Reinforced structure and method for reinforcing same

Abstract

The present disclosure discloses a polymeric furniture construction element and reinforcement thereof. The reinforced furniture element (12) comprises a furniture element (20) configured with a first face and a spaced apart second face, one or more reinforcement members (36) extending between the first face and the second face, and a plurality of through stud receiving bores (40) extending through the one or more reinforcement members (36) between the first face and the second face; the first face configured with a reinforcement element abutment surface and the second face configured with a stud abutment surface; and a reinforcement element (22) configured with a surface abutting the first face and a plurality of studs (50) extending from the surface abutting the first face and disposed in alignment with at least some of the stud receiving bores (40), the free ends of the studs being configurable with abutment heads for closely abutting on the stud abutment surface.

Description

[Technical field]

[0001] The present disclosure is generally in the field of reinforced structures and methods of reinforcing the same. More particularly, the present disclosure relates to polymeric furniture structural elements and reinforcement thereof. [Background technology]

[0002] The following references may be considered relevant as background to the subject matter of this disclosure: - JP3051780U - WO2016056912A1 - US6725785

[0003] JP3051780U discloses a base molded from a hard resin such as ABS or polycarbonate, and a frame surrounded by a descending wall and vertical ribs is formed on the back side of the base. A reinforcing frame molded from a hard resin such as BS or polycarbonate is fitted inside, and the reinforcing frame is integrally fixed to the base over substantially the entire length of the base by ultrasonic welding, high frequency welding, or adhesive, and a pair of reinforcing frames are integrated with both side edges of the base. This improves the bending strength of the base and prevents deformation of the base.

[0004] WO2016056912A1 discloses a shelf for a rolling container, a rolling container comprising the same, and a method for transporting and / or storing items. The shelf according to the invention comprises: a resting surface suitable for placing items thereon, a support plate arranged in use below the resting surface for supporting the resting surface, and a number of connecting hooks arranged at or near corner points of the resting surface and configured for attachment to a rolling container, the resting surface and the support plate being connected to each other by one or more shaped edges.

[0005] US6725785 discloses a protective cover for a grid-like article support, comprising a flat portion for holding an article and a peripheral wall joined to the edge of the flat portion. A clip element is provided on the bottom side of the flat portion, and a hook element is provided on the inside of the wall. The cover is firmly attached onto the article support, with the clip element clipped to a corresponding metal bar of the article support and the hook element hooked to the edge of the article support, so that the article can be stably held on the article support.

[0006] It is understood that the acknowledgment of the above references is not to be inferred as meaning that they are in any way relevant to the patentability of the presently disclosed subject matter. Summary of the Invention [Means for solving the problem]

[0007] In one of its aspects, the disclosure provides a reinforced furniture element comprising a furniture element and at least one reinforcement element, the furniture element comprising a first face and a spaced apart second face, one or more reinforcement members extending between the first face and the second face, and a plurality of through stud receiving bores extending through the one or more reinforcement members between the first face and the second face, the first face comprising a reinforcement element abutment surface and the second face comprising a stud abutment surface. The reinforcement element comprises a surface abutting the first face and a plurality of studs extending from the surface abutting the first face, the studs being positioned in alignment with at least some of the stud receiving bores, and free ends of the studs may be configured with abutment heads for tightly abutting on the stud abutment surface.

[0008] As used herein, the term "furniture" is used broadly to refer to all forms of furniture units and their structural elements, such as shelving units, table tops, dividers, etc.

[0009] This arrangement is such that, when the reinforcing element is applied onto and connected to the furniture element, it becomes fixed and firmly secured thereto, thereby improving the modulus of elasticity of the reinforced furniture element and, consequently, its bending resistance.

[0010] The effective length of the stud is defined along the stud and extends between the contact level of the first surface and the surface abutting the first surface and the stud abutment surface. The actual length of the reinforcing member is defined along the through stud receiving bore and is between the first surface and the stud abutment surface.

[0011] According to a particular example of the present disclosure, the effective length is slightly shorter than the actual length and, in the assembled position, pressure is applied to the studs, thereby applying an attractive force which acts in a manner that attracts the reinforcing element to be exposed on the first surface of the furniture element.

