GB2322070A - Making basket-work articles - Google Patents

Abstract

A method of making articles comprising basket-work constructions provides a means for producing a load-carrying joint between a panel 12 of basket-work material and an associated structural member 16, and comprises forming a slot 28 in the member 16 and utilising for the panel 12 a wire-based weave construction in which the longitudinal or weft wires extend lengthwise to the end edge at which the joint is to be made. A lifting flange is formed at the edge by bending the woven panel. The flange is friction-fitted into the slot and the weft wires serve to transfer lifting loads.

Description

MAKING ARTICLES COMPRISING WICKER OR BASKET-WORK This invention relates to a method of making articles comprising wicker or basket-work constructions. An example of such articles is an item of funiture such as a linen basket. A particular application of the invention is to the construction of trays and drawers in which a wicker or basket-work construction is adopted for the walls and there is provided a base which may, for example, be constructed of multi-ply wood, plastics or the like.

More specifically, the invention relates to the use in articles comprising a wicker or basket-work construction of a woven material comprising metallic elements or filaments as the lengthwise or warp elements of the woven assembly, and some other material (but not excluding some metallic content) forming the transverse or weft elements. A particular example of a suitable woven wicker or basket-work material is that material which has in the past been sold under the trade mark LLOYD LOOM. This consists of a woven assembly of paper-covered warp wires and weft elements consisting of a twisted paper yarn.

This material is well know for its widespread use in linen baskets, basket chairs and the like. We have identified a requirement for improvements in the method of constructing structural joints in articles involving the use of wicker or basket-work constructions whereby the labour of making such joints is reduced.

In the case of purely handmade articles in which osiers or cane or rushes or wire etc are hand-plaited, the traditional technique for producing structural joints is acceptable in terms of operational efficiency of such a hand-manufacturing technique whereby the slow method for producing a structural joint between a basket wall or side and a corresponding base is no slower than the remainder of the stages in the technique.

However, in the case of factory-manufactured wicker or basket-work constructions, such as materials of the kind previously known under the trade mark LLOYD LOOM, such a hand-construction approach to the production of structural joints is no longer acceptable. The woven material itself is manufactured using factory techniques whereby productivity is relatively high and therefore the disadvantages of hand-assembly have been largely eliminated from the techniques for the production of the main panels and sheets of woven material. However, despite the obvious need for improved techniques in joining such panels to structural members such as the bases of linen baskets, chair seats etc, to the best of the Applicants' knowledge no effective solution of this problem has been provided and the currently adopted technique for producing such structural joints is the laborious one of hand-forming a woven or plaited bead along the relevant edge of the woven material and then using this bead as a structural element enabling the material to be hand-fastened to the wood or other material of the base using a stapling technique.

It is a practical demonstration of the nonavailability of alternative techniques for such construction work that as of the date of filing of this priority-establishing patent application the majority of manufacturers of woven articles of this kind arrange that these hand-produced steps in the production of their product ranges are put into practice in countries in which the labour rates are relatively low so that the disadvantages of the slow and laborious production technique are thereby somewhat offset. The present invention seeks to provide a means whereby there will no longer be a need to export such work to territories in which labour rates are relatively low.

As a result of the adoption of this stapling and hand construction technique throughout the industry utilising fatory-woven sheet materials of this kind, the present Applicants consider it self-evident that no alternative techniques have yet been devised whereby a factory production technique can be applied to the construction of such basket-work or wicker articles. Therefore an object of the present invention is to provide a method whereby articles comprising a wicker or basket-work construction, (such as articles of furniture but not excluding many other articles such as baskets themselves, shopping trolleys, and indeed any other such basket or wickerwork construction where there is a need for tens in transmitting joints), in which the methods of forming the structural joint is improved with respect the hand-production techniques, or improvements generally are provided.

According to the invention there is provided a method of making an article comprising a wicker or basket-work construction, such as an article of furniture or the like, as defined in the accompanying claims.

In an embodiment of the invention there is provided an article comprising a wicker or basket-work construction in the form of a tray or drawer for use in kitchen units for storage purposes. A side panel or wall of the article is of woven wicker or basketwork construction comprising paper-covered metallic alloy warp elements and twisted paper weft elements or yarns, interwoven therewith. The panel is to be joined for load-transmission purposes and to form a mechanically integral structure to a structural member in the form of a base so that the article can be lifted when filled by means of lifting forces applied to the base from the associated panels or walls without the use of a vertical frame connected to the base.

In the embodiment, the woven panel or wall comprises a woven assembly of generally lengthwise or warp metallic elements and generally transverse or weft elements. In this panel, there is formed by bending at least one projecting lifting flange or lip.

This is formed at an edge of the panel, this edge being located such that it will be a lower edge of the panel when joined to the structural base. Also, the location of the flange is such that at least two of the metallic elements enter the flange across the bend and have associated with them the corresponding transverse or weft elements to provide the structure of the flange.

