CA3167901A1 - Corrugated plastic sheet furniture design and assembly system - Google Patents

Corrugated plastic sheet furniture design and assembly system Download PDF

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Publication number
CA3167901A1
CA3167901A1 CA3167901A CA3167901A CA3167901A1 CA 3167901 A1 CA3167901 A1 CA 3167901A1 CA 3167901 A CA3167901 A CA 3167901A CA 3167901 A CA3167901 A CA 3167901A CA 3167901 A1 CA3167901 A1 CA 3167901A1
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Prior art keywords
furniture
corrugated plastic
sheets
corrugated
columns
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CA3167901A
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French (fr)
Inventor
Bylahally Visweswaraiah Swaroop
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Individual
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Priority to CA3167901A priority Critical patent/CA3167901A1/en
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    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47BTABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
    • A47B13/00Details of tables or desks
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47BTABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
    • A47B96/00Details of cabinets, racks or shelf units not covered by a single one of groups A47B43/00 - A47B95/00; General details of furniture
    • A47B96/20Furniture panels or like furniture elements
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C19/00Bedsteads
    • A47C19/005Bedsteads dismountable
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C4/00Foldable, collapsible or dismountable chairs
    • A47C4/02Dismountable chairs
    • A47C4/021Dismountable chairs connected by slotted joints
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C5/00Chairs of special materials
    • A47C5/005Chairs of special materials of paper, cardboard or similar pliable material
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47CCHAIRS; SOFAS; BEDS
    • A47C5/00Chairs of special materials
    • A47C5/12Chairs of special materials of plastics, with or without reinforcement
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47BTABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
    • A47B2220/00General furniture construction, e.g. fittings
    • A47B2220/008General furniture construction, e.g. fittings characterised by materials
    • A47B2220/0083Furniture made of sheet material
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47BTABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
    • A47B2220/00General furniture construction, e.g. fittings
    • A47B2220/13Sound or noise reduction or dampening, e.g. built in via the furniture panels
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47BTABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
    • A47B2230/00Furniture jointing; Furniture with such jointing
    • A47B2230/0074Mortise and tenon joints or the like including some general male and female connections
    • A47B2230/0085Mutually slotted furniture joints
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47BTABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
    • A47B2230/00Furniture jointing; Furniture with such jointing
    • A47B2230/0074Mortise and tenon joints or the like including some general male and female connections
    • A47B2230/0092Furniture assembled by mutually slotted joints

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  • Assembled Shelves (AREA)

Abstract

Corrugated plastic sheets, characterized by a system of parallel walls sandwiched between two face-sheets, are one of the most lightweight, versatile, and shock-absorbent structural materials. My inventions are the corrugated plastic sheet furniture design and assembly system fabricated with corrugated plastic sheets (made of polypropylene or another kind of plastic) of varying sheet thickness in a unique structural construction arrangement. The corrugated plastic sheets used in the furniture could be either of virgin plastic or from dismantled or used advertising or election signboards for a lower environmental footprint.
The corrugated plastic sheet furniture offers portability, comfort, customization, modularity, and scalability. The furniture can be easily assembled without any tools. This furniture is suitable in numerous formal and informal settings such as urban spaces (apartments, events, offices, and airports), homes (living, patio, bedroom, dining, and casual spaces), daycares and schools, summer camps, trade shows, exhibits, outdoors spaces hospitals and urgent care facilities as well as short-term emergency housing facilities.
BACKGROUND:
Conventional furniture and its assembly systems are fabricated by combining several materials such as metals, wood, plywood, laminated wood, particle boards, oriented strand boards, plastics, medium density fiberboards, and other materials. Wood and metal furniture pieces are usually completed with finishing like varnish, veneer, paint or fabric/mattress layers, leather, and other cushioning materials for protection and aesthetic purposes. While conventional furniture is sturdy, structurally sound, and durable, but may lose geometric fit with time and with multiple assembly cycles. Often, they are bulky and heavy to handle and transport, and involve several assembly procedures involving joints, bolts, screws, and multiple tools. Conventional furniture can be costly with the costs depending on the materials used, its manufacturing supply chain, aesthetics, and brand. Many times, the shipping costs form a significant portion of the production costs. Some furniture systems incorporate modularity in their designs, which allows for the reconfiguration of the furniture pieces, but a total change in the appearance or the utility can be a costly proposition. The maintenance and repair of conventional furniture can be costly too. When conventional furniture becomes obsolete or worn out if it cannot be resold, it is frequently discarded in a landfill as separation and recycling of combined materials is not trivial. The supply chain, the extensive use of cushioning elements, the use of metals, and the disposal render conventional furniture unsustainable from the environmental perspective.
Another class of furniture system involves plastic, primarily injection-molded to the shape desired, usually with structural reinforcements in the form of ribs and webs. This system employs virgin or recycled plastic material and is an attractive and low-cost alternative.
However, injection molded plastic furniture offers limited customization options, involves high transportation costs, and seldom offers scalability and modularity in its designs.

