Classifications

• • A—HUMAN NECESSITIES
  • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
  • A47C—CHAIRS; SOFAS; BEDS
  • A47C5/00—Chairs of special materials
  • A47C5/005—Chairs of special materials of paper, cardboard or similar pliable material
• • 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
  • A47B3/00—Folding or stowable tables
  • A47B3/06—Folding or stowable tables with separable parts
• • 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
  • A47B47/00—Cabinets, racks or shelf units, characterised by features related to dismountability or building-up from elements
  • A47B47/04—Cabinets, racks or shelf units, characterised by features related to dismountability or building-up from elements made mainly of wood or plastics
  • A47B47/05—Cabinets, racks or shelf units, characterised by features related to dismountability or building-up from elements made mainly of wood or plastics with panels on a separate frame, e.g. a metal frame
• • 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
  • A47B55/00—Cabinets, racks or shelf units, having essential features of rigid construction
  • A47B55/06—Cabinets, racks or shelf units, having essential features of rigid construction made of cardboard, paper, or the like
• • 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
  • A47B73/00—Bottle cupboards; Bottle racks
• • 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
• • A—HUMAN NECESSITIES
  • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
  • A47C—CHAIRS; SOFAS; BEDS
  • A47C16/00—Stand-alone rests or supports for feet, legs, arms, back or head
  • A47C16/02—Footstools; Foot-rests; Leg-rests
• • A—HUMAN NECESSITIES
  • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
  • A47C—CHAIRS; SOFAS; BEDS
  • A47C19/00—Bedsteads
  • A47C19/02—Parts or details of bedsteads not fully covered in a single one of the following subgroups, e.g. bed rails, post rails
  • A47C19/021—Bedstead frames
  • A47C19/025—Direct mattress support frames, Cross-bars
• • A—HUMAN NECESSITIES
  • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
  • A47C—CHAIRS; SOFAS; BEDS
  • A47C4/00—Foldable, collapsible or dismountable chairs
  • A47C4/02—Dismountable chairs
• • A—HUMAN NECESSITIES
  • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
  • A47C—CHAIRS; SOFAS; BEDS
  • A47C4/00—Foldable, collapsible or dismountable chairs
  • A47C4/04—Folding chairs with inflexible seats
  • A47C4/08—Folding chairs with inflexible seats having a frame made of wood or plastics
• • A—HUMAN NECESSITIES
  • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
  • A47C—CHAIRS; SOFAS; BEDS
  • A47C4/00—Foldable, collapsible or dismountable chairs
  • A47C4/04—Folding chairs with inflexible seats
  • A47C4/18—Folding chairs with inflexible seats having a frame made of metal
• • A—HUMAN NECESSITIES
  • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
  • A47C—CHAIRS; SOFAS; BEDS
  • A47C5/00—Chairs of special materials
  • A47C5/12—Chairs of special materials of plastics, with or without reinforcement
• • A—HUMAN NECESSITIES
  • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
  • A47C—CHAIRS; SOFAS; BEDS
  • A47C7/00—Parts, details, or accessories of chairs or stools
  • A47C7/02—Seat 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
  • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
  • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
  • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
  • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
  • E04C2/36—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels
  • E04C2/365—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels by honeycomb structures
• • 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
  • A47B2220/00—General furniture construction, e.g. fittings
  • A47B2220/0052—Panels
  • A47B2220/0058—Furniture panels with assembly holes
• • 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
  • A47B2220/00—General furniture construction, e.g. fittings
  • A47B2220/008—General furniture construction, e.g. fittings characterised by materials
• • 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
  • B32B2305/02—Cellular or porous
  • B32B2305/024—Honeycomb
• • 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
  • B32B2419/00—Buildings or parts thereof
• • 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

Definitions

• the present invention relates to a construction material in particular but not exclusively reinforced cellular structure; furniture comprising the cellular structure; a method of reinforcing a cellular structure; a structural support for reinforcing a honeycomb structure; and a honeycomb structure modified to receive a structural support to achieve omni-directional rigidity and/or improved load bearing capacity.
• a cellular structure such as honeycomb can be manufactured by bonding together strips of material such as paper, wood, metal, or plastic in lines at regular intervals and in a staggered pattern from strip to strip, of which the distance between the lines of bond defines the cell size. This produces an unexpanded cellular structure pad. This pad may then be cut lengthwise into smaller sections before being mechanically expanded in a direction perpendicular to the face of the strips of material.