[0012] According to another aspect of the present disclosure, there is provided a method for assembling a reinforced furniture element, the method comprising the steps of: a. obtaining a furniture element configured with a first side and a spaced apart second side, one or more reinforcing members extending between the first side and the second side, and a plurality of through stud receiving bores extending through the one or more reinforcing members between the first side and the second side, the first side configured with a reinforcing element abutment surface and the second side configured with a stud abutment surface; b. obtaining a reinforcing member configured with a surface abutting the first side and a plurality of studs extending from the surface abutting the first side, the studs being positioned in alignment with at least some of the stud receiving bores, free ends of the studs being configurable with abutting heads; c. introducing a free end of the stud into the stud receiving bore until a surface abutting the first face of the reinforcing element abuts closely on the first face of the furniture element, the free end protruding from the stud abutting surface of the second face of the furniture element; and d. Configuring the abutment head of the stud to abut closely on the stud abutment surface.

[0013] Any one or more of the following features, designs, and configurations may be applied individually or in various combinations thereof to the reinforced furniture elements and furniture elements according to any aspect of the present disclosure; - the abutment head portion may be configured to have a diameter that exceeds the diameter of the through stud receiving bore; - The abutment head can be deformed into a mushroom shape; - the abutment head can be a compressible mushroom-shaped snap-on head; - the first and second faces of the furniture element can be arranged parallel to each other; - the plurality of studs may extend perpendicular to a surface abutting the first face; - Several studs may run parallel to each other; - the reinforcing elements can be arranged parallel to each other; - The reinforced furniture element can be a shelf; - the first surface can be a top surface or a bottom surface and the second surface can be a bottom surface or a top surface, respectively; - The reinforcing elements can be applied either to the top or bottom surface of the furniture element; - the stud abutment surface may be arranged parallel to the first face; - The stud abutment surface can be elastic; - the first surface may be configured with a recess for at least partially receiving at least some portions of the reinforcing element; - the first face and the second face can be flat or can be configured with a recess for receiving at least some parts of the reinforcing element; - the reinforced furniture element may be configured with one or more reinforcing elements, each of which is independently connected to the furniture element; - the furniture elements and the reinforcement elements may or may not be made of the same material; - furniture elements and reinforcing elements can be made of polymer materials; - The furniture elements and reinforcing elements can adopt different colors and different patterns; - the abutment head of the stud may be configured to abut on the stud abutment surface by melting the end of the stud and thereby deforming it into a mushroom-like shape of wide cross section; - melting the ends of the studs can be arranged by a heating device or by ultrasonic deposition; - the upper surface of the reinforcing element can be flush with the upper surface of the furniture element; - The reinforced furniture element is a shelf; - the reinforcing element can occupy the main surface of the furniture element; - the reinforced furniture element may be configured with two or more reinforcing elements, said two or more reinforcing elements may be configured on either face of the furniture element and on its side faces; - the through stud receiving bores and the respective studs can be of the same length or of different lengths; - the furniture elements and the reinforcing elements can be made of thermoplastic material, and the deformation of the studs by ultrasonic welding results in a molecular bond of the studs with the stud abutment surface; - furniture elements and reinforcing elements can be of rigid construction; - the arrangement is such that, in the assembled position, the configuration of the abutment head so as to abut closely on the stud abutment surface is performed simultaneously with the application of pressure so as to bring the furniture element and the reinforcing element into close adjacency, thereby causing stress in the stud.

[0014] In order to understand the invention and to see how it may be carried out in practice, embodiments will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which the features shown are intended to be illustrative of only some embodiments of the invention, unless otherwise implied. Similar reference numerals have been used in the drawings to indicate corresponding parts. [Brief description of the drawings]