Description

CORRUGATED PLASTIC SHEET FURNITURE DESIGN AND ASSEMBLY SYSTEM
Inventor: Swaroop Bylahally Visweswaraiah, Ph.D
Vrtta Green Solutions Inc., 17560, Rue Grier, Pierrefonds, Montreal, Quebec, Canada, H9J2A8 ABSTRACT:
Corrugated plastic sheets, characterized by a system of parallel walls sandwiched between two face-sheets, are one of the most lightweight, versatile, and shock-absorbent structural materials. My inventions are the corrugated plastic sheet furniture design and assembly system fabricated with corrugated plastic sheets (made of polypropylene or another kind of plastic) of varying sheet thickness in a unique structural construction arrangement. The corrugated plastic sheets used in the furniture could be either of virgin plastic or from dismantled or used advertising or election signboards for a lower environmental footprint.
The corrugated plastic sheet furniture offers portability, comfort, customization, modularity, and scalability. The furniture can be easily assembled without any tools. This furniture is suitable in numerous formal and informal settings such as urban spaces (apartments, events, offices, and airports), homes (living, patio, bedroom, dining, and casual spaces), daycares and schools, summer camps, trade shows, exhibits, outdoors spaces hospitals and urgent care facilities as well as short-term emergency housing facilities.
BACKGROUND:
Conventional furniture and its assembly systems are fabricated by combining several materials such as metals, wood, plywood, laminated wood, particle boards, oriented strand boards, plastics, medium density fiberboards, and other materials. Wood and metal furniture pieces are usually completed with finishing like varnish, veneer, paint or fabric/mattress layers, leather, and other cushioning materials for protection and aesthetic purposes. While conventional furniture is sturdy, structurally sound, and durable, but may lose geometric fit with time and with multiple assembly cycles. Often, they are bulky and heavy to handle and transport, and involve several assembly procedures involving joints, bolts, screws, and multiple tools. Conventional furniture can be costly with the costs depending on the materials used, its manufacturing supply chain, aesthetics, and brand. Many times, the shipping costs form a significant portion of the production costs. Some furniture systems incorporate modularity in their designs, which allows for the reconfiguration of the furniture pieces, but a total change in the appearance or the utility can be a costly proposition. The maintenance and repair of conventional furniture can be costly too. When conventional furniture becomes obsolete or worn out if it cannot be resold, it is frequently discarded in a landfill as separation and recycling of combined materials is not trivial. The supply chain, the extensive use of cushioning elements, the use of metals, and the disposal render conventional furniture unsustainable from the environmental perspective.
Another class of furniture system involves plastic, primarily injection-molded to the shape desired, usually with structural reinforcements in the form of ribs and webs. This system employs virgin or recycled plastic material and is an attractive and low-cost alternative.
However, injection molded plastic furniture offers limited customization options, involves high transportation costs, and seldom offers scalability and modularity in its designs.

