COMPOSITE BOARD, FURNITURE AND MANUFACTURING METHOD

Abstract

A composite panel includes a panel body, a frame, and parallel edges. The panel body has at least two layers of panels attached to each other. The thickness of the panel body at the parallel edges is less than that at an intermediate position of the panel body. The frame has grooves with a height corresponding to the thickness of the panel body at the parallel edges. The parallel edges of the panel body are inserted into corresponding grooves of the frame and can slide in the grooves to assemble the panel body and the frame together.

Claims

1-15. (canceled)

16. A composite panel comprising: a panel body including at least two panel layers attached to each other, the panel body having a pair of parallel edges, the panel body having a thickness at the parallel edges less than at an intermediate position of the panel body; a frame around the panel body, the frame having a groove facing the panel body; and the parallel edges of the panel body inserted into the groove to assemble the panel body and the frame together.

17. The composite panel of claim 16 wherein the at least two panel layers include a top panel and a bottom panel attached to each other, at least one of the top panel and the bottom panel having a first structure at the pair of parallel edges and having a second structure, different from the first structure, at a portion of the panel body between the parallel edges.

18. The composite panel of claim 17 wherein a top surface of the top panel and a bottom surface of the bottom panel are spaced apart from each other at the intermediate position, and the top panel and the bottom panel are joined together at the parallel edges to form a laminated structure.

19. The composite panel of claim 17 wherein bottom surfaces of the parallel edges of the panel body and a bottom surface of the bottom panel are in the same plane; and/or top surfaces of the pair of parallel edges of the panel body and the top surface of the top panel are in the same plane.

20. The composite panel of claim 18 wherein the bottom panel is a corrugated panel comprising a flat plate-shaped body portion having protrusions protruding upward from the body portion; and the top panel comprises a flat top wall main body and a top wall extension portion extending from the top wall main body obliquely downward toward the groove, an end of the top wall extension portion formed as an elongated tongue portion; the body portion of the bottom panel and the tongue portion fit together in the groove at the parallel edges of the panel body.

21. The composite panel of claim 20 wherein the protrusions are frusto-conical, substantially each protrusion having a top surface attached to a bottom surface of the top wall main body.

22. The composite panel of claim 16 wherein the frame comprises a hollow frame body having an extension bent at least partially over a top of the frame body to form the groove, with the rest of the frame body below the panel body.

23. The composite panel of claim 22 wherein the frame body has a hollow portion with a rectangular cross-section formed by a top wall, a bottom wall, an outer side wall and an inner side wall, an outer end of the top wall and an upper end of the outer side wall joined together to form the extension.

24. The composite panel of claim 16 wherein the at least two layers of panels are formed by blow molding.

25. Furniture comprising the composite panel of claim 16.

26. The furniture of claim 25 wherein the furniture is a table comprising the composite panel and legs pivotally attached to the composite panel.

27. The furniture of claim 26 wherein the table comprises at least two of the composite panels of claim 16, the composite panels foldable relative to each other.

28. The furniture of claim 26 wherein the legs are configured to fold up against the frame, parallel to the frame.

29. A method of manufacturing a composite panel comprising: attaching first and second panels to each other to form a panel body having a pair of parallel edges, the panel body having a thickness at the pair of parallel edges less than that at an intermediate position of the panel body; providing a frame around the panel body, the frame having a groove opening facing the panel body; and inserting the pair of parallel edges of the panel body into the groove, to assemble the panel body and the frame together to provide the composite panel.

30. The method of claim 29 wherein the frame comprises a plurality of beams, further including connecting the plurality of beams into the frame, each beam provided by a rectangular blank plate having a pair of first edges; connecting the pair of first edges together to form the blank plate into a tubular structure; shaping the tubular structure to include a hollow beam body portion and a beam extension portion extending upwardly from the body portion, wherein the beam extension portion is jointly formed by two walls that abut against each other and are joined at an end away from the beam body portion; and bending the beam extension portion relative to the beam body portion to form the groove open to one side between the beam extension portion and the beam body portion.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Reference may be made to preferred embodiments shown in the figures to enable better understanding of the above and other objects, features, advantages and functions of the present invention. The same reference numerals in the figures denote the same parts. Those skilled in the art should appreciate that the figures are intended to schematically illustrate the preferred embodiments of the present invention, and not intended to impose any limitations to the scope of the present invention. All parts in the figures are not drawn to scale.

[0036] FIG. 1 through FIG. 3 illustrate an assembling process of a composite panel according to a preferred embodiment of the present invention;

[0037] FIG. 4 is a cross-sectional view taken along line A-A in FIG. 3;

[0038] FIG. 5 is a partially enlarged view of a portion B of FIG. 4;

[0039] FIG. 6 is a partially enlarged view of a portion C in FIG. 4;

[0040] FIG. 7 is a bottom perspective view of a table according to a preferred embodiment of the present invention.

[0041] FIG. 8 and FIG. 9 are, in turn, schematic illustrations of a process of folding the table of FIG. 7.

