AU2017100403A4 - Improvements in Materials and Processes for Furniture Construction - Google Patents

Abstract

-15 Abstract A process of forming a material (12) for a furniture structure (10), the process including: providing a sleeve (22) of braided material over a core structure (23) so as to provide a flexible tubular structure (36); locating the flexible tubular structure (36) within a mould (27), and infusing the mould (27) with a resin material (26) so as to form a substantially rigid tubular structure (20). A process for forming a moulded furniture structure (10) and a furniture structure (10) including or formed by such processes are also disclosed. Figure 1

Description

-1- 2017100403 10 Apr 2017

Improvements in Materials and Processes for Furniture Construction Technical Field [001] The invention relates to improvements in materials, in particular composite materials, and related processes for furniture construction as well as furniture constructions including such materials.

Background [002] The construction or manufacture of structures and products, such as furniture, often requires the formation of unique shapes, sometimes referred to as organic shapes, which have curves and contours. These shapes often need to be either hand made or formed from complex moulding techniques using plastics or fibreglass. In additional to being formed to various unique shapes it is also desirable that the structures and products, such as furniture, are strong and lightweight.

[003] A problem with current furniture making techniques is that some furniture typically needs to use a lot of material or materials to achieve a desired strength and the resulting furniture relatively heavy to achieve this desired strength. Furthermore, due to the quantity of materials and size of the furniture required, the current furniture construction techniques are also relatively costly and time consuming [004] The invention disclosed herein seeks to overcome one or more of the above identified problems or at least provide a useful alternative.

Summary [005] In accordance with a first aspect there is provided, a process of forming a material for a furniture structure, the process including: Providing a sleeve of braided material over a core structure so as to provide a flexible tubular structure; Locating the flexible tubular structure within a mould; Infusing the mould with a resin material so as to form a substantially rigid tubular structure. -2- 2017100403 10 Apr 2017 [006] In an aspect, the process further includes: braiding a braidable material over at least a portion of the core structure so as to form the sleeve of braided material.

[007] In another aspect, the braidable material includes at least one of Kevlar, carbon fibre and carbon nano-tubes or a combination thereof.

[008] In yet another aspect, the core structure is a rope like structure.

[009] In yet another aspect the rope like structure is at least one of a rope, a cord, a line, a string, and twine.

[0010] In yet another aspect, the rope like structure is a rope formed from at least one of natural and synthetic fibres.

[0011] In yet another aspect, the rope like structure is absorbent.

[0012] In yet another aspect, the resin is a low viscosity resin.

[0013] In yet another aspect, the resin is a castable polyurethane elastomer.

[0014] In yet another aspect, the process further includes: Locating a mesh material within the mould so as to wrap at least partially around the flexible tubular structure such that infusion of the resin material bonds the mesh material to the substantially rigid tubular structure.

[0015] In yet another aspect, the mesh material is a polyester, Carbon fibre, Kevlar, carbon nanotube hex mesh or mesh netting.

[0016] In yet another aspect, the mesh material is a polyester hex mesh.

[0017] In yet another aspect, the process further includes: At least partially encasing the substantially rigid tubular structure within foam. -3- 2017100403 10 Apr 2017 [0018] In accordance with a second aspect there is provided, a furniture structure including a substantially rigid tubular structure as formed by a process as described above and herein.

[0019] In accordance with a third aspect there is provided, a process of forming a moulded furniture structure, the process including: Providing a sleeve of braided material over a core material so as to provide a flexible tubular structure; Providing a flexible mesh material; and Arranging the flexible tubular structure and mesh material within a mould with the mesh material extending at least partially across the mould and at least partially covering the flexible tubular structure; and Introducing a resin material into the mould so as to form a substantially rigid tubular structure bonded to the mesh material with the mesh material extending at least partially across the mould so as to support set resin material.

[0020] In accordance with a fourth aspect there is provided, a process of forming a moulded furniture structure, the process including: Providing a sleeve of braided material over a tubular core material so as to provide at least one flexible tubular structure; Providing a flexible mesh material; and Providing a mould into which the at least one flexible tubular structure and mesh material are arranged such that the mesh material extends between portions of the at least one flexible tubular structure; and Infusing the mould with a resin material so as to form a substantially rigid tubular structure bonded to the mesh material with the mesh material interlinking the portions at least one flexible tubular structure and supporting the set resin material therebetween.