Date Regue/Date Received 2022-07-15 Alternatively, corrugated fiberboard-based furniture and its assembly systems allow for a lightweight design, easy assembly, and can be flat-picked. They are portable and easily storable and are economical compared to conventional furniture. Corrugated fiberboard is paper fiber-based and comprises a corrugated core sandwiched between two or more face sheets. Corrugated fiberboard-based furniture is fabricated from single-wall, double-wall, or triple-wall corrugated fiberboards [Ref. 1]. Such furniture has a lower ecological footprint than conventional furniture, as corrugated fiberboard can be recycled through any curb side pick-up, and they also have high recycling rates. The disadvantages however outweigh these advantages. Corrugated fiberboard furniture does not favour the traditional structural construction method and imposes a limit on the placement of slots or cut-outs.
While the corrugated fiberboard provides adequate stiffness, the strength of the furniture is inferior due to the lower strength inherent to the fiberboard material. The current corrugated fiberboard furniture construction works only with thick multiple-walled corrugated cardboard sheets. The use of resilient joints in fiberboard furniture design is reported to be complicated to assemble and manufacture [Ref. 1, 2]. The furniture made from cardboard is reported to be prone to side fatigue loading, and slotted triple-wall joints may restrict movement in one plane, but may result in shortened life of the furniture [Ref. 1, 2]. They are seldom useful for outdoor applications and absorb moisture, promoting mold formation in humid conditions.
They allow insect growth in urban spaces as they are not sealed at the ends, offer very low water resistance, and lack fit retention through multiple assembly cycles.
Overall, considering their low durability, they often tend to be less sustainable [Ref. 3].
Corrugated cardboard furniture offers minimal customization options and is a cost-effective solution only when the need is temporary.
My inventions, the corrugated plastic sheet furniture design, and assembly system overcome many of the drawbacks of the three furniture systems outlined above.
SUMMARY OF THE INVENTION:
My inventions are the corrugated plastic sheet furniture design and assembly system fabricated with corrugated plastic sheets (made of polypropylene or another kind of plastic) of varying sheet thickness in a unique structural construction arrangement.
Corrugated plastic sheets are characterized by the presence of two face-sheets separated by a core (a system of parallel walls called the 'flutes'). This renders corrugated plastic sheets one of the most lightweight, versatile, and shock-absorbent materials. The corrugated plastic sheets used in the furniture could be either of virgin plastic or from dismantled or used advertising or election signboards for a lower environmental footprint. The corrugated plastic sheet furniture offers portability, comfort, customization, modularity, and scalability. The furniture can be easily assembled without any tools. This furniture is suitable in numerous formal and informal settings such as urban spaces (apartments, events, offices, and airports), homes (living, patio, bedroom, dining, and casual spaces), daycares and schools, summer camps, trade shows, exhibits, outdoors spaces hospitals and urgent care facilities as well as short-term emergency housing facilities.
Benefits of my invention:
The structural arrangement of my furniture design includes a typical construction comprising of: a). At least four vertical columns to resist the compression loads; b).
Three or more
2 Date Regue/Date Received 2022-07-15 transverse beams to resist the bending and shear loads; c). A combination of corrugated plastic sheets called the 'wrap-around sheets' to resist bending loads in addition to forming partially or fully closed structures with other members for better torsion stability. The vertical columns and transverse beams comprise multiple slots and/or cutouts for assembly with other parts and eliminate the need for any screws or other fastener elements.
The slots and cutouts are either die cut or CNC machined or laser cut. Superior stiffness and load carrying capacities are provided by the unique structural construction and the inherently stiff corrugated plastic sheets, while the strength and resilience are provided by the plastic material of the boards. Corrugated plastic sheet furniture can be customized to include many structural members such as multiple columns or transverse beams to withstand heavy loads.
My designs allow for scalability of the furniture, where multiple custom sizes of the furniture can be achieved as needed.
My design of corrugated plastic sheet furniture is simple to assemble without the need for any screws, tools, or joints. The average time for assembly and disassembly of each piece of furniture is estimated at 5-10 minutes, and the furniture retains its fit for approximately 30-40 assembly/disassembly cycles. Because the corrugated plastic sheet is extensively used for advertisement and other utilities, acquiring and repurposing them is an inexpensive and sustainable option. When not in use, many pieces are designed to fold up, making them easier to store in smaller spaces. Shipping is cheaper because it can be transported in a flat shape and it does not weigh as much as the material used for traditional furniture. The appearance of the furniture is highly customizable with the use of vinyl or polypropylene self-adhesive or glued films, which can provide a waterproof layer needed for humid and outdoor conditions.