• the cellular structure has the greatest strength and stiffness in the direction along the length of the bonded strips, and is substantially flexible in the direction perpendicular thereto.
• cellular structures There are many of uses for cellular structures but one common use is as a core substrate for a panel; these panels may be widely used in different industries as a substitute for solid or laminated boards such as wood, plywood, or fibreboard panels due to its excellent strength to weight ratio.
• the panel can be manufactured by bonding an expanded cellular structure between two sheets of material to form a rigid panel; this has many limitations in relation to manufacturing and construction.
• honeycomb panels it is common for honeycomb panels to be manufactured in standard and limited sizes, when one or more of these panels are joined to construct a larger panel. This creates weak points in the panel. To overcome this problem process of joining panels often requires additional components to be used to overlay the joints having the effect that a joint is more pronounced than desired.
• the structural members extend through the cellular structure transversely perpendicular to the face of the strips of material and optionally may be secured in position by means of component members connecting the honeycomb structures to the structural members.
• furniture as used herein includes items which are moveable such as, but not limited to, chairs, tables, benches, desks, bookcases, wine racks, cabinets, cupboards, stools, beds, and also items which are typically fixed, for example to a wall, such as shelving.
• an item of furniture comprising a reinforced cellular structure comprising one or more cellular structures and a load bearing support, the cellular structure adapted to receive the load bearing support wherein such that when installed the cellular structure is maintained in an at least partially expanded condition and support an external load when applied to it.
• the cellular structure is formed from strips of wood such as birch.
• the wood has a thickness in the range of 0.4mm to 1.5mm.
• the wood has a thickness of 0.8mm.
• the cellular structure is formed from strips of material, which strips have a non-uniform shape.
• the cellular structure is formed from strips of material and the strips have at least one non-linear edge.
• the cellular structure is non planar.
• the cellular structure is formed from paperboard.
• the load bearing support is formed from stainless steel.
• the item of furniture further comprises a coupling mechanism for coupling the load bearing support to the cellular structure.
• the load bearing support comprises one or more elements and the item of furniture further comprises one or more connection mechanisms for connecting a first one of said one or more elements to a second one of said one or more elements.
• kit of parts for forming an item of furniture comprising at least one unexpanded cellular structure at least one load bearing support element and at least one coupling mechanism for coupling the at least one cellular structure to the at least one load bearing support.
• the kit of parts further comprises at least one connection mechanism for connecting a first one of said load bearing support elements to a second one of said load bearing support elements.
• a reinforced cellular structure comprising one or more cellular structures adapted to receive at least one structural support wherein the least one structural support is installed within said one or more cellular structures whereby improving the rigidity of the cellular structure and/or the load bearing capacity.
• the structural support is removable from the cellular structure.
• the structural support is re-useable.
• the cellular structure is a honeycomb having hexagonal cells.
• the structural supports are formed from a rigid material.
• the reinforced cellular structure comprises an inter-connection mechanism for coupling two or more structural supports together.
• the reinforced cellular structure comprises a coupling mechanism for coupling one or more structural supports to one or more cellular structures.
• the reinforced cellular structure comprises a termination mechanism for terminating an end of a structural support.
• at least one structural support is extendable. More preferably, the structural support is telescopic.
• the structural support may be secured in an external or retracted position.
• the reinforced cellular structure is laminated with at least one sheet of material.
• the structural supports pass through apertures in opposing walls or cells forming the cellular structure.
• a method of manufacturing a panel comprising a reinforced cellular structure including the steps of providing an cellular structure comprising cells and having apertures in opposing walls of said cells; inserting a structural support into the cellular structure by passing the structural support through said apertures.
• the method further comprises the step of securing the cellular structure to the structural support.
• the method further comprises the step of laminating the cellular structure with sheet material.
• the method further comprises the step of securing a second reinforced cellular structure to the first cellular structure by inter -connection mechanism coupling structural supports in the first cellular structure to structural supports in the second cellular structure.
• the method further comprises placing a first part of a securing member into an endmost cell, passing a second part of a securing member through an outer wall of said endmost cell and securing said outer wall between said first and second part.