[0015] [Figure 1] FIG. 1 illustrates a perspective view of a shelving system comprising a plurality of reinforced furniture elements according to an example of the present disclosure. [Figure 2A] FIG. 2 is a top perspective view of a reinforced furniture element, i.e., a shelf of the shelving system seen in FIG. [Figure 2B] FIG. 2B is a bottom perspective view of the shelf seen in FIG. 2A prior to fastening the studs of the reinforcing element. [Figure 3A] FIG. 2B is an exploded perspective view of FIG. 2A (before fastening the studs of the reinforcing element). [Figure 3B] FIG. 2C is an exploded view of FIG. 2B. [Figure 4A] FIG. 2B is a cross-sectional view along line IV-IV in FIG. 2A (before fastening the studs of the reinforcing element). [Figure 4B] FIG. 4B is an enlarged view of the portion marked 4B in FIG. 4A. [Figure 4C] FIG. 4C is an enlarged view of the portion marked 4C in FIG. 2B. [Figure 4D] FIG. 4C is a bottom perspective view of the cross-sectional portion of FIG. 4B. [Figure 5A] FIG. 4B is a plan side view of the cross section of FIG. 4A. [Figure 5B] FIG. 5B is an enlarged view of the portion marked 5B in FIG. 5A. [Figure 6A] FIG. 2B is a bottom perspective view of the shelf seen in FIG. 2A after the studs of the reinforcing element have been fastened. [Figure 6B] FIG. 6B is an enlarged view of the portion marked 6B in FIG. 6A. [Figure 6C] FIG. 6B is a cross-sectional view taken along line VI-VI in FIG. 6A. [Figure 6D]FIG. 6D is an enlarged view of the portion marked 6D in FIG. 6C. [Figure 7A] FIG. 6D is a plan side view of the cross section of FIG. 6C. [Figure 7B] FIG. 7B is an enlarged view of the portion marked 7B in FIG. 7A. [Figure 7C] FIG. 7C is a further enlarged view of the portion marked 7C in FIG. 4B. [Figure 8A-8B] 1 is a schematic diagram showing deformation of a stud due to ultrasonic welding. FIG. [Figure 9A-9E] FIG. 2 is a schematic diagram of the coupling step. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] 1 and 2A, in this specific non-limiting example, there is shown a shelving system, generally indicated at 10, comprising five spaced shelves, each indicated at 12, supported on corner posts 14. For clarity, the shelving system is merely an example, and each shelf is considered herein to be a reinforced furniture element. However, reinforced furniture elements according to the present disclosure can be any type of article and can be of any shape and design.

[0017] With further reference to Figures 2B-5B, and as can best be seen in Figures 3A and 3B, the reinforced furniture elements, i.e., each shelf 12, comprise a furniture element 20 and a reinforcing element 22, where furniture element 20 is a base shelf structure configured for support by posts 14, and reinforcing element 22 is in the form of a substantially flat member sized to abut against furniture element 20, as described below.

[0018] Referring first in detail to the furniture element 20, it is a rigid polymeric rectangular element configured to have a first face (top) 26 and a spaced apart second face (bottom) 28. The first face 26 is configured with a reinforcing element abutment surface 30 which is a major recessed portion of the furniture element 20 defined by a peripheral rim 32, and the second face 28 is configured with a stud abutment surface 34. A plurality of reinforcing members 36, i.e., elongated ribs, extend between the first face 26 and the second face 28, and some portions of the reinforcing members 36 are configured to have a plurality of through stud receiving bores 40 extending between the first face 26 and the second face 28.

[0019] Turning now to the reinforcing element 22, it is a substantially flat, rigid polymeric element having a first surface abutting surface 44 (i.e., its bottom surface) and a top surface 46, and configured with a plurality of rigid studs 50 extending downwardly from the first surface abutting surface 44. This arrangement is such that when the reinforcing element 22 is placed on the furniture element 20, the studs 50 are aligned with the stud receiving bores 40, where the initial length L of the studs 50 is S The length of the stud receiving bore is 40 L B Larger than (L S >L B ), so that in an undeformed, assembled position, as described below, a free end 52 of stud 50 projects below stud abutment surface 34 of reinforcing member 36. Stud 50 is a tubular, cylindrical, elongated member, although other configurations are possible (not shown).

[0020] It will be appreciated that in certain instances the reinforcing members of a furniture element are not of equal height and comprise short reinforcing members 36S and long reinforcing members 36L, but this is by way of example only.

