions surrounding said central portion;
• opposing side panels connected to and extending upwardly from said opposing side portions, respectively;
• opposing end panels connected to and extending upwardly from said opposing end portions, respectively, wherein said planar support panel, and said opposing side and end panels define a recessed area;
• and
• a barrier layer impervious to fluid and coating said recessed area, said barrier layer having a first caliper adjacent said central portion and a second caliper adjacent distal edges of said opposing side and end panels, said first caliper at least 10 times greater than said second caliper.

A method of manufacturing a furniture unit having a support member impervious to fluids, comprising the steps of:

• providing an assembled furniture unit comprising a planar support portion;
• applying via a spray device having a spray nozzle at least first and second swaths of polyurea material onto said planar support portion, said first and second swaths forming a first coat of polyurea material having a caliper of at least about 20 mils and a raised seam intermediate said first and second swaths, wherein said planar support portion is spaced a first distance from said spray nozzle when applying said first and second swaths;
• and
• applying via said spray device at least a third swath of polyurea material onto said first and second swaths and covering said raised seam, said third swath forming a second coat of polyurea material having a caliper of about 2 mils or less, wherein said planar support portion is spaced a second distance from said spray nozzle when applying said third swath, said second distance at least about twice said first distance.