• the method further comprises the step of engaging the securing member to the structural support.
• the method further comprises the step of removing the structural support or securing member to modify the cellular structure.
• a structural support system comprising at least one structural member coupleable to a cellular structure and/or to another structural member by connection assemblies whereby securing a cellular structure in an expanded state or partially expanded state and providing structural integrity to the cellular structure.
• a honeycomb substructure system comprising a system of structural support that can be installed into a honeycomb structure that is modified to accommodate the said system in order to achieve substantial omni-directional rigidity in the said honeycomb structure in order to bear load in excess of normal circumstance; and the said system of structural support that can also be uninstalled from the said honeycomb structure to reverse therefrom.
• the modified honeycomb structure comprises one or more through apertures that bore through the said honeycomb structure transversely perpendicular to the face of the honeycomb strips.
• the said system of structural support comprises at least one structural member comprising a substantially rigid and elongated piece with cross-sectional dimension and shape that correspond to that of the said through aperture, with an axial connection means at each of its distal ends.
• Figure la shows a perspective view of an unexpanded honeycomb structure as known in the prior art
• Figure lb shows a perspective view of an expanded honeycomb structure as known in the prior art
• Figure 2a shows a perspective view of an unexpanded honeycomb structure according to a first embodiment of the present invention
• Figure 2b shows a perspective view of the expanded honeycomb structure of Fig 2a in an expanded condition
• Figure 3 shows an exploded perspective view of a substructure system in accordance with a first embodiment of the present invention
• Figure 4 shows an exploded perspective view of the embodiment of Figure 5;
• Figure 5 shows a perspective view of a honeycomb structure installed with a substructure system in accordance with a first embodiment of the present invention
• Figure 6 shows a perspective view of a honeycomb structure installed with a substructure system in accordance with a second embodiment of the present invention
• Figure 7 shows an exploded perspective view of a connection assembly between the distal end of a structural member and a honeycomb structure
• Figure 8 shows an exploded perspective view of a connection assembly between the distal ends of two structural members and two honeycomb structures
• Figure 9 shows an exploded perspective view of a connection assembly between the distal ends of two structural members
• Figure 10 shows an exploded perspective view of a connection assembly between the distal ends of two structural members and two honeycomb structures according to an alternative embodiment
• Figure 11 shows an exploded perspective view of the embodiment of Figure 12
• Figure 12 shows a perspective view of a substructure system in accordance with a third embodiment of the present invention.
• Figure 13 shows a perspective view of a honeycomb structure installed with substructure system in accordance with a third embodiment of the present invention
• Figure 14 shows a plan view of the embodiment of Figure 13
• Figure 15 shows a cross sectional view of the embodiment of Figure 13 taken along line S-S';
• Figure 16 shows an end view of the embodiment of Figure 13
• Figure 17 shows an exploded perspective view of the embodiment of Figure 18
• Figure 18 shows a perspective view of a substructure system in accordance with a fourth embodiment of the present invention.
• Figure 19 shows a perspective view of a substructure system in accordance with a fifth embodiment of the present invention.
• Figure 20 shows a perspective view of a honeycomb structure installed with a substructure system of the embodiment of Fig 19;
• Figure 21 shows a part exploded perspective view of the embodiment of Figure 22
• Figure 22 shows a perspective view of a substructure system comprising in accordance with a sixth embodiment of the present invention.
• Figure 23 shows a perspective view of a substructure system in accordance with a sixth embodiment of the present invention.
• Figure 24 shows a perspective view of a honeycomb structure installed with a substructure system in the embodiment of Figure 23;
• Figure 25 shows a part exploded perspective view of the embodiment of Figure 26
• Figure 26 shows a perspective view of a substructure system in accordance with a seventh embodiment of the present invention.
• Figure 27 shows a perspective view of a substructure system in accordance with an eighth embodiment of the present invention.
• Figure 28 shows a perspective view of a honeycomb structure installed with a substructure system of the embodiment of Fig 27;
• Figure 29 shows a perspective view of assembly of items of furniture comprising a reinforced cellular structure
• Figures 30 shows a perspective view of the items of furniture of Figure 29 in a disassembled state
• Figure 31 shows a perspective view of the item of furniture of Figure 29 in an assembled condition
• Figure 32 shows a perspective view of an item of furniture according to an alternative embodiment in an assembled condition
• Figure 33 shows a perspective view of the item of furniture of Figure 32 in use
• Figure 34 shows a perspective view of an item of furniture according to an alternative embodiment in an assembled condition
• Figure 35 shows a perspective view of a further alternative item of furniture comprising a reinforced cellular structure.
