WO2019034925A1

WO2019034925A1 - A composite furniture section

Info

Publication number: WO2019034925A1
Application number: PCT/IB2017/056435
Authority: WO
Inventors: Vinod Khetabhai PATEL; Damodar Khetabhai PATEL
Original assignee: Patel Vinod Khetabhai; Patel Damodar Khetabhai
Priority date: 2017-08-14
Filing date: 2017-10-17
Publication date: 2019-02-21

Abstract

The present disclosure envisages a composite furniture section whose moisture absorption and warping tendency is minimum. The composite furniture section comprises a substrate layer having a first operative surface and a second operative surface. A core layer is disposed on the first operative surface of the substrate layer. A rebate layer is disposed on the core layer. A top layer is disposed on the rebate layer such that the top layer partially covers the rebate layer to define a rebate surface on the rebate layer.

Description

A COMPOSITE FURNITURE SECTION

FIELD

The present disclosure relates to the field of frame structures. BACKGROUND Conventional frames, typically frames of doors and windows, are made by joining multiple vertical and horizontal components together. The conventional frames are fitted within a cavity formed in a structure, typically a wall, by means of fasteners such as screws. These frames are typically made of wood, or medium density fiber (MDF), or polyvinyl chloride (PVC) or any other similar material. However, all such frames have drawbacks, e.g., wood or medium density fiber frames absorb moisture and water, and have a swelling tendency. Further, any decorative surface provided on such frames delaminates due to absorption of water and moisture. The polyvinyl chloride (PVC) frames lack aesthetics, and strength to bear the load of a wooden door. Furthermore, these materials tend to warp along the length of the frame sections. Therefore, there is felt a need for a frame that alleviates the aforementioned drawbacks of the conventional frames.

OBJECTS

Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows: An object of the present disclosure is to provide a composite frame section that that is water resistant and whose moisture absorption tendency is minimum.

Another object of the present disclosure is to provide a composite frame section that has minimum warping tendency.

Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure. SUMMARY

The present disclosure envisages a composite furniture section in which both moisture absorption and warping tendency is minimum. The composite furniture section comprises a substrate layer having a first operative surface and a second operative surface. A core layer is disposed on the first operative surface of the substrate layer. A rebate layer is disposed on the core layer. A top layer is disposed on the rebate layer such that the top layer partially covers the rebate layer to define a rebate surface on the rebate layer.

In an embodiment, the substrate layer is at least one selected from a group consisting of plywood, particle board, wood, engineered wood, medium density fiber board, high density fiber board, block-board, imitation wood, and wood polymer composite (WPC).

In another embodiment, the core layer is at least one selected from a group consisting of plywood, particle board, wood, engineered wood, medium density fiber board, high density fiber board, block-board, imitation wood, and wood polymer composite (WPC).

In another embodiment, the rebate layer is at least one selected from a group consisting of plywood, particle board, wood, engineered wood, medium density fiber board, high density fiber board, block-board, imitation wood, and wood polymer composite (WPC).

In another embodiment, the top layer is at least one selected from a group consisting of plywood, particle board, wood, engineered wood, medium density fiber board, high density fiber board, block-board, imitation wood, and wood polymer composite (WPC). In another embodiment, at least one edge of the composite furniture section is edge bound.

In another embodiment, a ornamental layer is provided on the top layer, the rebate layer, and at least one edge of composite furniture section. In another embodiment, the thickness of the substrate layer ranges from 5% to 50% of the thickness of the composite furniture section.

In another embodiment, the thickness of the core layer ranges from 15% to 80% of the thickness of the composite furniture section.

In another embodiment, the thickness of the rebate layer ranges from 5% to 50% of the thickness of the composite furniture section. In another embodiment, the thickness of the top layer ranges from 10% to 45% of the thickness of the composite furniture section.