To co-operate with the lifting flange there is formed in the structural member or base a generally horizontal slot which is adapted to receive the lifting flange. The latter is caused to enter the slot as a friction fit therein with the metallic elements or warp filaments extending in a generally upward/downward direction outside the slot and extending across the bend and into the slot so as to provide strength in the flange for transmitting the lifting forces to the structural base.

By virtue of the inherent strength of the arrangements whereby the lifting flange projects outwardly from the panel and enters the slot formed in the base and resists bending, the mechanical connection between these members ensures that a forcetransmitting connection is effected whereby lifting load transmission is readily achieved without even the necessity for a bonding step. Thus the embodiment of the invention enables the production of a loadtransmitting joint to be formed between the woven panel and its associated structural member or base by the simple step of forming by bending a projecting lifting flange and simply lodging the flange in the slot for force-transmission purposes. These steps can be readily carried out relatively rapidly in a factory situation and without the need for the intervention of hand labour, although hand production would still be advantageous. Accordingly, the technique of joining the woven panel to its associated structures is reduced to a simple factory operation consisting of the formation of the flange, the formation of the corresponding slot for the flange, the lodging of the flange in the slot and (if so desired) the provision of a bonding medium to hold the flange in the slot in a permanent or controlled basis. In short, the hitherto inherently hand-constructed structural joints provided in woven materials of this kind are no longer a necessity.

Further features of the described embodiment include the provision of the slot in a side edge face of the structural member or base and at a location such that it is intermediate the upper and lower edge faces thereof so that the woven panel at least partially screens the upper portion of the thickness of the base. In this way, the construction becomes even more visually similar to that of the established hand made product. This visual feature is enhanced in the embodiment by the provision of the slot at a location such that it is nearer to the bottom edge than the top edge of the base so that the weave of the panel more closely simulates the hand made technique of joining natural materials such as osiers, rushes, cane etc to the slender base of a basket-work construction.

The inclination of the lifting flange with respect to the adjacent portion of the panel is, in the embodiment, in the range of 80 to 100 degrees and preferably in the range of 85 to 95 degrees. The exact angle provided is not critical to the functionality of the embodiment but does affect the ease with which the lifting flange can be caused to enter its corresponding slot. It will be understood that the stiffness or bend-resistance of the metallic warp elements is such that they will effectively serve to transmit loads to the structural base or other member at a considerable range of angles but a disposition of 90 degrees or a few degrees on each side of this is preferred for ease of assembly.

Also in the embodiments, the lifting flange is bonded into its associated slot in order that its location there for load transmission purposes is thereby rendered permanent or at least semi-permanent.

Likewise in the embodiments, the construction of the lifting flange is such that only one flange is provided along the relevant edge of the woven panel although it is envisaged that some variation from this preferred arrangement can be adopted in order to meet the needs of the particular circumstances, this variation going as far as the provision of multiple spaced short flanges, each accommodating the provision of at least two of the metallic warp elements or filaments and their associated weft elements. The spacing of these short lifting flanges from each other may be chosen in accordance with the requirements of a particular case, notably in accordance with the lifting and load transmission factors.

Although in the embodiments the lifting flange is bonded into its associated slot for reasons of permanency of the load-transmission arrangement, nevertheless such bonding is not essential and where not provided, the friction fit of the lifting flange within its slot should be sufficiently tight to cause sonme compression of the transverse weft element.

Indeed, where such bonding is not provided, then where some deviation from an angle of 90 degrees at the bend is provided, then the use of an included angle of less than 90 degrees will lead to an enhanced security of retention of the lifting flange within its slot.

A further preferred feature relates to the exact configuration of the bend formed in the panel at the junction with the lifting flange. This bend should generally be of angular rather than rounded construction and after assembly should be located close to the edge of the slot in the base or rail so that the line of action of the tensile forces applied from the panel is likewise close to that edge.

Embodiments of the invention will now be described by way of example with reference to the accompanying drawings in which: Fig 1 shows an elevation view of a woven panel assembly forming an embodiment of the invention and including at the upper edge of the panel a lifting flange; Fig 2 shows, in a side elevation view generally in the direction indicated by the arrow II in Fig 1, the panel and lifting flange assembly of Fig 1 together with an indication of the relative dispositions of the weft elements which are interwoven with the metallic warp elements; Fig 3 shows, on a much larger scale, a side elevation view with internal details indicated of a single metallic warp element from the woven assembly of Fig 1 together with its associated paper covering for the metallic interior or core, together with an end sectional view of the element; Fig 4 shows, in view similar to that of Fig 3, a corresponding enlarged view of one of the weft elements of the assembly of Figs 1 and 2, this being shown likewise in side elevation and end elevation views; Fig 5 shows a sectional view part of an article of furniture, in the form of a drawer or tray incorporating woven side panels, the section being taken in a generally vertical plane and showing the side panel and associated upper and lower structural members or rails and the base panel or floor of the drawer or tray; and Fig 6 shows, on a larger scale, a detail of the assembly of Fig 5, namely the co-operation of the upper lifting flange of the panel of Fig 5 with its associated structural member or rail.

