Extendible functional panel made of plastic

Abstract

The invention relates to a method for producing a table top, comprising the following steps: providing an injection moulding tool (1) having a hollow space with a shape corresponding to the functional panel (2) to be produced, wherein the injection moulding tool (1) has at least two space separators (7', 7") for producing at least two recesses (7) in the functional panel (2), which are next to one another in the extension direction (RI) and are spaced apart by empty spaces (6') in the hollow space to produce strips (6) of the functional panel (2), and at least two space separators (7', 7") are positioned next to one another and perpendicular to the extension direction (RI), and wherein at least two consecutive space separators (7', 7") in the extension direction (RI) are each offset perpendicular to the extension direction (RI), wherein the space separators (7', 7") have a size of at least 2 mm in the extension direction (RI); and introducing a plastic into the hollow space to produce the functional panel (2). The invention also relates to a functional panel (2) produced according to this method.

Description

[0001] Extendable functional plate made of plastic

[0002] The invention relates to a method for producing an extendable functional panel, in particular an extendable furniture panel or extendable table panel. In a further aspect, the invention relates to a functional panel that is manufactured in one piece and has elongated recesses extending perpendicular to the extension direction and penetrating the functional panel. Between these recesses, webs are formed to create a length-variable section of the functional panel. At least two recesses are located adjacent to one another in the extension direction and are spaced apart by webs, and at least two recesses are located adjacent to one another perpendicular to the extension direction and are spaced apart by connecting sections.

[0003] Extendable wooden furniture panels are known from the prior art, for example, from AT 503 246. According to this document, several thin strips are glued together at nodes to produce an extendable furniture panel. To increase the stability of this furniture panel, a stabilizing device is provided that limits the mutual spacing between the individual strips.

[0004] A further development of extendable wooden furniture panels disclosed in EP 2 764 797 B1 provides for the extendable furniture panel to be manufactured from a single base panel by using a cutting process to cut cuts into the base panel with the smallest possible gap width. In particular, the gap width should not exceed 1 mm. This cutting process can simulate a table panel in the closed state that visually resembles a conventional table panel. Furthermore, the narrow gap widths allow particularly thick webs to be produced, so that this table panel can subsequently be extended to particularly great extents. According to the cited document, this makes it possible for the connection at the connecting sections of the webs to remain intact even by a factor of up to approximately 3 when the extension of the furniture part changes.

[0005] However, the latter type of furniture panel, which uses a cutting process to create the narrowest possible gap, also has disadvantages. In particular, it has been found in practice that cutting processes such as laser cutting or waterjet cutting result in a visually unappealing back of the furniture panel, necessitating complex post-processing. Furthermore, it has been shown that such furniture panels are very difficult to clean. Particles such as food scraps, stones, or dust particles often become trapped in the narrow recesses between the webs. These particles cannot simply be wiped out of the gaps with a cloth because the narrow gaps trap the particles too tightly in the tapered connecting areas.Therefore, if this furniture board is used as a dining table top or placed outdoors, it will always give an unclean impression and will in fact be unhygienic.

[0006] It is therefore the object of the invention to provide a functional plate and a method for producing such a functional plate which does not have the aforementioned disadvantages.

[0007] This object is achieved in a first aspect of the invention by a method for producing a functional panel that can be extended in an extension direction, preferably an extendable functional panel or extendable table panel, comprising the steps:

[0008] - Providing an injection mold with a cavity whose shape corresponds to the furniture panel to be produced, wherein the injection mold has at least two space dividers for producing at least two recesses of the functional panel, which are adjacent to one another in the pull-out direction and are spaced apart by empty spaces for producing webs of the functional panel, and at least two space dividers are adjacent to one another normal to the pull-out direction and are spaced apart from one another for producing connecting sections of the functional panel, and wherein at least two space dividers following one another in the pull-out direction are each offset normal to the pull-out direction, wherein the space dividers have a size of at least 2 mm in the pull-out direction, and

[0009] - Inserting a plastic into the cavity to produce the functional plate.