• Figure la illustrates a honeycomb structure 010 as known in the prior art in an unexpanded form
• Figure lb illustrates the honeycomb structure 010 of Fig la in an expanded state
• Figure 2a illustrates a honeycomb structure 020 according to a first embodiment of the present invention; in which the honeycomb structure
• Apertures 021 are provided in the honeycomb structure 020; the apertures are provided in the strips of material forming the honeycomb structure 020 and form a through aperture 021.
• Figure 2b illustrates the honeycomb structure 020 in an expanded state. It is envisaged that the apertures 021 will be created in the honeycomb structure in an unexpanded state, however it is also envisaged that in an alternative embodiment the apertures 021 will be provided in the strips of material prior to assembly of the unexpanded honeycomb structure 020.
• the through aperture 021 is axially aligned to a notional line passing through the centre of a column of cells.
• the through aperture 021 may be of any dimension and shape and will be adapted to accommodate the cross-sectional dimension and shape of a reinforcing member such as structural member 100 as illustrated in Fig 3.
• the through aperture 021 may be of any dimension and shape and will be adapted to accommodate the cross-sectional dimension and shape of a reinforcing member such as structural member 100 as illustrated in Fig 3.
• the honeycomb structure 021 is dimensioned such that it is sufficiently smaller than the height of the strips of material forming the honeycomb structure 020; this ensures that the honeycomb structure 020 retains sufficient structural integrity about the through aperture 021. Furthermore it is envisaged that the cross-sectional dimension of the through aperture 021 is also equal or less than the width of a cell wall of the honeycomb structure 020; this ensures that the cross-sectional shape of the through aperture 021 is not distorted when the honeycomb structure 020 is expanded.
• the number of through apertures 021 provided will correspond to the number of structural members 100 to be inserted.
• the two, three or more through apertures 021 are provided in order to achieve the desired structural stability and strength.
• the through apertures 021 will be equidistance from one another when more than two through apertures 021 are provided.
• FIG 3 illustrates an exploded view of a first embodiment of a substructure system for incorporation into a honeycomb structure 020.
• Figure 4 illustrates an exploded view of the embodiment of Figure 5 which illustrates a honeycomb structure 020 into which the substructure system of Figure 3 is installed.
• a pair of structural members 100 extending through the through apertures 021.
• the honeycomb structure 020 in an expanded state or condition; the length of the expanded honeycomb structure 020 is equal to the length of the structural members 100.
• the honeycomb structure need not be expanded to its full capacity but may only be partially expanded.
• Each structural member 100 comprises a substantially rigid and elongated element such as a tube or rod.
• the structural member 100 comprises a female connecting section 101 that is recessed axially at each end thereof.
• the recess comprises a screw thread on the internal bore of the recess for engagement with a complementary threaded bar or bolt.
• the through aperture 021 should be sized such that it is in proximal contact with the engaging structural members 100.
• the end strips 022 of the honeycomb structure 020 are connected to the distal ends of the structural members 100 by end connection assemblies 1.
• the end connection assembly 1 comprises an end connector member 200, a disk member 400 and optionally a bracing member 600.
• FIG. 7 illustrates an exploded view of an end connection assembly 1.
• An end connection assembly 1 comprises an end connector member 200 fastened to the distal end of a structural member 100.
• Disk member 400 is coupled to end connector 200; a bracing member 600 and preferably the end strip 022 of a honeycomb structure 020 are fastened therebetween.
• the end connector member 200 is formed of a substantially rigid material arranged as a rod or tube, with a cross-sectional dimension and shape corresponding to that of the structural member 100.
• the end connector member 200 comprises a male connecting section 201 substantially equal to the internal diameter of the structural member 100 at a first end thereof.
• the end connector member 200 also comprises a disk section 202 at a second end opposing said first end.
• the disk member 202 extends radially outward from the end connector member 200.
• the male connecting section 201 is complementary with the female connecting sections 101 of the structural members 100 such that they can be fastened together with a fastening means, for example, but not limited to, mechanical threading.