My design of corrugated plastic sheet furniture is scalable and modular. In the context of this invention, modularity refers to the extent of creating furniture for different utilities using two or more pieces of furniture initially designed for a specific use. Most importantly, my designs with 'modularity slots' lend themselves to modularity allowing pieces to be expanded or reconfigured without being fully replaced. In other words, two or more pieces can be interchanged or combined to make a new piece of furniture serving another purpose. For example, a coffee table and a chair in this invention are both modular and can be connected to create a reclining chair or bed.
Scalability refers to the various sizes of furniture that can be created.
Scalability in my invention is achieved in two ways:
A). Scalability through design versatility ¨ The design is versatile; various sizes of furniture (such as kid's size or adult size) can be fabricated with the same structural layout, but with thicker corrugated plastic sheets or more number of structural members as needed. For example, a bigger adult chair might need thicker sheets or more vertical columns to sustain the anticipated load compared to a kid's chair.
B). Scalability through modularity ¨ Modular pieces, for example, four coffee-tables can be combined to form a twin bed. Two more modules of coffee-tables can be joined to the twin bed to scale it to a queen bed. Two more modules to the queen bed can transform it into a king-size bed.
3 Date Regue/Date Received 2022-07-15 The most obvious benefit of this invention is its sustainability. Corrugated plastic sheet furniture requires fewer resources to manufacture than conventional furniture as it is available locally in most regions either in the form of virgin sheets, recycled sheets, or dismantled/used signboards. A preliminary life cycle analyses indicate that the reuse of the dismantled/used signboards reduces the environmental footprint by up to 50%
compared to conventional furniture. Corrugated plastic sheet furniture is more environmentally friendly because it can be recycled alongside regular boxes or containers once it has served its purpose, and does not involve metals with a higher environmental footprint.
BRIEF DESCRIPTION OF THE DRAWINGS:
Figure 1. Side handle corrugated plastic sheet furniture assembly using vertical columns, transverse beams, and wrap-around corrugated plastic sheets.
Figure 2. General purpose corrugated plastic table assembly using columns, transverse beams, and wrap-around corrugated plastic sheets.
Figure 3. Illustrates a simple and direct integration of a table-like design from its separate pre-cut pieces of flat corrugated plastic sheets.
Figure 4. Illustrates varying placement of vertical columns and their assembly with the wrap-around corrugated plastic sheets for a sofa and a coffee table structure.
Figure 5. Illustrates bed-like structure arrangements of corrugated plastic sheets.
Figure 6. Illustrates the design and assembly of corrugated plastic sheet furniture with modularity slots, including a double sofa, triple sofa, and relaxing sofa with leg rest.
Figure 7. Illustrates a vinyl sheet with a wood appearance used to conceal the corrugated ends as well as for aesthetic purposes.
Figure 8. Illustrates a simple and direct assembly of a cushion with seating surfaces using velcros arrangements.
Figure 9. Illustrates a column of corrugated plastic furniture with through perforations and perforations on one of the face-sheets for better sound absorption.
Figure 10: Illustrates corrugated plastic sheet furniture with rubber footpads at the bottom.
DETAILED DESCRIPTION:
My inventions are the corrugated plastic sheet furniture design and assembly system fabricated with corrugated plastic sheets. Columns are essentially corrugated sheets used as vertical structures to carry compressive loads, while the horizontal transverse beams are corrugated sheets that sustain shear and bending loads. The wrap-around corrugated sheets carry bending and in-plane loads while creating a closed structure (or closed cell or closed volume) improving the torsion stability. My design is characterized by an assembly of columns (103), transverse beams (101) (102), and wrap-around corrugated plastic sheets
4 Date Regue/Date Received 2022-07-15 (105) (106) (107) (108), assembled with a plurality of slots and cutouts, to provide efficient load paths and structural stability to the furniture.
Figure 1 illustrates the assembly of corrugated plastic sheets to build sustainable furniture with side handles for added comfort. A series of vertical sheets of the same thickness are used as columns (103) as shown in (104). The columns can be spaced uniformly (401) or non-uniformly (402). The upper ends of the columns have several slots. These slots are designed to accommodate the transverse beams by friction and there are no fasteners or glued joints.
The horizontal slotted transverse beams (101) (102) are inserted along at least four columns (103) in the system. The transverse beams (101) are accommodated by slots in the columns.
The columns are also fitted with one horizontal beam (102) on the upper side.
After inserting the transverse beams into columns with the predefined slots, the base skeleton of the chair (104) is completed. It is then covered by three wrap-around corrugated plastic sheets (105), (106), and (107) with specific angular bends to fit into the base skeleton.
The side handles (108) are attached to the base skeleton (104) to complete the chair assembly as shown in (109). All assembly steps involve the interlocking of parts in the slots without the need for any fasteners or glue.