[0010] Surprisingly, it has been discovered that tabletops such as those disclosed in EP 2 764 797 B1 do not necessarily have to be made of wood, as long as the basic shape of the functional panel is modified. The production of an extendable functional panel made of plastic was originally not possible because a cutting process such as that disclosed in EP 2 764 797 B1 is not directly transferable to plastic panels. A cutting process with a gap width of less than 1 mm is only possible for plastic panels if the furniture panel undergoes intensive post-processing, which should be avoided for cost reasons.

[0011] The inventive concept is thus based on the realization that an extendable functional plate does not necessarily have to be manufactured in two phases (preparing the plate and subsequently cutting the plate), but can be cast in a single step. In this case, the basic shape of the functional plate to be produced is also modified to accommodate the space dividers of the injection mold, which, according to the invention, have a width of at least 2 mm.

[0012] The recesses produced in the functional panel with a size of at least 2 mm in the pull-out direction enable easier cleaning of the functional panel according to the invention. The aforementioned minimum size of the longitudinal extension of the recesses prevents, in particular, particles from accumulating in the recesses, whereby the functional panel can be cleaned by simply wiping indoors or spraying with a garden hose outdoors, making the functional panel particularly suitable as an outdoor tabletop. In addition, the larger recesses result in a lower weight of the functional panel and the functional panel can also be compressed due to the size of the recesses, making the functional panel easier to transport than is known from the prior art, which in turn is particularly advantageous for outdoor use.It is understood that the size of the recess described herein is measured in the non-extended state of the functional plate, i.e., in the relaxed state of the functional plate or during production, and this size may increase as the functional plate is extended. In other words, the recesses have a size of at least 2 mm in the extension direction in the non-extended state of the functional plate.

[0013] It should be emphasized, however, that no further special requirements are placed on the recesses and webs of the functional plate produced by the injection molding process. In particular, the length of the recesses and webs normal to the pull-out direction and the number of recesses and webs both in the pull-out direction and normal to the pull-out direction can be chosen arbitrarily. Furthermore, the recesses and webs are not tied to any specific shape, so that, for example, the size of the recesses and webs in the pull-out direction could vary within a single recess or web, as long as the size of the recesses in the pull-out direction is at least 2 mm. Furthermore, not all recesses and webs have to be designed the same; rather, the lengths, sizes, and shapes of the recesses and webs could vary within a functional plate.The shape and proportions of the recesses and ribs can be determined, for example, by a desired design or the material of the functional plate. The only requirement is that the recesses and ribs allow the functional plate to be extendable, with the functional plate being extendable by a factor of 1.5 to 2.5, for example, based on the relaxed state of the functional plate or based on the state of the functional plate during manufacture.

[0014] The plastic polyoxymethylene is particularly suitable for the production of the functional panel, meaning the functional panel is made of this plastic or contains it, e.g., the plastic contains more than 90 wt% polyoxymethylene. Due to its advantageous material properties, this plastic is particularly suitable for use as a tabletop.

[0015] Alternatively, the plastic introduced into the injection mold can also be polyamide or thermoplastic polyurethane, especially if they are glass fiber reinforced. Alternatively, the plastics polyvinylidene fluoride or polyethylene terephthalate glycol are also suitable for the functional plate. In all of the above cases, it is preferred if the material introduced into the injection mold to produce the functional plate comprises more than 90% by weight of the aforementioned plastics or more than 90% by weight of a mixture of these plastics.

[0016] Furthermore, the plastic introduced into the injection molding tool can preferably be fiber-reinforced in order to increase the stability of the functional plate.

[0017] As explained at the beginning, the room dividers and thus also the recesses in the functional plate have a minimum extension of 2 mm in the extension direction. It is generally preferred if the webs and the recesses are approximately the same size in the extension direction. This is achieved if the room dividers have a first extension in the extension direction and the empty spaces have a second extension in the extension direction, whereby the first and second extensions differ by a maximum of 10%, based on the first extension. This results in particularly advantageous design variants, as there is a balanced ratio between the webs and the recesses in the functional plate. On the one hand, the webs are still thick enough to ensure sufficient stability for extending the functional plate, and on the other hand, sufficiently large recesses are achieved, which establish the inventive effects described above.