[0021] When the reinforcing element 22 is placed on the furniture element 20, the abutment surface 44 of the reinforcing element 22 abuts on the first (top) face 26 of the furniture element 20 and the studs 50 are received in the respective stud-receiving bores 40. In this position, the reinforcing element 22 is received within the recessed portion and the top surface 46 is flush with the peripheral rim 32.

[0022] 6A-7C, the furniture element 20 is reinforced by deforming the free ends 52 of the studs 50 into mushroom-shaped abutment heads 60 that tightly abut on the stud abutment surfaces 34 of the reinforcing member 36.

[0023] This arrangement is such that configuring the abutment head 60 to abut closely against the stud abutment surface 34 simultaneously applies pressure to bring the furniture element 20 and the reinforcing element 22 into close abutment, thereby creating stress in the stud 50. Thus, in the assembled position of the reinforced furniture element (shelf 12), as shown in FIG. 7C, the effective length E of the stud L is the actual length of the reinforcing member A L Slightly shorter than E L L The effective length E L is defined along the stud; extends between the contact level between the first surface and the surface abutting the first surface and the stud abutment surface; actual length A L is defined along the through stud receiving bore and is between the first face and the stud abutment surface.

[0024] 8A and 8B, an example of the steps of manufacturing a reinforced furniture element according to the present disclosure is depicted. Referring first to Fig. 8A, a sonotrode 70 is applied to the free end 52 of the stem 50, said sonotrode 70 being configured to have a penetrating head 72 adapted to be introduced into the lumen 75 of the stem end 52, and to have a shaped head 74 adapted to be deposited, i.e. to melt the free end 52 by applying heat to it so that it reshapes to match the shape of the head 74, so that upon cooling the abutment end takes the form of a mushroom-shaped abutment head 60 which abuts against the stud abutment surface 34, as in Fig. 8B.

[0025] ​9A-9E show successive steps in the thermal deposition of the free end 52 of the stud 50 onto the mushroom-shaped abutment head 60. In the first step, shown in FIG. 9A, the position of the free end 52 through the bore 40 is identified. Next, a heated anvil / iron 76 (same shape as the sosotrode 70 of FIG. 8A) is advanced to the free end 52 of the stud 50 (FIG. 9B) and heat is applied thereto (FIG. 9C), transforming the free end into a mushroom-shaped abutment head 60 that abuts the stud abutment surface 34, and water cooling the abutment head 60 applies cooling to the anvil 76 (FIG. 9D), resulting in the mushroom-shaped abutment head 60 abutting the stud abutment surface 34, as shown in FIG. 9E.

[0026] In the example shown, the abutment head is mushroomed by a heat deformation process, but it is understood that other arrangements are possible for applying pressure to the stud in the stud-receiving bore in the assembled position. One such example is to preform the stud with a snap-fit ​​mushroom-shaped free end that can be configured to be introduced through the bore and to snap-fit ​​naturally into sap engagement when it penetrates the bottom end of the reinforcing member 36.

Claims

1. A reinforced furniture element comprising a furniture element and at least one reinforcement element, the furniture element comprises a first face and a spaced apart second face, one or more reinforcing members extending between the first face and the second face, and a plurality of through stud receiving bores extending through the one or more reinforcing members between the first face and the second face, the first face comprising a reinforcing element abutment surface and the second face comprising a stud abutment surface; the reinforcing element may comprise a surface abutting the first face and a plurality of studs extending from the surface abutting the first face, the studs being positioned in registration with at least some of the stud-receiving bores, and free ends of the studs being configured with abutment heads for tightly abutting on the stud abutment surface; The reinforced furniture element is configured with two or more reinforcing elements, the two or more reinforcing elements being configured on either the first face or the second face of the furniture element as well as on its side faces.

2. 2. Reinforced furniture element according to claim 1, wherein when the reinforcing element is applied onto the furniture element and connected, the reinforcing element becomes fixed and rigidly fastened thereto, thereby increasing the modulus of elasticity of the reinforced furniture element and thereby increasing the bending resistance of the reinforced furniture element.

3. 2. A reinforced furniture element according to claim 1, wherein pressure is applied to the studs, thereby applying an attractive force that acts in the sense of attracting the reinforcement element so that it is exposed on a first surface of the furniture element.