• the male and female sections may each comprise an aperture or through aperture arranged to be in registry with one another, through which aperture a fastening means may be placed to prevent separation of the structural member from the end connection member.
• Such fastening means may for example comprise a lynch pin, split pin, hair pin, cotter pin or R-pin.
• the structural member 100 comprises a circular cross section however in alternative embodiments the structural member may have alternative cross-sectional shape, it will be further appreciated that the end connector 200 will be adapted to have cross-sectional shape corresponding to the structural member 100.
• a disk member 400 formed of a substantially rigid material and having overall dimension and shape corresponding to that of the disk section 202 of the end connector member 200.
• the disk member 400 comprises an aperture 401 and forms an O-ring.
• the aperture 401 is adapted to receive the end connector member 200 and is optionally in mechanical engagement therewith.
• the disk member 400 is axially aligned to the through aperture 021.
• the internal surface of the end strip 022 of the honeycomb structure 020 is engaged by the disk member 400 and the external surface of the end strip 022 is engaged by the end connector member 200.
• the aperture 401 engages with the end connector member 200, for example but not limited to, magnetic attachment or mechanical attachment such as a screw thread.
• the disk member 400 is adapted to engage male connecting section 101. It is envisaged that in alternative embodiments the disk member 400 may be replaced with a circlip receivable in a circumferential groove formed in the end connector member 200.
• a bracing member 600 formed of a substantially rigid material preferably formed as a flat plate and comprises an aperture 601 dimensioned and arranged to correspond to the through aperture 021 of the honeycomb structure 020.
• the aperture 601 is axially aligned with the through aperture 021.
• the end strip 022 of the honeycomb structure 020 and the bracing member 600 are fastened in position between mating surfaces of the disk section 202 of the end connector member 200 and the disk member 400 respectively.
• Figure 6 illustrates a second embodiment of a substructure system for incorporating into a honeycomb structure 020.
• a third structural member 100 is installed equidistance between the first and second structural members 100.
• Figure 11 illustrates an exploded view of Figure 12 which illustrates a third embodiment of a substructure system for incorporation into a honeycomb structure 020.
• Figure 13 illustrates a honeycomb structure 020 into which the third embodiment of the substructure system is installed.
• Figures 14-16 illustrate a plan view, cross-sectional view through lines S-S', and end view of the embodiment of Figure 13 respectively.
• the third embodiment comprises second structural members 110 which are connected at one distal end to the structural members 100 of the previous embodiments.
• the second structural members 110 are each coupled to the end of the structural member 100 by mid connection assembly 2 at one end and terminated by the end connection assembly 1 at the other.
• the honeycomb structures 020 are engaged by the second structural members 110 via the mid connection assemblies 2 at one end, and more preferably by the end connection assemblies 1 at the other end.
• the second structural member 110 is similar to a structural member 100 as described previously; the second structural member 110 is provided with an arcuate section substantially at one end thereof and preferably said arcuate section provides a substantially 90° bend having a radius of curvature, although other angles and other shape and configuration are envisaged.
• a mid connection assembly 2 comprising a mid connector member 300, a disk member 400, and a bracing member 600, is provided for coupling the structural member 100 to the structural member 110.
• FIG. 8 illustrates an exploded view of a mid connection assembly 2.
• the mid connection assembly 2 comprises a mid connector member 300 axially fastenable between distal ends of a pair of structural members 100, or alternative structural members such as second structural member 110 or any combination thereof.
• Disk member 400 is coupled to mid connecter member 300, an optional bracing member 600 and preferably the end strips 022 of two honeycomb structures 020 are fastened therebetween.
• the mid connector member 300 is formed of a substantially rigid material and may be arranged as a rod or tube with cross- sectional dimension and shape corresponding to that of the structural member 100.
• the mid connector member 300 comprises a male connecting sections 301 at both ends and a disk section 302 therebetween; the disk section 302 extends radially outward from a notional axial line.
• the mid connector member 300 is axially aligned with the through aperture 021 and passes through the end strip 022 of honeycomb structure 020.
• the disk section 302 engages with an internal face of the end strip 022 of a first honeycomb structure 022.
• a disk member 400 is axially aligned with the through aperture 021 and engages with an internal surface of the end strip 022 of a second honeycomb structure 020.