[0018] The size of the recesses, at least 2 mm, already results in easier cleaning, as it is less likely that particles will become trapped along the recesses. This effect can be further enhanced if the dividers, and thus the recesses, are rounded at their ends perpendicular to the extension direction, for example, with a rounded diameter that corresponds to the width of the recess in the extension direction. This enables even easier cleaning of the functional panel, as particles cannot become trapped in the end areas of the recess.

[0019] In a second aspect of the invention, an extendable functional panel is provided, preferably an extendable furniture panel or extendable table panel, which is manufactured in one piece and has elongated recesses extending normal to a pull-out direction and passing through the functional panel, between which webs are formed to produce a length-variable section of the functional panel, wherein at least two recesses lie next to one another in the pull-out direction and are spaced apart by the webs, and at least two recesses lie next to one another normal to the pull-out direction and are spaced apart by connecting sections, and wherein at least two recesses following one another in the pull-out direction are each offset normal to the pull-out direction, wherein the functional panel is made of plastic and the recesses in the pull-out direction have a size of at least 2 mm.

[0020] The same design variants can be used for this functional plate as were mentioned for the manufacturing process.

[0021] Advantageous and non-limiting embodiments of the invention are explained in more detail below with reference to the drawings.

[0022] Figure 1 shows the extendable functional plate according to the invention in an intermediate state during production in a plan view.

[0023] Figure 2 shows a process for producing the functional plate according to the invention.

[0024] Figure 3 shows detail A of Figure 1.

[0025] Figure 4 shows an illustration of a prototype of the extendable functional plate according to the invention in a first state.

[0026] Figure 5 shows an illustration of the extendable functional plate of Figure 4 in a second state.

[0027] Figure 6 shows another embodiment of the functional panel according to the invention. Figure 7 shows an embodiment of the extendable functional panel with rigid panel parts.

[0028] Figure 1 shows an injection molding tool 1 used according to the invention to produce an extendable functional plate 2 made of plastic. For this purpose, the injection molding tool 1 has a cavity whose shape corresponds to the functional plate 2 to be produced.

[0029] The extendable functional plate 2 is designed as a table top, but could also - if necessary by adapting the dimensions and / or materials - be used for other purposes, in particular for pieces of furniture, in which case the functional plate 2 is generally referred to as a furniture plate.

[0030] The injection mold 1 has, for example, a housing in which the aforementioned cavity is incorporated. The housing of the injection mold 1 can, for example, have an outer length LI and an outer width B1, which are each greater than a length L2 and a width B2 of the functional plate 2 to be produced. The length L2 of the functional plate 2 refers herein to its length in the unstressed state. This allows the functional plate 2 to be produced inside the injection mold 1, i.e. the functional plate 2 does not lie directly against one of the long sides or wide sides of the housing. The cavity is, for example, completely enclosed by the housing. In the top view shown in Figure 1, the housing forms a continuous, circumferential frame 5. It is not apparent that the housing is also covered at the top and bottom with regard to the selected view, for example with a flat upper plate and a flat lower plate.

[0031] Also not shown are one or more inlet openings through which plastic can be introduced into the cavity of the injection mold 1. The position of the inlet openings can be selected accordingly by a specialist.

[0032] The plastic introduced into the cavity to produce the functional plate 2 is or comprises, for example, polyoxymethylene, polyamide, thermoplastic polyurethane, polyvinylidene fluoride, or polyethylene terephthalate glycol. The plastic introduced into the cavity may comprise fibers, e.g., glass fibers, so that the functional plate 2 can be made of fiber-reinforced plastic. Preferably, the functional plate 2 consists exclusively of one of the aforementioned plastics or a mixture thereof, which may optionally be mixed with fibers.