[0021] In accordance with a fifth aspect there is provided, a process of forming a moulded furniture structure, the process including: Forming sleeves of braided material over a tubular core material so as to provide at least two flexible tubular structures; Providing a flexible mesh material; and Providing a mould into which the at least two flexible tubular structures are supported with the mesh material extending therebetween and at least partially extending around the at least two flexible tubular structures; Introducing a resin material into the mould such that the at least two flexible tubular structures are rigidified and interlinked by the mesh material and set -4- 2017100403 10 Apr 2017 resin carried by the mesh material extending between the at least two flexible tubular structures.

[0022] In accordance with a sixth aspect there is provided, a furniture structure formed at least partially or fully by a process as described above and herein.

Brief Description of the Figures [0023] The invention is described, by way of non-limiting example only, by reference to the accompanying figures, in which; [0024] Figure 1 is a side view illustrating a furniture structure including the substantially rigid tubular material; [0025] Figure 2 is a detailed exposed parts perspective view illustrating detail A as indicated in Figure 3; [0026] Figure 3 is a detailed side view illustrating detail B as indicated in Figure 4; [0027] Figure 4 is a top exposed parts view illustrating a support panel of the furniture structure; [0028] Figure 4a is a perspective view illustrating a bottom half of a mould in which the support panel shown in Figure 4 is formed; [0029] Figure 5 is a perspective exposed parts view illustrating the support panel embedded within foam; [0030] Figure 6 is a perspective front view illustrating the panel removed from the furniture structure; [0031] Figure 7 is a perspective exposed parts view illustrating the support panel fitted to the furniture structure; -5- 2017100403 10 Apr 2017 [0032] Figure 8 is a flow diagram illustrating a process of forming a substantially rigid tubular material for furniture; and [0033] Figure 9 is a flow diagram illustrating a process of forming a moulded structure including a rigid tubular material and a mesh material.

Detailed Description [0034] The processes disclosed herein relate to the formation or manufacture of materials, in particular supporting or reinforcing materials, for, but not limited to, furniture structures.

[0035] Referring to Figures 1 to 7, there is shown an example of a furniture structure 10 including a supporting or reinforcing material or material arrangement 12. The furniture structure 10 may be an organic shaped furniture structure 10 having various curvatures and the reinforcing materials 12 are utilised on various parts of the furniture structure 10 including, but not limited to the base 14, the rim 16 and the seat 18. It is noted that the furniture structure 10 shown in Figures 1 to 7 is for example purposes only and the reinforcing materials 12 and processes of construction disclosed herein may be applied to any suitable structure.

[0036] Referring more specifically to Figure 2, the support material 12 includes a substantially rigid tubular structure 20 that is formed in accordance with processes 100, 200 as described below. The substantially rigid tubular structure 20 may be formed from a sleeve 22 of braided material over a tubular core material or core structure 23 that is provided here in the form of a rope like structure 24 that is set or located within a resin material 26 to form the substantially rigid tubular structure 20. More specifically, the sleeve 22 of braided material is initially fitted over a tubular core material 23 to form a flexible tubular material 36 that is then rigidified by the infusion of the resin material 26 to form the substantially rigid tubular structure 20. The substantially rigid tubular structure 20 having a skin or casing of the set resin material 26.

[0037] The substantially rigid tubular structure 20 is used to support various parts of -6- 2017100403 10 Apr 2017 the furniture structure 10 including, but not limited to the base 14, the rim 16 and the seat 18. For example, in Figure 2, the substantially rigid tubular structure 20 is moulded to support the curved rim 16 of the furniture structure 10, although the substantially rigid tubular structure 20 may be formed to any shape or curvature such as being straight, curved, sinuous or circular. It is also envisaged that in some examples the substantially rigid tubular structure 20 may have or include square, oval or a circular cross section and such as the term “tubular” herein encompasses at least these cross sections.