Figure 2 illustrates a simple implementation of a table design characterized by the construction involving columns, beams, and wrap-around corrugated sheets outlined in this invention. The table comprises horizontal transverse beams (201), vertical columns (202), and wrap-around corrugated plastic sheets (204) (205). At least three horizontal transverse beams (201) are assembled into the slots of vertical columns (202) to form an intermediate assembly or the base skeleton of the table. The wrap-around sheets (204) (205) wrap the intermediate assembly to form closed volumes or closed cells between the columns adding stability. The table top is formed by the wrap-around sheet (204) with either an angular fold or a straight fold. The wrap-around sheet (204) adds bending load carrying capacity and torsional stability to the table-top. All the parts are assembled with the interlocking of parts in the slots without the need for any fasteners or glue. Figure 5B also represents a table-like design, but with no inclined folds on the top wrap-around sheet (details below).
Figure 3 illustrates a simple assembly of a serving table or a coffee table characterized by the construction involving columns, beams, and wrap-around sheets outlined in this invention.
Accordingly, the table comprises horizontal transverse beams (301), vertical columns (302), and wrap-around corrugated plastic sheets (304). All the parts are assembled with the interlocking of parts in the slots without the need for any fasteners or glue.
Figure 4 illustrates a sofa structure with side handles without frontal cutouts (403) and a coffee table without frontal cutout (406). The wrap-around sheets create multiple closed cells (either equally spaced or unequally spaced) with the vertical columns when assembled.
All the designs are characterized by columns, beams, and wrap-around sheet construction. All the parts are assembled with the interlocking of parts in the slots without the need for any fasteners or glue.
Figures 5 (A-C) illustrate the design and assembly of a scalable corrugated plastic sheet bed using modular concepts. Figure 5A represents the design of a headboard assembly.
Headboards are made by joining 501 and 502 together with the vertical column (503). Due to the geometry, the wrap-around sheet (502) also sustains compression loads like a vertical Date Regue/Date Received 2022-07-15 column while the folds in them act as horizontal beams when assembled into the slots. The wrap-around sheets (501) (502) also form closed cells between vertical columns when assembled (504). Figure 5B illustrates the simple construction of a table (510) that is connected to the headboard (504) by linkage elements (512) (513) through the modularity slots. Multiple table modules such as (510) are interconnected with each other using linkage elements (514) (515). In Figure 5C, for example, four tables (510) and two headboards (504) are assembled into a twin bed. An interim assembly without the top sheets is shown in 516.
Figure 5D shows the various assembly choices, which include queen and king-size beds demonstrating scalability with modular assemblies. Corrugated plastic sheet beds are lightweight and easy to assemble, portable, and can find use in hospitals and urgent care facilities as well as short-term emergency housing facilities.
Figure 6 illustrates the corrugated plastic sheet sofa structure designed with 'modularity slots' (605) that enable the expansion or reconfiguration of modular sofa units into a double-seated sofa (607) with the use of linkage elements (603) as shown in Figure 6A. Two or more pieces of furniture can be put together to create a new piece that serves different purposes, for example, a triple sofa (611) and a relaxing recliner (617) shown in Figures 6B and 6C, respectively.
Figure 7 depicts the use of self-adhesive sheets/films of custom prints to conceal the corrugations at the ends of corrugated plastic sheets in the furniture. Figure 702 illustrates the bare surface of corrugated plastic sheets, and section A of (702) (703) is enlarged to demonstrate the corrugated ends. Utilizing these films increases the aesthetics and protects the furniture against water in addition to concealing the corrugated ends.
Corrugated plastic sheets are sanded to enhance the adhesion if additional glue is applied externally.
Figure 8 illustrates a simple and direct assembly of a cushion using a velcro arrangement on a seating surface (or a wrap-around corrugated plastic sheet). Part (801) is assembled with (802) to form a final assembly as shown in (805). Both (801) and (802) have a mating element of velcro each, attached to them either by sewing or using an adhesive.
Figure 9 illustrates plastic corrugated plastic sheet furniture with through-perforations and perforations on one of the face-sheets for sound absorption. A vertical column (901) of furniture corrugated plastic sheet has either through-perforations (902) or perforations on one of the face-sheets (903) to trap sound waves and act as sound absorbing panels. This is based on the Helmholtz principle that sound waves of varying frequencies dissipate their energy when in a column or a cavity as they are trapped. As sound waves enter the face-sheet perforations, each of these micro columns formed by the corrugations act like Helmholtz resonators. This dissipates the energy of the sound wave through vibrations.
When soundproofing a space, hard, flat materials tend to reflect sound waves, which are undesirable. Sound waves are absorbed by the hollow spaces or multi-cell spaces between the vertical columns in the furniture when the sheets have through-perforations. These perforations are either staggered randomly or placed uniformly and can be of varying diameters. The perforated parts help in sound attenuation in noisy places such as restaurants, conferences, etc.
Figure 10 illustrates a piece of corrugated plastic sheet furniture with a thin rubber layer glued at the bottom (Figure 10 section D) to provide anti-slip properties.