[0033] In order for the functional plate 2 to be produced to be extendable, it should have a plurality of elongated, parallel webs 6. The webs 6 are formed by empty spaces 6' in the cavity. If plastic is introduced into the cavity or the empty spaces 6', this will form the webs 6 after solidification. In the finished state of the functional plate 2, the webs 6 are integrally connected, but are spaced from recesses 7 in the extension direction RI such that the functional plate 2 can be extended in the extension direction RI. The extension direction RI lies parallel to the long sides 9 of the functional plate 2. In order to produce the recesses 7 in the functional plate 2, the injection mold 1 comprises space dividers 7', 7", which protrude into the cavity. Some of the space dividers 7' can protrude directly from the frame 5 of the housing of the injection mold 1 shown in Figure 1.These space dividers 7' will form elongated recesses 7 in the manufactured functional plate 2, which recesses are located directly on the long sides 9 of the functional plate 2. Other space dividers 7" are detached from the frame of the housing of the injection mold 1 shown in Figure 1 and are therefore located inside the injection mold 1. These space dividers 7" can be held, for example, by the top plate and bottom plate of the housing of the injection mold 1 (not shown in Figure 1). The recesses formed by the space dividers 7" will be located inside the functional plate 2, ie they will not be adjacent to the long sides 9.

[0034] In order to achieve the extendability, the recesses 7 are designed to be elongated, i.e. they have a greater length in a normal direction R2 normal to the extension direction RI than in the extension direction RI, and a plurality of recesses 7, i.e. at least two recesses 7, are provided in the normal direction R2, which are separated from one another in the normal direction R2 by connecting sections 8, which are also part of the cavity. Furthermore, a plurality of recesses 7 are provided which are spaced apart from one another in the extension direction RI, so that the aforementioned webs 6 are subsequently produced. The connecting sections 8 thus connect webs 6 lying next to one another in the extension direction RI or normal direction R2, whereby the functional plate 2 continues to remain in one piece.

[0035] The recesses 7 are not aligned in the pull-out direction RI, but are arranged, for example, opposite each other, as can be seen from Figure 1, whereby the connecting sections 8 are also offset from one another in the pull-out direction RI. In other words, at least two recesses 7 following one another in the pull-out direction RI are each offset perpendicularly to the pull-out direction RI. This ensures that the functional plate 2 is not manufactured continuously at any imaginary cut in the pull-out direction RI, which enables the length of the functional plate 2 to be varied. Such an arrangement of recesses 7 is known per se from the prior art, although the recesses 7 shown here differ from the known designs in that they have an extension of at least 2 mm, preferably at least 3 mm or at least 4 mm, in the pull-out direction RI.

[0036] The extendability of the functional plate 2 also requires, in particular, that some of the recesses 7 penetrate the longitudinal sides 9 of the functional plate 2 to be manufactured, so that the longitudinal sides 9 of the functional plate 2 are not manufactured continuously. As a result, several webs 6 are present next to each other, but separated from each other, on the longitudinal sides 9 after the functional plate 2 has been removed from the injection mold 1.

[0037] Overall, the aforementioned recesses 7 result in a functional plate 2 with a variable-length longitudinal side 9 and a constant-length wide side 10. The longitudinal side 9 of the functional plate 2 can be dimensioned, for example, in the stress-free state, i.e., in the state in which the functional plate 2 is manufactured in the injection mold 1.

[0038] If the recesses 7 were cut thin as in the prior art, thicker webs 6 would result. However, these cutting processes are not readily transferable to plastic sheets, so that the recesses 7 are produced during an injection molding process as proposed according to the invention and have a size of at least 2 mm, preferably at least 3 mm or at least 4 mm, in the pull-out direction RI, whereby the webs 6 also become correspondingly thinner.

[0039] Furthermore, Figure 1 shows that the functional plate 2 has a connection strip 11 on the broad sides 10, i.e., an optionally reinforced section, on which mounting holes 12 can be provided, for example, in the form of bores or elongated holes. The mounting holes 12 can be created subsequently, e.g., by drilling, or directly by an additional room divider during injection molding. On the broad sides 10, i.e., at the connection strips 11, the functional plate 2 is generally continuous. Rigid, non-extendable functional plate components, for example, can be mounted at the mounting holes 12.

[0040] The manufacturing process for the functional plate 2 is explained below with reference to Figure 2. In a first step, the injection mold 1 is prepared, in which the cavity corresponding to the functional plate 2 to be produced is already present. Plastic is then introduced into the cavity to form the functional plate 2. The plastic can be introduced into the cavity in liquid or viscous form, for example by heating the plastic. The plastic is then allowed to solidify in the cavity, for example by allowing it to cool. In this state, the functional plate 2 can be removed from the injection mold 1 and, if necessary, subjected to post-processing such as polishing, although this is not mandatory. Alternative injection molding processes are also possible, as is known to those skilled in the art.