In another embodiment, the thickness of the ornamental layer ranges, which includes digital printing, from 0.1 % to 20% of the thickness of the composite furniture section. BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING

A frame of the present disclosure will now be described with the help of the accompanying drawing, in which:

Figure 1A and Figure IB illustrate different views of a composite furniture section, in accordance with an embodiment of the present disclosure. LIST OF REFERENCE NUMERAL

100 - Composite furniture section 110 - Substrate layer 120 - Core layer 130 - Rebate layer 130A - Rebate surface 140 - Top layer DETAILED DESCRIPTION

The present disclosure envisages a composite furniture section that can be used in making of furniture. The composite furniture section, as envisaged in the present disclosure, in which moisture absorption is minimum, which results in a longer adhesion of the decorative surface on the furniture section. Further, the composite furniture section, of the present disclosure, has minimum warping tendency.

A composite furniture section 100, of the present disclosure, is now described with reference to figure 1A and figure IB. The composite furniture section 100 (hereinafter referred to as section 100) comprises a substrate layer (110) having a first operative surface and a second operative surface. A core layer (120) is disposed on the first operative surface of the substrate layer (110). A rebate layer (130) is disposed on the core layer (120). A top layer (140) is disposed on the rebate layer such that the top layer (140) partially covers the rebate layer (130) to define a rebate surface (130A) on the rebate layer (130). The rebate surface (130A) is the surface of the section (100) that abuts with the door supported on a door frame.

In an embodiment, the core substrate layer (110), the core layer (120), the rebate layer (130), and the top layer (140) are adhered to each other via a bonding agent. In an embodiment, after applying the bonding agent, the core substrate layer (110), the core layer (120), the rebate layer (130), and the top layer (140) are pressed upto a pressure of 50kg/cm for a period of upto 24 hours. Subsequent to the pressing operation, the edges of the section 100 are edge bound. In an embodiment, the decorative edge bands can be of any decorative material. Furthermore, in another embodiment, an ornamental layer is provided on the top layer (140), the rebate layer (130), and at least one edge of composite furniture section (100), wherein the ornamental layer of any decorative material. The ornamental layer can also include a dec- paint or digital printing as well. The ornamental layers are applied at all the locations of the section (100) which will be externally visible. Further, the bonding agent is used for edge banding of the composite furniture section (100). The bonding agent does not weaken the edge banding when heated or melted. Further, the bonding agent is moisture resistant and also difficult to detach once bonded.

In an embodiment, the substrate layer (110) is at least one selected from a group consisting of plywood, medium density fiberboard, high density fiberboard, particle board, composite wood, solid wood, block-board, imitation wood, and Wood Polymer composite (WPC). In another embodiment, the thickness of the substrate layer ranges from 5% to 50% of the thickness of the composite furniture section. The substrate layer (110) has even thickness.

In another embodiment, the core layer (120) is at least one selected from a group consisting of plywood, particle board, engineered wood, medium density fiberboard, high density fiberboard, composite wood, block-board, imitation wood, and Wood Polymer composite (WPC). In another embodiment, the thickness of the core layer ranges from 15% to 80% of the thickness of the composite furniture section. To configure the core layer (120), multiple blocks of the wood or block-board or plywood or engineered wood or medium-density fiberboard or high-density fiberboard or particle board or imitation wood or Wood Polymer composite (WPC) are disposed adjacent to each other in an abutting relationship. In an embodiment, two blocks of the soft wood or hard wood or block-board or plywood or engineered wood or medium-density fiberboard or high-density fiberboard or particle board or imitation wood or Wood Polymer composite (WPC) glued in a parallel configuration. In another embodiment, one block of the soft wood or hard wood or block-board or plywood or engineered wood or medium-density fiberboard or high-density fiberboard or particle board or imitation wood or Wood Polymer composite (WPC) is glued orthogonally to other blocks to form the core layer (120). Further, the core layer (120) can have a single block of wood. The core layer (120) can be formed by bonding multiple plies of soft wood or hard wood or block-board or plywood or engineered wood or medium-density fiberboard or high-density fiberboard or particle board together. The blocks used to form the core layer (120) can have all grains aligned vertically. In an embodiment, the core layer (120) is a monolithic structure formed by a single ply of the spruce wood or soft wood or hard wood or block-board or plywood or engineered wood or medium-density fiberboard or high-density fiberboard or particle board. In another embodiment, the core layer (120) is formed by joining multiple plies. In another embodiment, the core layer (120) comprises a metallic block. In another embodiment, the rebate layer (130) is at least one selected from a group consisting of plywood, particle board, wood, engineered wood, medium density fiber board, high density fiber board, block-board, imitation wood, and wood polymer composite (WPC). The rebate layer (130) has even thickness. Further, the rebate layer (130) can be made of resin bonded sheets. The rebate layer (130) can be made of single ply or multiple plies bonded together. In another embodiment, the rebate layer (130) can also be, spruce wood or solid wood or engineered wood or soft wood or hard wood or block-board or medium density fiberboard or high-density fiberboard or particle board. In another embodiment, the thickness of the rebate layer ranges from 5% to 50% of the thickness of the composite furniture section.

