Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
• • A—HUMAN NECESSITIES
  • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
  • A47B—TABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
  • A47B96/00—Details of cabinets, racks or shelf units not covered by a single one of groups A47B43/00 - A47B95/00; General details of furniture
  • A47B96/20—Furniture panels or like furniture elements
  • A47B96/205—Composite panels, comprising several elements joined together
  • A47B96/206—Composite panels, comprising several elements joined together with laminates comprising planar, continuous or separate layers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
  • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
  • B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
  • B29C70/021—Combinations of fibrous reinforcement and non-fibrous material
  • B29C70/025—Combinations of fibrous reinforcement and non-fibrous material with particular filler
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
  • B32B37/04—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2305/00—Condition, form or state of the layers or laminate
  • B32B2305/10—Fibres of continuous length
  • B32B2305/18—Fabrics, textiles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2305/00—Condition, form or state of the layers or laminate
  • B32B2305/10—Fibres of continuous length
  • B32B2305/20—Fibres of continuous length in the form of a non-woven mat
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2305/00—Condition, form or state of the layers or laminate
  • B32B2305/30—Fillers, e.g. particles, powders, beads, flakes, spheres, chips
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2305/00—Condition, form or state of the layers or laminate
  • B32B2305/70—Scrap or recycled material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/40—Properties of the layers or laminate having particular optical properties
  • B32B2307/402—Coloured
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2479/00—Furniture
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2607/00—Walls, panels