[0041] As an optional post-processing, for example, chamfers can be produced on all edges of the recesses 7, which have a size of 0.1 mm to 1 mm, preferably 0.3 mm to 0.7 mm, particularly preferably 0.5 mm.

[0042] In a further optional step, the side surfaces of the recesses 7 can be provided with a surface quality by means of a rotary milling process (synchronous milling) or pendulum milling process, which makes further mechanical processing before a final surface treatment unnecessary.

[0043] Figure 3 shows a part of the functional plate 2, which is manufactured in detail A of Figure 1. This clearly shows that the webs 6 and the recesses 7 have essentially the same width in the extension direction RI. Specifically, it is shown that the webs 6 have a width of 4.10 mm and the recesses 7 have a width of 4.00 mm, each in the extension direction RI. In general, it can be provided that the width of the webs 6 and the width of the recesses differ by a maximum of 5%, a maximum of 10%, or a maximum of 20%, in each case based on the width of the webs 6, regardless of whether the webs 6 or the recesses 7 have a greater width. Preferably, all webs 6 or all recesses 7 are the same size in the extension direction RI, but it could also be provided that webs 6 of different widths or recesses 7 of different widths are provided.In general, the webs in the extension direction RI can, for example, have a size of at least 2 mm, at least 4 mm or at least 6 mm, although there is a great deal of design flexibility in this regard.

[0044] Figures 4 and 5 show the functional plate 2 after it has been removed from the injection mold 1. Figure 4 shows the functional plate 2 in the state it is in immediately after production, i.e. in the non-extended, stress-free state. Due to the large recesses 7, the functional plate 2 could even be compressed to make it even more compact. Figure 5 shows the functional plate 2 in an extended state, for example by being pulled apart manually. Due to the pulling-out movement, the webs 6 take up a greater distance from one another and the size of the recesses 7 increases in the pulling-out direction RI. Due to the recesses 7, which are essentially the same size as the webs 6 themselves in the pulling-out direction RI, the functional plate 2 can be pulled out by a factor of 2 - 2.5 before the webs 6 usually overstretch at the connecting sections 8.

[0045] Figure 6 shows a preferred embodiment of the functional plate 2, wherein the outer housing of the injection mold 1 is shown only schematically. In particular, it can be seen that the number of webs 6 and recesses 7 is not limited to a specific number, but can be chosen arbitrarily.

[0046] It is understood that the functional panel 2 described above, which, as shown, is extendable in the extension direction RI parallel to the long side 9 and has a greater width B2 than the length L2, could alternatively also be extendable in the extension direction RI parallel to the long side 9 and have a smaller width B2 than the length L2. Furthermore, the terms "long side", "wide side", "length", "width", etc. used herein are used only to define the functional panel 2 and in particular do not refer to a specific intended use. In particular, the functional panel 2 described above can, for example, also be used as a table panel with a constant length, for example 200 cm, which is extended in width over its entire length, as seen in use by an end user.

[0047] The functional plate 2 explained above with reference to Figures 1 to 6 has a rectangular shape, but could just as easily be oval, circular, or otherwise shaped. In this case, too, two long sides and two wide sides can be defined, which, although curved, can nevertheless be essentially parallel or perpendicular to the extension direction RI.

[0048] As an alternative to the embodiment of Figure 1, where rigid, non-extendable functional plate parts are mounted on the connecting leads 11 by means of the mounting holes 12, these can also be formed integrally on the functional plate 1. Figure 7 shows that it is also possible to produce at least one, preferably both, of the rigid, non-extendable functional plate parts 13 directly during the injection molding process, so that the functional plate 2 comprises one or two rigid, non-extendable functional plate parts 13 and one extendable functional plate part 14. Such a functional plate 2 would thus have a broad side 10 of the same size as the aforementioned functional plate 2, but for example a three times larger long side 9, wherein the recesses 7 are provided only over one third of the length of the long side 9, for example in the middle third of the long side.However, the invention is in no way limited to specific ratios of length Ln of the non-extendable functional plate parts 13 to the length La of the extendable functional plate parts. For example, length ratios of Ln:La:Ln of 1:1:1, 1:2:1, 2:1:2 or 2:1:1 could be selected if an extendable functional plate part is arranged between two non-extendable functional plate parts. If only one extendable functional plate part is arranged next to a non-extendable functional plate part, the length ratios La:Ln can be selected, for example, as 1:1, 2:1 or 1:2. Optionally, mounting holes 12 could also be provided on such functional plates, in particular along the wide sides, in order to mount the functional plate as a table top, for example on a wall.