Date Regue/Date Received 2022-07-15

Claims

CLAIMS:
Claim 1: General Claims (a) wherein corrugated plastic sheet furniture design and assembly system are fabricated with corrugated plastic sheets.
(b) Wherein the corrugated plastic sheets could be either of virgin plastic materials or from dismantled advertising or election signboards with or without printed content.
(c) Wherein the structural design of the furniture consists of at least four vertical columns to resist compression loads, two or more transverse beams to resist bending and shear loads, and a combination of wrap-around corrugated plastic sheets to resist bending loads and form closed cells (or volumes) to improve the furniture's torsion stability.
(d) Wherein the columns, transverse beams, and the wrap-around sheets include a plurality of slots for easy assembly without the need for any fasteners or glue.
(e) Wherein a corrugated plastic sheet furniture structure comprises of corrugated plastic sheets of varying thickness and varying number as needed to sustain pre-determined loads.
(f) Wherein the modularity slots allow the corrugated plastic sheet furniture to be scaled or reconfigured.
(g) Wherein an alignment of flutes of corrugated sheets in the columns is vertical, on wrap-around corrugated sheets they are horizontal to help to fold, and in transverse beams, they are horizontal (along the beam span).
(h) Wherein the legs of the furniture support comprises of inclined surface on the front for better leg room and comfort.
(i) Wherein a seating surface supports an inclined surface for comfort.
Claim 2: Sofa with side handles (a) wherein design and assembly of corrugated plastic sheet furniture includes side handles for added comfort.
(b) Wherein a series of vertical sheets of the same thickness are used as columns (103). The transverse beams (101) are accommodated by slots in the columns.
The columns are fitted with one transverse beam (102) on the backrest of the sofa.
The side handles (108) are attached to the slots in the transverse beams (101).
(c) Wherein a sofa structure with side handles is designed using corrugated plastic sheets with wrap-around sheets that are either with the frontal cut out (109) or without the frontal cut out (403).
Claim3: General purpose table (a) wherein a method that comprises of constructing a general-purpose table using different pieces (201), (202), (204) of corrugated plastic sheets.