There are shown in the drawings the constructional detail of a part of an article of furniture in the form of a drawer or tray for a kitchen unit. Drawer 10 comprises side panels or walls 12 connected to structural members in the form of a base rail 14 and an upper rail 16. Base rail 14 supports a drawer base panel 18.

The general construction of drawer 10 is such that it can be lifted manually by means of upper rails 16 at opposite sides of the drawers so that lifting loads for raising the drawer (which may be filled with a relatively heavy material such as potatoes), are transferred from upper rails 16 through the side panels or walls 12 to the base rail 14 and thus to the drawer base panel 18 and the lifted materials. It will be appreciated that in these circumstances, a secure joint is required between the side panel 12 and both the upper rail 16 and the base rail 14. There will be described below details of the method by which this connection is made.

First however, there will be described the construction of the side panels or walls 12 themselves with reference to Figs 1 to 4 of the drawings.

As shown in Fig 1, side panel or wall 12, is formed integrally with similar side panels or walls all round drawer 10, and comprises interwoven longitudinal warp elements 20 and lateral weft elements 22. Details of the construction of these warp and weft elements are shown in Figs 3 and 4. As they are shown, warp elements 20 comprise a simgle core 24 comprising an electro-galvanised steel wire of 1.2 millimetres diameter and having a tensile strength of 68 tons per square inch. This core material is integrally covered with a paper coating formed by a helically-wound surface layer of paper 26 which has the corresponding proportional thickness indicated in Fig 3. Weft elements 22 are formed as filaments of twisted paper yarn and do not include a metallic conponent. They serve to form the main substance of the woven material due to their much closer spacing (as shown in Figs 1 and 2) as compared with the spacing of the weft elements 20.

Fig 1 clearly shows the woven disposition of the weft elements 22 with respect to the warp elements 20, the weave comprising a simple under-and-over pattern executed in a uniform manner by the weft elements in relation to the warp elements. This is clearly seen in the upper edge of the panel 12 seen in Fig 1. The outer surface of a panel such as panel 12 is usually provided with a surface treatment such as painting in the latter stages of the manufacture of an article of commerce such as a linen basket or other article. In the case of the drawer or tray for a kitchen unit, a natural-look surface treatment may be employed.

Considering now the general construction of the drawer 10, it comprises four generally upright side panels or walls 12 extending along each of its generally rectangular edges as seen in plan view profile. These are formed as a single planar sheet of woven material which is suitably formed by bending to the required rectangular format and the then adjacent two edges are joined, at the rear of the drawer or tray, by means of a suitable slotted joint member (not shown). The side or wall panels are joined for load transmission purposes to the generally horizontal structural members constituted by upper rail 16 and base rail 14. This structure can thus be listed when filled by means of lifting forces applied to the lower rail 14 from panels 20, without the use of a vertical frame connected to the lower rail for load transmission purposes. Of course, in particular cases there may be a need for some vertically extending structure, such as the member for joining the adjacent ends of the side panels at the rear of the drawer or tray, but such provision does not compromise or change the fact that the majority of the lifting forces applied to the lower rail 14, and thus to the base panel 18 of the drawer, are transmitted through the side panels 12 in use.

Details of the structure whereby the side panels 12 are connected to rails 14 and 16 will now be further described.

As clearly shown in Figs 1, 2, 5 and 6 there are formed at the edges of panel 12 projecting lifting flanges 28,30. These flanges are located at the lower and upper edges of the panel and the warp elements 20 extend across the bends 32,34 and into the flanges and have associated therewith, within the flanges, their corresponding transverse weft elements 22.

In addition to the formation of the lifting flanges, and in order to co-operate with these, there are formed in each of the rails 14 and 16 a generally horizontal (in the normal use attitude of the drawer or tray 10) slots 36,38 to receive the flanges.

As shown in Fig 6, the lifting flanges are caused to enter the slots as a friction fit therein with the warp elements 20 extending in their upward/downward direction outside the slots and extending likewise across the bends 32,34 and into the slots so as to provide strength in the flanges 26,28 for transmitting lifting forces to the rails 14 and 16 in use.

In the drawing of Fig 5, the panel 12 is indicated (for simplicity of illustration) as a simple planar structure, but of course it has the woven format indicated in Fig 6.

As can be seen in Fig 5, the relative dispositions of the slot 38 in lower rail 14 and panel 12 are such that the panel at least partially screens the upper portion of the thickness of the rail 14 so that the woven structure of the panel appears to emerge from a relatively thin base structure in a manner which simulates the hand made technique of joining natural materials to the slim base of a basket-work construction.