• the male connecting sections 301 are complementary to female connecting sections 101 of the structural members 100, or alternative structural members of similar nature, such that they are fastened together by way of fastening means for example but not limited to, mechanical threading.
• the disk member 400 is engaged by the mid connector member 300 when the aperture 401 receives an end of connector member 300.
• the disk member is in magnetic attachment with the mid connecter member 300.
• the end strips 022 of each of the two honeycomb structures 020 and the bracing member 600 are fastened in position contiguously between the mating surfaces of the disk section 302 of the mid connector member 300 and the disk member 400 when assembled.
• FIG. 10 illustrates an exploded view of a mid connection assembly 2 according to an alternative embodiment.
• the mid connection assembly 2 comprises a mid connector member 700 axially fastenable between distal ends of a pair of structural members 100, or alternative structural members such as second structural member 110, or any combination thereof.
• a disk member 400 is coupled to each side of mid connector member 700; an optional bracing member 600 and preferably the end strips 022 of two honeycomb structures 020 are fastened between mid connector member 700 and a respective one of the structural members 100 to which the mid connector member 700 is coupled.
• the mid connector member 700 is formed of a substantially rigid material such as stainless steel and may be arranged as a rod or tube with cross-sectional dimension and shape corresponding to that of the structural member 100.
• the mid connector member 700 comprises a male connecting sections 701 at both ends and a disk section 702 therebetween; the disk section 702 extends radially outward from a notional axial line.
• the mid connector member 700 is axially aligned with the through aperture 021 and passes through the end strip 022 of honeycomb structure 020.
• the disk section 702 engages with a face of the end strip 022 of a first honeycomb structure 022.
• Each disk member 400 is axially aligned with the through apertures 021 and engages with an internal surface of the end strip 022 of a second honeycomb structure 020.
• the male connecting sections 701 are complementary to the female connecting sections 101 of the structural members 100, or alternative structural members of similar nature, such that they can be fastened together by a fastening means, for example but not limited to, mechanical threading but could also be a push fit.
• the disk member 400 is engaged by the mid connector member 700 when the aperture 401 receives an end of connector member 700.
• the disk member 400 is in magnetic attachment with the mid connector member 700.
• the end strips 022 of each of the two honeycomb structures 020 and the bracing member 600 are fastened in position contiguously between the mating surfaces of the disk section 702 of the mid connector member 700 and the disk member 400 when assembled.
• Figure 17 illustrates an exploded view of the embodiment of Figure 18 which illustrates a fourth embodiment of a substructure system for incorporation into a honeycomb structure 020.
• Figure 19 illustrates a fifth embodiment of a substructure system.
• Figure 20 illustrates a honeycomb structure 020 into which the fifth embodiment of the substructure system is installed.
• the fourth embodiment differs from the third embodiment in that the structural members 100 and second structural members 110 have been replaced with first modular structural members 120 and second modular structural member 122.
• the modular structural members 120 and/or second modular structural members 122 are coupled to one another by means of inter- connection assemblies 3.
• the two honeycomb structures 020 are each coupled to the modular structural members 120; at one end by the mid connection assembly 2 and at the other end by the end connection assemblies 1.
• the modular structural member 120 is similar to the structural members 100 and the modular structural member 122 is similar to the structural members 110 as described previously; this allows for reconfiguration of a substructure system by means of rearranging the components parts.
• the fifth embodiment shows an example of this reconfiguration
• FIG. 9 illustrates an exploded view of an inter-connection assembly 3.
• the inter-connection assembly 3 is illustrated coupled between the distal ends of two structural members 100, but it is envisaged that it could be coupled between second structural members 110, or modular structural members 120, or members of similar nature or any combination thereof.
• the inter-connection assembly comprises an inter-connector member 500 which is formed of a substantially rigid material and may be arranged as a rod, or tube with cross-sectional dimension and shape corresponding to that of the structural member 100 to which it is to be coupled.
• the interconnector member 500 comprises male connecting sections 501 at both ends and extending axially therefrom.
• the male connecting sections 501 are complementary to female connecting sections 101 of the respective structural members 100.
• the inter -connector member 500 is axially aligned between the modular structural members 120 and may be engaged thereto by fastening means for example, but not limited to, mechanical threading.