[0038] Referring additionally to Figures 3 to 5, the substantially rigid tubular structure 20 may also be partially or fully wrapped or located within a mesh material 28 (shown in Figure 4) that interlinks and extends between one or more of the substantially rigid tubular structures 20. For example, as shown in Figure 4, the support material 12 may include a first curved substantially rigid tubular structure 20a that forms a perimeter and a second straight substantially rigid tubular structure 20b that is arranged intermediate support material 12.

[0039] The mesh material 28 is arranged to extend between the substantially rigid tubular structure 20a, 20b. The resin material 26 is moulded over the substantially rigid tubular structure 20a, 20b and the interlinking mesh material 28. The support material 12, in this example, may include windows in the resin material 26 to assist to reduce weight. As shown in Figure 5, the support material 12 may be embedded in foam 32 so as to form a seat support 34 as shown in Figures 5 and 6.

[0040] The processes of forming the above support material 12 and the substantially rigid tubular structures 20 are now further described with reference to Figures 8 and 9 and processes 100, 200.

[0041] Referring initially to Figure 8, there is provided a first example of a process 100 of forming the material 12 for a furniture structure 10. In particular, process 100 provides an example of forming a substantially rigid tubular structure 20 (also referring to as a support bar). The process 100 including the steps of: at step 102, providing the sleeve 22 of braided material over the tubular core material 23 provided in this example in the form of the rope like structure 24 so as to provide an initially -7- 2017100403 10 Apr 2017 flexible tubular structure 36. At Step 204, locating the flexible tubular structure 36 at least partially within or within a mould 27. The mould 27 may be a two-part mould (such as having left/right hand parts or top/bottom parts) as shown in Figure 4a with one part removed for clarity. In the example shown in Figure 4a, the top and bottom parts may be generally tray shaped. Of course, the mould 27 may take any suitable shape and may be provided in sets or segments. This example of the mould 27 has a fibreglass shell 29 and a rubber insert 31.

[0042] Once the flexible tubular structure 36 is located in the mould 27, the mould 27 may be closed. At step 106 infusing the mould 27 with the resin material so as to form a substantially rigid tubular structure 20. The resin material may be poured or otherwise gravity fed into the mould 27. Once set it can be demoulded and in some examples the moulded structure may be placed inside a second mould so pour foam 32 can be added.

[0043] In some examples, the process 100 further includes braiding a braidable material over at least a portion of the rope like structure 24 so as to form the sleeve 22 of braided material. In some examples, the process further includes: placing or locating the mesh material 28 within the mould 27 so as to wrap at least partially around the flexible tubular structure 36 such that infusion of the resin material 26 bonds the mesh 28 to the substantially rigid tubular structure 20.

[0044] In some examples the mesh 28 is laid out over the fiberglass shell 29 and the rubber insert 31 the mesh 28 is overhanging the outer channels of the rubber insert 31 enough so that it can be folded back over the flexible tubular structure 36 reconnecting with itself inside the mould 27. The flexible tubular structure 36 is pushed down into the channels to lock the mesh 28 and carbon flexible tubular structure 36 in place so that all other segments of the mould 27 can be moved around and reassembled without the internal reinforcement material moving and falling out of place.

[0045] In some examples, the flexible tubular structure 36 and the mesh 28 are bonded in a single step on the addition of the resin material 26 to the mould 27. In further examples, the process further includes at least partially encasing the -8- 2017100403 10 Apr 2017 substantially rigid tubular structure 20 within foam such as the foam 32 shown in Figure 5. The encasing with foam may take place in a further, typically larger, mould once the internal structure has set and been released from the mould 27.

[0046] Referring now finally to Figure 9, another example of the process 200 is for forming a moulded furniture structure 10 or part thereof. The process 200 is similar to process 100. However, process 200 specifically includes the flexible mesh material 28 that may be used to interlink portions of the tubular structure 20 or multiples of the flexible tubular structure 20.