[0049] The functional plate 2 described herein has, for example, in the extension direction RI in the relaxed state, a length L2 (La+Ln) of between 0.3 m and 3 m, preferably between 0.5 m and 1.5 m, wherein the non-extendable functional plate part 13 is particularly preferably between 0.5 m and 1.5 m long, preferably substantially 0.7 m long. Independently of this, the functional plate 2 preferably has a width B2 in the normal direction R2 normal to the extension direction RI of between 0.5 m and 2 m, preferably between 0.7 m and 1.5 m. Furthermore, the functional plate 2 preferably has a thickness of between 10 mm and 20 mm, preferably substantially 12 mm.

Claims

Claims:

1. Method for manufacturing a functional panel (2) extendable in an extension direction (RI), preferably an extendable furniture panel or extendable tabletop, characterized by the steps: - Providing an injection mold (1) with a cavity whose shape corresponds to the functional plate (2) to be produced, wherein the injection mold (1) has at least two space dividers (7', 7") for producing at least two recesses (7) of the functional plate (2), which are located next to each other in the extraction direction (RI) and are spaced apart by voids (6') in the cavity for producing webs (6) of the functional plate (2), and at least two space dividers (7', 7") are located next to each other perpendicular to the extraction direction (RI) and are spaced apart from each other for producing connecting sections (8) of the functional plate (2), and wherein at least two space dividers (7', 7") that are successive in the extraction direction (RI) are each offset perpendicular to the extraction direction (RI), wherein the space dividers (7', 7") have a size of at least 2 mm in the extraction direction (RI), and - Introducing a plastic into the cavity to produce the functional plate (2).

2. The method of claim 1, wherein the plastic is or comprises polyoxymethylene.

3. The method of claim 1, wherein the plastic is or comprises polyamide or thermoplastic polyurethane.

4. The method of claim 1, wherein the plastic is or comprises polyvinylidene fluoride or polyethylene terephthalate glycol.

5. Method according to any one of claims 1 to 4, wherein the plastic is fiber-reinforced.

6. Method according to any one of claims 1 to 5, wherein the space dividers (7') have a first size in the extension direction (RI) and the voids (6') have a second size in the extension direction (RI), wherein the first and the second size differ by a maximum of 10%, based on the first size.

7. Method according to any one of claims 1 to 6, wherein the space dividers (7') are rounded at their ends which are normal to the direction of extension (RI).

8. Extendable functional panel (2), preferably an extendable furniture panel or extendable tabletop, which is manufactured in one piece and has elongated recesses (7) extending perpendicular to an extension direction (RI) and passing through the functional panel (2), between which webs (6) are formed to create a length-variable section of the functional panel (2), wherein at least two recesses (7) are located next to each other in the extension direction (RI), which are spaced apart by the webs (6), and at least two recesses (7) are located next to each other perpendicular to the extension direction (RI), which are spaced apart by connecting sections (8), and wherein at least two successive recesses (7) in the extension direction (RI) are each offset perpendicular to the extension direction (RI), characterized in that the functional panel (2) is made of plastic and the recesses (7) have a size of at least 2 mm in the extension direction (RI).

9. Extendable functional plate (2) according to claim 8, wherein the functional plate (2) consists at least partially, preferably at least 90 wt%, of polyoxymethylene, polyamide, thermoplastic polyurethane, polyvinylidene fluoride or polyethylene terephthalate glycol and is preferably fiber reinforced.

10. Extendable functional plate (2) according to claim 8 or 9, wherein the recesses (7) have a first size in the extension direction (RI) and the webs (6) have a second size in the extension direction (RI), wherein the first and the second size differ by a maximum of 10%, based on the first size, and wherein the recesses (7) are preferably rounded at their ends normal to the extension direction (RI).

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