Although not shown in the drawings, there is provided a bonding medium within slots 36 and 38 to bond the lifting flanges 28,30 in place in their respective rails.

Amongst other modifications which may be made in the above embodiments while remaining within the scope of the invention are the following: 1 In some circumstances, it may not be necessary to retain the weft elements in the lifting flanges so that it may in those cases be possible to make a satisfactory joint between the warp elements 20 and the slots or other holes or recesses provided to receive same.

2 Where a bonding medium is used to retain the lifting flanges in position, it is not strictly necessary for a friction fit to be provided beetween the lifting flanges and their associated slots.

3 As indicated above, the provision of vertical members in the structure of a product in accordance with the invention may of course be provided for a variety of aesthetic or practical reasons without affecting the structural significance of the lifting flanges and their load bearing cooperation with the corresponding slots formed in the associated structural members or rails.

4 Likewise, references to the horizontal attitude of the structural members refer to the normal disposition of these when in a load-bearing attitiude, but such attitude indications refer only to the normal attitude and disposition when bearing loads and the parts may of course depart from this strict attitude by significant amounts in particular cases and indeed when load-bearing use does not arise.

Claims (13)

1 A method of making an article comprising wicker or basket-work construction, such as an article of furniture or the like, comprising: a) providing an upright side panel or wall of woven wicker or basket-work construction; b) providing a lower, for example generally horizontal, structural member to which said side panel or wall is to be joined for load-transmission purposes to form a mechanically integral structure such as a load-carrying basket or tray which can be lifted when filled by means of lifting forces applied to said lower structural member from said panel or wall without the use of a vertical frame connected to said structural member; c) said woven panel or wall comprising a woven assembly of generally lengthwise or warp metallic elements and generally transverse or weft elements; characterised by d) forming by bending at least one projecting lifting flange or lip in said panel at an edge thereof, said lifting flange being located at an edge thereof which will be a lower edge of said panel when joined to said structural member and which is also so located that at least two of said metallic elements enter said flange across the bend joining same to the remainder of said panel and have associated therewith their corresponding transverse weft elements to provide therewith the structure of said at least one lifting flange; e) forming a generally horizontal slot in said structural member to receive said at least one lifting flange; and f) causing said lifting flange to enter said slot as a friction fit therein with said metallic elements extending in a generally upward/downward direction outside said slot and extending across said bend and into said slot so as to provide strength in said flange for transmitting said lifting forces to said structural member in use.

2 A method of making an article comprising a wicker or basket-work construction characterised by forming a slot in a structural member of said article and causing a lifting flange provided on a wall or panel of woven construction of said article to enter said slot to transmit lifting forces to said structural member in use.

3 A method according to claim 1 or claim 2 characterised by said slot being formed in a side edge face of said structural member intermediate upper and lower edge faces thereof so that said panel at least partially screens the upper portion of the thickness of said structural member.

4 A method according to claim 3 characterised by said slot being formed in a base structural member of said article and being located nearer to the bottom edge than to the top edge of said base structural member so that the weave of said panel more closely simulates the handmade-technique of joining natural materials to the base of a basket-work construction.

5 A method according to any one of the preceding claims characterised by said step of forming by bending said projecting lifting flange comprising bending the flange so that it is at an angle in the range of 80 degrees to 100 degrees with respect to the adjacent portion of said panel.

6 A method according to claim 5 characterised by said step of bending comprising bending said flange to an angle within the range of 85 degrees to 95 degrees with respect to the adjacent portion of said panel.

7 A method according to any one of the preceding claims characterised by the step of bonding said lifting flange into said slot.

8 A method according to any one of the preceding claims characterised by said step of forming by bending at least one projecting lifting flange comprising forming only only one such flange at said edge of said panel and said flange extending along substantially the full length of said edge of said panel.

9 A method according to any one of the preceding claims characterised by said step of forming said slot in said structural member comprising forming same in a base member of an item of furniture.

10 A method according to any one of claims 1 to 8 characterised by said step of forming said slot comprising forming same in an upper structural member of an item of furniture in order that lifting forces may be manually applied thereby to said panel.

11 A method according to any one of the preceding claims characterised by said friction fit of said lifting flange into said slot being sufficiently tight to cause some compression of the transverse weft elements of said flange as said flange is caused to enter said slot.

12 A method according to any one of the preceding claims characterised in that said step of forming by bending said projecting lifting flange comprises forming said bend as a generally angular bend rather than as a rounded bend, and said bend being located close to the edge of said slot so that the line of the action of tensile forces applied to said flange is likewise close to said edge.

13 A method of making an article comprising a wicker or basket-work construction such as an article of furniture or the like substantially as described herein with reference to the accompanying drawings.