Definitions

• the invention relates to office landscape systems and the like. More particularly, the invention relates to trim panels, insert panels, or other furniture panels that are useful with office landscape partition panel systems and with storage cabinets.
• a furniture panel of the invention has a layer of moldable material and a decorative facade or finish material.
• the layer of moldable material has a first side and an opposing second side.
• the finish material is disposed upon at least the first side and is at least
• the finish material includes filaments of moldable material and further yet, a predetermined number of the filaments in the finish material may be colored a preselected color.
• the layer of moldable material may include a filler material. More
• the filler material may define a stratum within the layer of moldable material.
• a member may be molded within the layer of moldable material.
• the member may be any of a hydraulic conduit, a pneumatic conduit, an electrical conduit, electrical conductors, fiber optic conductors, and structural reinforcement.
• Figure 2 is a schematic fragmentary cross-sectional view of a furniture panel of the
• Figure 3 is an exploded schematic fragmentary cross-sectional view of an number of strata of materials for a furniture panel of the invention.
• Figure 4 is the view of Fig. 3, showing a first alternative construction of a furniture panel
• Figure 5 is the view of Fig. 3, showing a second alternative construction of a furniture panel of the invention, including a rigid structure;
• Figure 6 is the view of Fig. 2, showing the second alternative construction of Fig. 5 incorporated in a furniture panel of the invention.
• Figure 7 is an end perspective view of a flipper door storage cabinet that has a door panel according to the invention in a closed position
• Figure 8 is the view of figure 7 showing the door panel in an open position
• Figure 9 is a front perspective view of a first alternative door panel that is adapted for use with a pre-existing flipper door panel
• Figure 10 is a centerline cross-sectional view thereof; and Figure 11 is the view of figure 10 with the pre-existing flipper door panel removed; and
• Figure 12 is a front perspective view of a second alternative door panel that incorporates
• Figure 13 is a perspective view of a furniture panel according to the invention.
• Figure 14 is an enlarged fragmentary cross-sectional detail view taken along line XIV-
• Figure 15 is a perspective view of a first alternative embodiment of a decorative furniture
• Figure 16 is an end elevational view thereof, partially wrapped around a post; and Figure 17 is a fragmentary cross-sectional view of two panels matted to provide a unified panel with two opposing finish sides; and
• Figure 18 is an exploded fragmentary cross-sectional view thereof.
• a preferred embodiment of a furniture panel according to the invention is generally shown in the drawing figures and discussed below.
• a furniture panel or decorative panel according to the invention may be formed with any of various configurations as may be dictated
• a furniture panel or decorative panel according to the invention may include flipper doors, wall panels, tack boards, seat back panels, soft sided storage cabinets, light shields, divider screens, and modesty panels, for example.
• the furniture panel may commonly be a generally planar rectangular panel member
• a furniture panel of the invention is a molded member and is thereby influenced by the method of construction, including without limitation, such factors as closed mold temperature and pressure, and material densities.
• the panel is a unified or monolithic member that has a layer of moldable material 12 into which a stratum of a filler material 14 may be embedded and into which a facade or finish material 16 is at least partially imbedded on one or both of two opposing side surfaces (Fig. 2). This is distinguished from prior known insert
• the prior known panels have discrete layers of distinct materials with defined boundaries between them.
• the layer boundaries are emphasized or further defined by the adhesives that are interposed between the substrates or layers.
• the adhesives in prior panels may be provided as
• the layer 12 of moldable material in the invention is preferably a blend of materials with at least one of the component materials being a thermoplastic, including, and not limited to, polyester, co-polyester, polypropylene, nylon, or blends thereof, for example.
• Another of the component materials may have a higher melting point, providing a matrix to which lower melting point materials may bond.
• This other material may also include various thermoplastics such as polyester, co-polyester, polypropylene, and nylon, for example, or may include natural materials such as, sisal, cotton, flax, and hemp, for example.
• thermoplastics such as polyester, co-polyester, polypropylene, and nylon, for example, or may include natural materials such as, sisal, cotton, flax, and hemp, for example.
• composition for example, may provide a freer flowing base material that will conform to tighter radius mold shapes and that other resulting furniture panel characteristics may be preselected by the composition of the layer of moldable material.
• the layer 12 is preferably provided as a non- woven mat.
• Re-cycled or virgin polyester and polypropylene for example, may be chopped, shredded, carded, blended and lofted into a non-woven sheet and rolled into a roll, as is known.
• a homogenous mixture of polyester and polypropylene many be provided with a resulting ratio or mix of component materials being preselected according to predetermined desired resulting properties.
• the furniture panel may be successfully constructed and used with a single mat of material, as one having ordinary skill in the art will understand.