[0047] The process 200 including the steps of: at step 202 providing the sleeve 22 of braided material over the rope like structure 24 so as to provide a flexible tubular structure 36 and, at step 204, providing the flexible mesh material 28. At step 206, the process further includes providing the mould 27 into which the flexible tubular structure 36 and the mesh material 28 is arranged with the mesh material 28 extending at least partially across the mould 27 and at least partially covering the tubular structure 36. The mould 27 is then typically closed, and at step 208, infusing the mould 27 with a resin material 26 so as to form a substantially rigid tubular structure 20 bonded to the mesh material 28 with the mesh material 28 extending at least partially across the mould 27 supporting set resin material 26. Preferably, the mesh material 28 is arranged to wrap around the flexible tubular structure 36 and extend between portions thereof or adjacently arranged flexible tubular structures 20 so as to interlink and support the set resin material 26 there between.

[0048] In some examples, like process 100, the process 200, may also further include braiding a braidable material over at least a portion of the rope like structure 24 so as to form the sleeve 22 of braided material. In this example, the flexible tubular structure 36 and the mesh 28 are also preferably bonded in a single step on the addition of the resin material 26 to the mould 27. In further examples, the process further includes at least partially encasing the substantially rigid tubular structure 20 within foam such as the foam 32 shown in Figure 5.

[0049] In above process examples, the braidable material may include at least one of Kevlar, carbon fibre and carbon nano-tubes and a combination thereof. The rope like -9- 2017100403 10 Apr 2017 structure 24 may be at least one of a rope, a cord, a line, a string, and twine. The rope like structure 24 is preferably a rope formed from at least one of natural and synthetic fibres. In this example, a three-strain twisted polyurethane spun rope may be used. The rope material is preferably absorbent to take up some of the resin material 26 and draw the resin material 26 through the sleeve material 22.

[0050] The resin material 26 may include or be a lower viscosity castable polyurethane elastomer with a hardness of about 80 A and with a de-mould time of 10-15 min. Preferably, the resin material is low viscosity so as to flow to all parts of the mould and around the rope core, fibreglass and hex mesh that may create obstructions. The mould 27 may be a fibreglass mould for the foam part of the process, and a fibreglass mould with a silicon rubber internal surface membrane or insert for the substantially rigid tubular structure that, for example, forms the armature part. The mould 27 may be two part. The inner surface of the mould may be soft silicone rubber to assist with release. The moulds may be pre-shaped, preferably by 3D printed master shapes. The resin material 26 is typically about 2 - 10mm in thickness.

[0051] In above process examples, the braidable material may include at least one of Kevlar, carbon fibre and carbon nano-tubes and a combination thereof. The rope like structure may be at least one of a rope, a cord, a line, a string, and twine. The material rope like structure 14 is preferably a rope formed from at least one of natural and synthetic fibres. In this example, a three-strain twisted polyurethane spun rope may be used. The rope material is preferably absorbent to take up some of the resin material 26 and draw the resin material 26 through the sleeve material 22.

[0052] An example of the substantially rigid tubular structure 20, formed with process 100, has been tested via a standard 3-point test using a hydraulic press and a load cell. The test was conducted using a carbon fibre braided material over a three-strain twisted polyurethane spun rope and the resin material was a polyurethanes elastomer. In this test, a 350mm x 35mm round bar of polyurethane elastomer with a 12mm piece of rope with a 3k carbon fibre braided sleeve was able to sustain at least a load of 338kg without breaking. In comparison, a 350mm x 35mm round bar of polyurethane elastomer snapped at just 148kg. Accordingly, the addition of the carbon 2017100403 10 Apr 2017 -10- fibre braided material over a three-strain twisted polyurethane spun rope increased the strength by at least 57.71%. Based on these results, the rigid tubular structure 20 appears to substantially increase the strength of the furniture structures 10 and allows less material to be used to achieve the same given strength.

[0053] Advantageously, there has been described processes including the placing or braiding of a braidable material, such as carbon fibre, over a core such as rope to provide a flexible light weight length of tubular material that can be shaped and held in place with a mould and then infused with a resin to create reinforcement structures or bars for furniture structures such as a sub-structure/armature or seat bases. The furniture structures may then be painted or encased within foam for the purpose of furniture creation. Further advantageously, the reinforcement structures, bars or tubes may joined to each other with a sheet of plastic resin 2-10mm thick embedded with, preferably a polyester hex mesh material wrapping around and in between the reinforcement bars. These processes assist to reduce the weight and costs whilst maintaining the strength requirements of organic shaped furniture.