• Figure 21 illustrates a partially exploded view of the embodiment of Figure 22 which illustrates a sixth embodiment of a substructure system for incorporation into a honeycomb structure 020.
• Figure 23 illustrates a sixth embodiment of a substructure system with telescopic sections in an extended state.
• Figure 24 illustrates a honeycomb structure 020 installed with the sixth embodiment of the substructure system is installed.
• the sixth embodiment differs from the third embodiment whereby each of the aforementioned second structural members 110 is replaced with a telescopic structural member 130.
• the honeycomb structures 020 are coupled to the telescopic structural member 130 the mid connection assembly 2 at one end and by the end connection assemblies 1 at the other end.
• the honeycomb structure 020 may be further expanded subsequent to engagement with the respective connection assembly 1, 2, such that its length may be increased by extension of the extended telescopic structural members 130.
• the telescopic structural members 130 may be extended prior to their engagement and/or insertion into the honeycomb structure 020.
• the telescopic structural member 130 is similar in construction to the structural member 100 as described previously; it may be of any axial length and shape providing a telescopic property allowing for a change of length by means of extension and retraction 132 of one or more telescopic sections.
• the telescopic section may then be secured in the desired extended or retracted state for example, but not limited to, a twist-lock mechanism integrated into the telescopic structural member 130, alternatively a mechanical threading may be used.
• the sixth embodiment shows an example of use of the telescopic structural members 130 in which the telescopic structural members 130 are extended.
• Figure 25 illustrates a partially exploded view of the embodiment of Figure 26 which illustrates a seventh embodiment of a substructure system for incorporation into a honeycomb structure 020.
• Figure 27 illustrates an eighth embodiment of a substructure system.
• Figure 28 illustrates a honeycomb structure 020 into which the eighth embodiment of a substructure system is installed.
• the seventh embodiment comprises shaped structural members 140.
• the honeycomb structure 020 is coupled to the shaped structural members 140 at both ends by the mid connection assemblies 2.
• the length of the honeycomb structure 020 when expanded matches the length of the preformed shaped structural members 140.
• the shaped structural member 140 is similar to the structural members 100 as described previously; it may be of any length and be formable into any desired shape, which shape may be fixed to form a rigid structural support, preferably permanently.
• the shaped structural member 140 may be preformed into the desired shape by means of bending with tools or machines. The desired shape shall be retained, it is envisaged that the shaped structural member 140 is formed from materials providing strength and stiffness to bear load.
• the eighth embodiment shows the shaped structural members 140 formed into an alternative shape.
• FIG 29 shows a lounge chair 6 and a footstool 7.
• the lounge chair 6 comprises a pair of support member 160, the support members are coupled to one another at both ends by bracing member 600, which is fixedly attached to the support members 160 by end connector 200.
• the cellular structure 020 is threaded onto each of the support members 160 prior to coupling the ends together.
• the cellular structure is expanded by pulling opposing ends of the cellular structure 020 in opposite directions as indicated by direction arrows D3, D4.
• the cellular structure 020 is coupled to support members 160 by the disk member 400 and the end connector 200.
• the footstool 7 is assembled in a similar manner to that described above in respect of the lounge chair 160.
• the footstool 7 comprises support members 170 each of which is shaped so that opposing ends thereof are facing one another, such that the support members 170 when coupled by mid connector assembly 2 or 4, in the illustrated embodiment mid connector assembly 4 is used, the support member each form a loop.
• the cellular structure 020 is threaded prior to connecting the ends of the support members together and is again stretched across the support members 170 by pulling opposing ends in opposite directions; the ends of the cellular structure are held in position by the mid connector assembly 4.
• FIG 30 there is shown a lounge chair 6 and footstool 7 in a disassembled state ready for transportation; it will be appreciated that this provides a compact package for shipping.
• Figure 31 illustrates a perspective view of the lounge chair 6 and footstool 7 in an assembled condition in which the cellular structure 020 has been expanded about the structural supports.
• Figure 32 illustrates an alternative chair, a dining chair 162 the construction this chair 162 is substantially the same as that described above.
• Figure 33 illustrates the dining chair 162 in use.
• Figures 34 and 35 illustrate alternative items of furniture.