• the one will further understand that a predetermined combination of multiple component mats that have different preselected compositions will result in a furniture panel that has a customized structure according to a user's requirements. This combining of multiple component mats that have differing content still
• a second mat 18 comprised of a blend including the filler material 14 may be used with the mat 12 to introduce and position the stratum of filler
• the stratum of filler material 14 is provided by embedding the filler into a second mat of the moldable material. This is conveniently accomplished by the same procedure that is used to provide the layer 12 of moldable material just discussed, with an
• the filler materials may include any of various materials that preferably have a melting point temperature that is higher than that of the moldable material that is used to mold the furniture panel of the invention.
• filler materials that may be used as filler include, without limitation, polyester, polypropylene, nylon, ceramics, metals, sisal, cotton, flax, and hemp.
• furniture panels of the invention may include a load station 22, an uncoiler 24, a shear 26, a high intensity oven 28, a bonding press 30, and a fabric carousel 32.
• the press 30 is provided with cooperating mold halves or dies, so the press can mold a desired, pre-determined panel configuration.
• a first conveyor portion 42 may interconnect the loading station 22, the uncoiler 24, the shear 26, the high intensity oven 28, and the bonding press 30.
• a second conveyor portion may interconnect the fabric carousel 32 and the bonding press 30.
• an automatic unloader 46 may be provided to remove panels from the bonding press 30 and stack them on a pallet or transfer them to another conveyor, for example.
• filler may be provided on separate rolls 50 at the load station 22 or may be concentrically rolled on the same roll. Either way, when the furniture panel is to be constructed with an embedded
• the two mats are aligned and simultaneously feed through the shear 26.
• the mats are cut at a predetermined length or into a predetermined shape by the shear 26 and feed by the conveyer portion 42 into the oven 28.
• the moldable material in the mats 12 and 14 is preferably heated in the oven 28 to a point of transition from the solid state to the liquid state of the material.
• moldable material may liquefy in the oven while others remain solid and yet others may be in a transition or gel-like condition. Thus, the material becomes very soft and pliable, yet can still be handled because it retains enough of the mat structure.
• the hot mats 12 and 14 are further transferred by conveyer portion 42 from the oven 28 to the bonding press 30. Substantially simultaneously, or previously, a corresponding piece of fabric 16 may be transferred from the
• the hot moldable material may transition to a liquid material state in the mold. Regardless of the extend to which the hot moldable material of mats 12 and 14 may or may not further transition to a liquid state, the hot moldable material does flow in the mold or become pressed throughout the mold because of the
• the two mats 12 and 14 become one layer of moldable material with a stratum of filler embedded in the moldable material.
• the molten moldable material flows throughout the mold cavity and attaches, even fuses with, to the non-molten material.
• the molten material is also pressed into the finish fabric 16, so the fabric becomes at least partially embedded into the moldable material.
• the mold halves or dies are temperature controlled below the melting temperature of the moldable material.
• the oven heats the moldable material and the pressure of the closed mold in the press shapes the material before the transfer of heat from the material to the dies sets the material in the solid state.
• Structural characteristics of the resulting panel may be controlled by adjustment of the material make up, as indicated above, the material density and the mold pressure. For a given amount of material, a given mold cavity volume will result in a particular material density. By holding the mold cavity constant, an increase in the amount of material will increase the
• a resulting panel with a relatively higher resulting material density will be a relatively tougher panel that resists puncturing, including the insertion of pins and the like.
• a decrease in the amount of material will produce a panel with a relatively lower resulting material density, and will be less tough, that is more susceptible to the insertion of pins.
• a furniture panel of the invention can be a fully tackable panel, for example, by adjusting the resulting material density appropriately. That is to say that the panel may be constructed so papers or the like may be posted anywhere on the panel with a push-pin or tack. As a mater of geometry, the tackable furniture panel should have an at least three eighths inch (10 mm) thickness to support a weighted push-pin, as one having ordinary skill in the art will
• moldable material will commonly be viscous and will not flow freely, merely pouring throughout the mold cavity. Rather, the moldable material will tend
• the panel may have localized areas of relatively higher material density, and associated greater material toughness, where the mold cavity and the resulting furniture panel cross-sectional thickness is thinner or where added mat thickness was originally placed in the mold. Further depending upon the requirements of a particular office landscape installation,
• a fire barrier may be required in the furniture panel. This may be implemented with a stratum 14 of fiberglass or a layer of foil under the finish fabric 16.
• a mat 14 (Fig 3) that uses fiberglass as the filler material and has a relatively high ratio blend of fiberglass to moldable material may provide an acceptable level of fire barrier characteristic.