[0054] Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

[0055] The reference in this specification to any known matter or any prior publication is not, and should not be taken to be, an acknowledgment or admission or suggestion that the known matter or prior art publication forms part of the common general knowledge in the field to which this specification relates.

[0056] While specific examples of the invention have been described, it will be understood that the invention extends to alternative combinations of the features disclosed or evident from the disclosure provided herein. 2017100403 10 Apr 2017 -11- [0057] Many and various modifications will be apparent to those skilled in the art without departing from the scope of the invention disclosed or evident from the disclosure provided herein.

Claims (17)

1. The claims defining the Invention are as follows:

   1. A process of forming a material for a furniture structure, the process including: Providing a sleeve of braided material over a core structure so as to provide a flexible tubular structure; Locating the flexible tubular structure within a mould; Infusing the mould with a resin material so as to form a substantially rigid tubular structure.
2. 2. The process according to claim 1, wherein the process further includes: braiding a braidable material over at least a portion of the core structure so as to form the sleeve of braided material.
3. 3. The process according to claim 1, wherein the braidable material includes at least one of Kevlar, carbon fibre and carbon nano-tubes or a combination thereof.
4. 4. The process according to claim 1, wherein the core structure is a rope like structure.
5. 5. The process according to claim 4, wherein the rope like structure is at least one of a rope, a cord, a line, a string, and twine.
6. 6. The process according to claim 4, wherein the rope like structure is a rope formed from at least one of natural and synthetic fibres.
7. 7. The process according to claim 4, wherein the rope like structure is absorbent.
8. 8. The process according to claim 1, wherein the resin is a low viscosity resin.
9. 9. The process according to claim 1, wherein the resin is a castable polyurethane elastomer.
10. 10. The process according to any one of the previous claims, wherein the process further includes: Locating a mesh material within the mould so as to wrap at least partially around the flexible tubular structure such that infusion of the resin material bonds the mesh material to the substantially rigid tubular structure.
11. 11. The process according to claim 9, wherein the mesh material is a polyester hex mesh.
12. 12. The process according to any one of the previous claims, wherein the process further includes: At least partially encasing the substantially rigid tubular structure within foam.
13. 13. A furniture structure including a substantially rigid tubular structure formed by a process as defined in any one of the previous claims.
14. 14. A process of forming a moulded furniture structure, the process including: Providing a sleeve of braided material over a core material so as to provide a flexible tubular structure; Providing a flexible mesh material; and Arranging the flexible tubular structure and mesh material within a mould with the mesh material extending at least partially across the mould and at least partially covering the flexible tubular structure; and Introducing a resin material into the mould so as to form a substantially rigid tubular structure bonded to the mesh material with the mesh material extending at least partially across the mould so as to support set resin material.
15. 15. A process of forming a moulded furniture structure, the process including: Providing a sleeve of braided material over a tubular core material so as to provide at least one flexible tubular structure; Providing a flexible mesh material; and Providing a mould into which the at least one flexible tubular structure and mesh material are arranged such that the mesh material extends between portions of the at least one flexible tubular structure; and Infusing the mould with a resin material so as to form a substantially rigid tubular structure bonded to the mesh material with the mesh material interlinking the portions at least one flexible tubular structure and supporting the set resin material therebetween.
16. 16. A process of forming a moulded furniture structure, the process including: Forming sleeves of braided material over a tubular core material so as to provide at least two flexible tubular structures; Providing a flexible mesh material; and Providing a mould into which the at least two flexible tubular structures are supported with the mesh material extending therebetween and at least partially extending around the at least two flexible tubular structures; Introducing a resin material into the mould such that the at least two flexible tubular structures are rigidified and interlinked by the mesh material and set resin carried by the mesh material extending between the at least two flexible tubular structures.
17. 17. A furniture structure formed by a process as defined in any one of claims 14 to 16.