In another embodiment, the top layer (140) is at least one selected from a group consisting of plywood, particle board, wood, engineered wood, medium density fiber board, high density fiber board, block-board, imitation wood, and wood polymer composite (WPC). The top layer (140) has even thickness. The top layer (140) can be of marine ply or plywood. Further, the top layer (140) can be made of resin bonded sheets. The top layer (140) can be made of single ply or multiple plies bonded together. In another embodiment, the top layer (140) can also be, spruce wood, solid wood, and engineered wood or hard wood or block-board or plywood or medium-density fiberboard or high-density fiberboard or particle board. In another embodiment, the thickness of the top layer ranges from 10% to 45% of the thickness of the composite furniture section.

In another embodiment, the thickness of the ornamental layer ranges from 0.1 % to 20% of the thickness of the composite furniture section.

The section (100) of the present disclosure can be used in manufacturing of door frames, window frames, wardrobes, and other furniture products. The section (100) of the present disclosure has improved rigidity which reduces the warping tendency.

TECHNICAL ADVANCEMENTS

The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a composite frame section that: · is water resistant and its moisture absorption tendency is minimum;

• has minimum warping tendency.

The foregoing disclosure has been described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration. The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

The foregoing description of the specific embodiments so fully revealed the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

The use of the expression "at least" or "at least one" suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.

Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.

The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary. While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

Claims

CLAIMS:

1. A composite furniture section comprising:

a substrate layer having a first operative surface and a second operative surface; a core layer disposed on said first operative surface of said substrate layer;

a rebate layer disposed on said core layer; and

a top layer disposed on said rebate layer, said top layer partially covering said rebate layer to define a rebate surface on said rebate layer.

2. The composite furniture section as claimed in claim 1, wherein substrate layer is at least one selected from a group consisting of wood, block-board, plywood, engineered wood, medium-density fiberboard, high-density fiberboard, and particle board.

3. The composite furniture section as claimed in claim 1, wherein said core layer is at least one selected from a group consisting of wood, block-board, plywood, engineered wood, medium-density fiberboard, high-density fiberboard, and particle board.

4. The composite furniture section as claimed in claim 1 , wherein said rebate layer is at least one selected from a group consisting of wood, block-board, plywood, engineered wood, medium-density fiberboard, high-density fiberboard, and particle board.

5. The composite furniture section as claimed in claim 1, wherein said top layer is at least one selected from a group consisting of wood, block-board, plywood, engineered wood, medium-density fiberboard, high-density fiberboard, and particle board.

6. The composite furniture section as claimed in claim 1, wherein at least one edge of said composite furniture section is edge bound.

7. The composite furniture section as claimed in claim 1, wherein an ornamental layer is provided on said top layer, said rebate layer, and at least one edge of composite furniture section.

8. The composite furniture section as claimed in claim 1, wherein the thickness of said substrate layer ranges from 5% to 50% of the thickness of said composite furniture section.

9. The composite furniture section as claimed in claim 1, wherein the thickness of said core layer ranges from 15% to 80% of the thickness of said composite furniture section.

10. The composite furniture section as claimed in claim 1, wherein the thickness of said rebate layer ranges from 5% to 50% of the thickness of said composite furniture section.

11. The composite furniture section as claimed in claim 1, wherein the thickness of said top layer ranges from 10% to 45% of the thickness of said composite furniture section.

12. The composite furniture section as claimed in claim 7, wherein the thickness of said ornamental layer ranges from 0.1% to 20% of the thickness of said composite furniture section.