• a table 190 is shown in Figure 34 comprising a series of shelves has been formed by shaping support members to bend back upon themselves creating a series of 'S' or 'Z' shapes similar to a concertina.
• the shelves are inclined to be horizontal, however in alternative embodiments they may be vertical.
• a media bench is shown in Figure 35, similar to the footstool, the support members have been shaped so that opposing ends thereof face one another and are coupled to one another by mid connector assembly 2 or 4.
• the honeycomb structure 020 need not comprise plurality of contiguously arranged hexagonal cells but may have a different cell shape or different cell arrangement or both.
• end connector member 200, mid connector member 300, and disk member 400 may be omitted or alternatively substituted with the inter -connector member 500 if it is not desirable to couple the honeycomb structure 020 to the structural members 100, second structural members 110, modular structural members 120, telescopic structural members 130, shaped structural members 140, or members of the same type.
• the bracing member 600 may be regarded as an optional component, in circumstances and may be omitted if its absence does not compromise structural stability.
• the disk member 400 may be provided with a screw thread on the internal face of the aperture 401 which is adapted to be complementary to the screw head on the mid connection member 300 or end connection member 200, such that a cell wall of the honeycomb structure 020 may be secured between the disk member 400 and the radial protrusion 202 of the either connection member 200 or the radial protrusion 302 of the mid connection member 300. It will be further appreciated that this could also secure brace member 600.
• the disk member 400 may also be provided with a key mechanism to allow a user to engage the disk member with the mid-connection member 300 or end connection member 200 by rotating the disk member 400 about its central axis.
• the key mechanism may take the form of at least one pair flat surfaces on the external circumferential face of the disk member 400 such as may be engaged by a spanner or wrench.
• the structure support 100 will abut the disk member 400 rather than pass through the aperture 401.
• the honeycomb substructure system has a vast array of applications in a vast array of environments, in particular, but not limited to, the manufacturing and construction industries. It exploits the unidirectional strength of the structural honeycomb by providing structural support perpendicular thereto without the necessity of lamination.
• the system can be used as part of a framework tool for preforming honeycomb structures which may then be laminated over with sheet materials to produce honeycomb panels.
• the system may be used as permanent substructure for honeycomb structures which may then be laminated with sheet materials thereafter to improve strength and stiffness.
• the cellular structures may be formed of paperboard, however in some applications greater load bearing strength may be needed, the cellular structure may be formed from wood such as but not limited to birch.
• the wood will have thickness on the range 0.4mm to 1.5mm more preferably the thickness will be 0.8mm.
• the cellular structure may be formed from strips of material such as but not limited to wood, plastic or metal, which material is flexible and strong.
• Each of the strips of material may comprise a shaped edge, the shape and or dimension of adjacent strips being non uniform such that when expanded the cellular structure has a non planar shape, this may have ergonomic benefit to a user.
• Such shaping could be carried out using a laser cutting tool.
• the substructure system has numerous advantages over the conventional honeycomb structures. For example the production of a rigid honeycomb structure is no longer confined to the production environment of a factory as the lamination process may now be carried out in situ when a substructure system is installed into a honeycomb structure.
• the present invention provides an inexpensive, simple, and efficient method for preforming and fabricating curved honeycomb structures.
• the present invention also improves the precision and accuracy for producing honeycomb structures having non-linear geometry, since the shape of the honeycomb structure is wholly dependent on the shape of the substructure system which substructure system may be fine tuned to the desired shape before installation and/or before any lamination process. Furthermore, alteration to the shape of the honeycomb structure in situ is now possible as the substructure system may be readily uninstalled.

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Life Sciences & Earth Sciences (AREA)
• Wood Science & Technology (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Laminated Bodies (AREA)
• Rod-Shaped Construction Members (AREA)

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• 2009
  • 2009-11-10 GB GB0919651A patent/GB2475248A/en not_active Withdrawn
• 2010
  • 2010-11-09 GB GB1210136.6A patent/GB2489618B/en not_active Expired - Fee Related
  • 2010-11-09 WO PCT/GB2010/051864 patent/WO2011058348A1/en active Application Filing
  • 2010-11-09 CN CN201080061087.3A patent/CN102781282B/zh not_active Expired - Fee Related
• 2013
  • 2013-05-13 HK HK13105677.4A patent/HK1177879A1/zh not_active IP Right Cessation

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