4. 2. The reinforced furniture element of claim 1, wherein the abutment head is configured with a diameter that exceeds the diameter of the through stud receiving bore.

5. 5. A reinforced furniture element according to claim 4, wherein the abutment head is deformed into a mushroom-like shape.

6. 5. A reinforced furniture element according to claim 4, wherein the abutment head is a compressible mushroom-shaped snap-on head.

7. 2. The reinforced furniture element of claim 1, wherein the first and second faces of the furniture element are arranged parallel to each other.

8. 2. The reinforced furniture element of claim 1, wherein the plurality of studs extend perpendicular to a surface abutting the first face.

9. 2. The reinforced furniture element of claim 1, wherein the studs extend parallel to one another.

10. 2. A reinforced furniture element according to claim 1, wherein the reinforcing members are arranged parallel to one another.

11. 10. The reinforced furniture element of claim 1, wherein the reinforced furniture element is a shelf.

12. 2. A reinforced furniture element according to claim 1, wherein the first surface is a top surface or a bottom surface and the second surface is a bottom surface or a top surface, respectively.

13. 2. A reinforced furniture element according to claim 1, wherein the reinforcement element is applied to either or both of the top and bottom surfaces of the furniture element.

14. 2. The reinforced furniture element of claim 1, wherein the stud abutment surface is disposed parallel to the first face.

15. 2. A reinforced furniture element according to claim 1, wherein the stud abutment surface is resilient.

16. 2. The reinforced furniture element of claim 1, wherein the first surface is configured with a recess for at least partially receiving at least some portions of the reinforcement element.

17. 2. The reinforced furniture element of claim 1, wherein the first and second surfaces are flat or configured with recesses for receiving at least some portions of the reinforcement element.

18. 10. The reinforced furniture element of claim 1, wherein the reinforced furniture element comprises one or more reinforcement elements, each of the reinforcement elements being independently connected to the furniture element.

19. 10. The reinforced furniture element of claim 1, wherein the furniture element and the reinforcement element are made of a polymer material.

20. 2. A reinforced furniture element according to claim 1, wherein the abutment heads of the studs are configured to abut on the stud abutment surface by melting the ends of the studs, thereby deforming them into a mushroom-like shape of wide cross section.

21. 2. A reinforced furniture element according to claim 1, wherein the top surface of the reinforcement element is flush with the top surface of the furniture element.

22. 2. A reinforced furniture element according to claim 1, wherein the reinforcement element occupies a major surface of the furniture element.

23. 2. The reinforced furniture element of claim 1, wherein the through stud receiving bores and respective studs are of the same length or of different lengths.

24. 10. The reinforced furniture element of claim 1, wherein the furniture element and the reinforcement element are rigid structures.

25. 1. A method for assembling reinforced furniture elements, said method comprising: obtaining a furniture element configured with a first surface and a spaced apart second surface, one or more reinforcement members extending between the first surface and the second surface, and a plurality of through stud receiving bores extending through the one or more reinforcement members between the first surface and the second surface, wherein the first surface is configured with a reinforcement element abutment surface and the second surface is configured with a stud abutment surface; b) obtaining a reinforcing member comprising a surface abutting the first face and a plurality of studs extending from the surface abutting the first face, the studs being positioned in alignment with at least some of the stud-receiving bores, the free ends of the studs being configurable with abutting heads; c) introducing the free end of the stud into the stud-receiving bore until the surface abutting the first face of the reinforcing element tightly abuts on the first face of the furniture element, the free end protruding from the stud abutting surface on the second face of the furniture element; d. Melting the end of the stud with a heating device or by ultrasonic deposition, so that the abutment head of the stud rests tightly on the stud abutment surface; A method comprising:

26. 26. The method of claim 25, wherein the furniture element and the reinforcement element are made of a thermoplastic material, and the deformation of the stud by ultrasonic welding results in a molecular bond between the stud and the stud abutment surface.

27. 26. The method of claim 25, wherein configuring the abutment head to abut tightly on the stud abutment surface in the assembled position is performed simultaneously with applying pressure to bring the furniture element and reinforcement element into close abutment, thereby creating stress in the stud.

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