• a foil may be layered under the finish fabric. A micro perforation of the foil, with cleanly punctured perforations or perforations that leave a tab, may enhance unity of the panel structure.
• an panel of the invention may be constructed with various alternative 'lay-ups' of multiple mats prior to
• a lay-up of fabric 16, a filler blend mat 18, and a moldable material mat 12 (Fig 3) will produce a unified furniture panel with an embedded filler stratum 14 adjacent the facade or
• finish fabric 16 (Fig 2), for example.
• the embedded filler stratum 14 may be spaced from the fabric 16, if desired, by using an additional moldable material mat 12 as shown in drawing figure 4. Further, strength and other panel characteristics may be enhanced with the use of metal or ceramic fibers.
• a rigid structure including a metal mesh 20, for example, may be embedded in the unified panel by including the structure in the mat lay-up (Figs 5 and 6).
• a first specific embodiment of a furniture panel according of the invention is shown in drawing figures 7 and 8 as a flipper door 110 of a storage cabinet 112.
• the door 110 may be fabric finished with embedded mounting brackets or embedded mounting fasteners anchors.
• the mounting brackets or anchors may be embedded metal or plastic members, for example. As plastic members, the brackets or anchors may easily be integrally formed with the panel by providing a high density of the moldable material in pre-selected localized areas. By providing a layer of moldable material of sufficient thickness, density, and area, the moldable material may define a mounting or anchor.
• the panel may be constructed as a veneer piece 120 that overlays a preexisting flipper door 122 or the like (Figs. 9-11).
• the door cover 120 may similarly be used with an external support frame 124 (Fig. 12).
• the cover panel 120 will have very little
• the frame 124 may also be molded within the panel 120 as required.
• Yet another feature of a panel that is constructed according to the invention is the ease in which not only a face of the panel can be finished, but also the edges of the panel may be formed to facilitate wrap around finishing of the panel.
• the panel 140 may be formed with
• connection 144 between the flange 142 and the panel 140 may be formed in the press 30 as a localized high density portion of the panel, what is commonly known as a living hinge.
• the flange 142 extends from a body portion of the panel 140 to a terminal end 146 of the flange, which may be cleanly formed by shearing in the press 30. The folding over of the
• flange 142 may also be performed as a machine operation and may also include capturing a frame or other component member in a space 148 that is defined between the panel body and the folded flange.
• a pair of cooperating panels 140 and 141 may be monolithically bonded and produce a unified panel of the invention that has a finish material 16 on at least both opposing sides 150 and 152, and up to all exposed sides being covered with a finish material (Figs. 17 and 18).
• This process may be easily accomplished with a pair of cooperating panels 140 and 141 of the invention because of the unique construction of the panels as will be understood from this disclosure by one having ordinary skill in the art.
• the two panels 140 and 141 are fabricated as discussed in detail above, with at least one of two opposing sides 150 and
• the raw mating surface 154 and 156 may be heated by any appropriate method, including tubular quartz infe ⁇ ed heating elements, for example, to melt the moldable material to
• a rectangular panel is notched 164 to define corners 166 between adjacent panel portions 168A-D.
• the notches 164 may be symmetrical with each of the panel portions 168A-D being substantially similar, although specific installation requirements may dictate that some or all of the panel portions be unique and so the notches may also be non-uniform.
• a panel by panel fabrication line may include a load station 22, an uncoiler 24, a shear 26, a high intensity oven 28, a bonding press 30, and a fabric carousel 32 (Fig. 1).
• a continuous fabrication process line may include the load station 22, the uncoiler 24, a continuous feed high intensity oven, a fabric
• the continuous feed oven will heat the materials as they are continuously fed through the oven.
• the fabric may then be fed into the process after the moldable material mats are heated.
• the heated moldable material mats and the fabric feed through the continuous feed press, which may use a roll form process to contour the materials.
• the continuously fed and now molded panels may then be cut to various
• predetermined lengths with a cutter or shear without disrupting the continuous flow of the forming process.
• a decorative panel or furniture panel that are within the scope of the disclosed concept may include, without limitation, wall panels, tack boards, seat back panels, soft sided storage cabinets, light shields, divider screens, and modesty panels. Narious relational terms, including left, right, front, back, top, and bottom, for example, are used in the detailed description of the invention and in the claims only to

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Composite Materials (AREA)
• Laminated Bodies (AREA)
• Dry Formation Of Fiberboard And The Like (AREA)

Applications Claiming Priority (3)

Publications (2)

Family

ID=22606806

Family Applications (1)

Country Status (4)

Families Citing this family (5)

Family Cites Families (11)

• 2000
  • 2000-11-21 AU AU24255/01A patent/AU2425501A/en not_active Abandoned
  • 2000-11-21 EP EP00987992A patent/EP1237709A4/de not_active Withdrawn
  • 2000-11-21 CA CA002393893A patent/CA2393893A1/en not_active Abandoned
  • 2000-11-21 WO PCT/US2000/032272 patent/WO2001038073A1/en not_active Ceased

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