(b) Wherein a table has three sections: horizontal transverse beams with slots, vertical columns spaced at a particular distance, and the tabletop. The table top is a large rectangle with two individual angular folds bent at an angle to the plane created by the columns of the assembled table.
Claim 4: Coffee table (a) wherein the design of a coffee table or similar piece of furniture that can be used as a serving table as well as a decorative piece of furniture.
(b) Wherein a table-like structure is made up from its separate pre-cut pieces of flat corrugated plastic sheets. A table design comprising two horizontal transverse beams (302), and two vertical sheets of the same thickness used as columns (301).
The columns have a number of slots at the upper ends of the legs (303). The columns are slotted at specific locations to fit the transverse beams without the use of fasteners and/or glue. Two corrugated plastic sheets are bent at an angle to create the tabletop (304).
(c) Wherein a table is designed using corrugated plastic sheets with wrap-around sheets either with the frontal cut out (305) or without the frontal cut out (406).
Claim 5: Bed: wherein a headboard is assembled by joining 501 and 502 together with the vertical interconnection sheet (503). These headboards can be connected in parallel to create any bed frame as long as they are size compatible.
(b) Wherein the design of a table-like structure is made by slotted vertical columns (505), horizontal transverse beams (506), and wrap-around sheets with folds.
(c) Wherein the legs of table-like structure (510), are covered with the component 509. Figure 5C demonstrates the construction of a corrugated plastic sheet bed by joining several table-like structures using modularity slots.
(d) Wherein several transverse beams (512) (513) join the headboard (511) to the table-like structure (510). Multiple table-like structures (510) are linked together by the components (514) (515), to make the bed structure.
(e) Wherein scalability is achieved by linking multiple modular assemblies (Figure 5D).
Claim 6: Modularity (a) wherein the vertical columns and transverse beams comprise of a plurality of slots and/or cut-outs to fit the corrugated plastic sheets as membrane elements or for connections with other parts to eliminate the need for any screws or other fastener elements.
(b) Wherein a corrugated plastic sofa structure is designed with 'modularity slots' (605) by enabling the expansion or reconfiguration of independent units without the need for complete replacement as shown in Figure 6A.
(c) Wherein two or more pieces of furniture can be put together to create a new piece that serves a different purpose as shown in double sofa (607) and triple sofa (611) and relaxing sofa with leg rest (617).

Claim 7: (a) wherein the procedure to clean corrugated plastic sheets involves removing unwanted prints or stickers from dismantled or used election or advertising signboards with a solvent.
(b) Wherein the sanding of corrugated plastic sheets is carried out to improve the adhesion to films.
(c) Wherein custom-designed films are used to conceal the corrugated ends as well as for aesthetic purposes on the furniture.
(d) Wherein the external appearance of the furniture can be easily customized by using self-adhesive films or glued films that also provide a waterproof layer.
Claim8: Wherein cushions are attached to the wrap-around corrugated sheets through a velcro arrangement as shown in Figure 8. Figure 805 demonstrates the sofa seating surface with a cushion cover, where 801 is the sofa seating surface covered by customizable cushions (802).
Claim 9: (a) Wherein corrugated plastic sheet furniture is designed with sound absorbing panels (901).
(b) Wherein a design of furniture made of corrugated plastic sheets has through perforations to trap sound waves and act as sound absorbing panels (902).
(c) Wherein a design of furniture made of corrugated plastic sheets has perforations on one side of the face-sheet (903) to confine sound waves within the corrugated walls.
Claim 10: Wherein corrugated plastic sheet furniture has rubber footpads at the bottom that act as an anti-slip feature (Figure 10 section D).
Although specific embodiments are described above for instructional purposes, the principles of this patent document are not limited to the specific embodiments described above. For example, while the general-purpose table (Figure 2) and coffee table (Figure 3) are shown in rectangular shapes, the table can be built in a square shape with equal side lengths on each side of the tabletop. As a matter of fact, various modifications, adaptations, and combinations of various features of the described embodiments are possible without departing from the scope of the invention as set forth in the claims.
REFERENCES:
[Ref 1.] CORRUGATED FIBERBOARD CONSTRUCTIONS, Zachary Rotholz, Patent No.: US
10,578,142 B2.
[Ref 2.] CORRUGATED FURNITURE DESIGN AND CONSTRUCTION SYSTEM, Zachary Rotholz, Pub .No . : US 2019 / 0111650 Al.

[Ref 3.] T. Dovramadjiev, P. Bratanov, K. Cankova, and G. Jecheva, "CREATING
AND
RESEARCHING SUSTAINABLE DESIGN OF CORRUGATED CARDBOARD FURNITURE WITH
ADVANCED TECHNOLOGICAL MEANS," vol. 4, p. 2, 2014.
CA3167901A 2022-07-15 2022-07-15 Corrugated plastic sheet furniture design and assembly system Pending CA3167901A1 (en)

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