REFERENCE NUMERALS

[0042] 100 Panel body [0043] 101 Longitudinal edge of the panel body [0044] 200 Frame [0045] 201 Edge longitudinal beam [0046] 202 Transverse beam [0047] 203 Intermediate longitudinal beam [0048] 204 Receiving opening [0049] 205 Pivot portion [0050] 110 Top panel [0051] 101 Extension flat plate [0052] 120 Bottom panel [0053] 121 Bottom wall of the bottom panel [0054] 122 Top wall of the bottom panel [0055] 123 Connecting wall of the bottom panel [0056] 201a frame body [0057] 201b groove [0058] 2011 Inner side wall of the frame body [0059] 2012 Bottom wall of the frame body [0060] 2013 Outer side wall of the frame body [0061] 2014 Top wall of the frame body [0062] 300 Composite panel [0063] 340 Table [0064] 400 Leg

DETAILED DESCRIPTION OF EMBODIMENTS

[0065] Specific embodiments of the present disclosure will now be described in detail with reference to the figures. What are described herein are only preferred embodiments of the present invention. Those skilled in the art may implement other manners of the present disclosure on the basis of the preferred embodiments, and said other manners also fall within the scope of the present disclosure.

[0066] The present invention provides a composite panel, furniture comprising the composite panel and a method of manufacture the composite panel. FIG. 1 through FIG. 9 show some preferred embodiments according to the invention.

[0067] FIG. 1 through FIG. 6 show a composite panel 300 according to the present invention. The composite panel 300 for example may be used as a table panel of a table 340 shown in FIG. 7 through FIG. 9. Alternatively, the composite panel 300 shown in FIG. 1 through FIG. 6 may also be used as a box panel, a bed panel, or other furniture parts.

[0068] First, it should be appreciated that directional terms and positional terms mentioned in the present invention may be understood with reference to the embodiments shown in FIG. 1 through FIG. 9. The directional terms and positional terms mentioned in the present invention are relative directions and positions rather than absolute directions and positions of various parts. For example, a transverse direction mentioned in the embodiments is the D1 direction shown in the figures, a longitudinal direction is the D2 direction shown in the figures, and a thickness direction is a direction perpendicular to both the transverse direction D1 and the longitudinal direction D2.

[0069] Reference is first made to FIG. 1 through FIG. 3. A composite panel 300 according to a preferred embodiment of the present invention comprises a panel body 100 and a frame 200. The panel body 100 is a generally rectangular plate-like structure having a pair of longitudinal edges 102 and a pair of transverse edges. The frame 200 surrounds the panel body 100 and can engage edges of the panel body 100. The frame 200 is a rectangular frame structure and comprises a pair of edge longitudinal beams 201, a front transverse beam 202 and an intermediate longitudinal beam 203. The pair of longitudinal edges 102 of the panel body 100 can engage the frame 200 such that the panel body 100 can be made move from a receiving opening 204 of the frame 200 into engagement with the frame 200 and continue to slide relative to the frame 200 in the longitudinal direction D2 to a position where the panel body 100 fully engages the frame 200.

[0070] The detailed arrangement of the panel body 100 and the frame 200 is shown in FIG. 4 through FIG. 6. Referring first to FIG. 4 and FIG. 5, the panel body 100 comprises two layers of panels attached to each other, and may comprise three or more layers of panels in other embodiments. It should be appreciated that a top panel and a bottom panel mentioned in the present invention are only of a pair of panels attached to each other. For example, in an embodiment comprising four layers of panels, if the second and third layers of panels counted from top to bottom are studied, the second layer of panel may be referred to as the top panel and the third layer of panel may be referred to as the bottom panel. That is, there may still be other panels on a top side of the top panel and other panels below a bottom side of the bottom panel.

[0071] Further referring to FIG. 6, the thickness of the panel body 100 at the pair of longitudinal edges (i.e., the thickness at the ends in the direction D1 in FIG. 6) is less than that at a middle position of the panel body 100. A groove 201b opening towards the panel body 100 and extending along an extension direction of the parallel edges is provided at a position of the frame 200 corresponding to the pair of longitudinal edges 102 of the panel body 100, and the groove 201b has a height corresponding to the thickness of the panel body 100 at the pair of longitudinal edges 102. In other words, the groove 201b is formed on the pair of edge longitudinal beams 201 of the frame 200. The pair of longitudinal edges 102 of the panel body 100 may be inserted into the corresponding grooves 201b of the frame 200, and the panel body 100 is enabled to slide relative to the frame 200 in the longitudinal direction D2 so that the panel body 100 is assembled together with the frame 200. Although in the present embodiment, the pair of parallel edges of the panel body 100 cooperating with the frame 200 are longitudinal edges thereof, in other embodiments not shown, the pair of parallel edges may be transverse edges or a pair of parallel edges in an irregular shape.

[0072] Some preferred embodiments of the panel body 100 and the frame 200 are given in the present embodiment.

[0073] With respect to the arrangement of the panel body 100, for example, referring to FIG. 4 and FIG. 5, at least two layers of panels comprise a top panel 110 and a bottom panel 120 that contact each other.

[0074] Further referring to FIG. 5 and FIG. 6, in the present embodiment, the bottom panel 120 is a corrugated panel including a bottom panel 120 body having a flat plate shape and protrusions opened at a lower end recessed upward from the bottom panel 120 body. The protrusions are formed in a truncated cone shape and each have a top surface closely fitted with a bottom surface of the top panel 110. That is, as for the bottom panel 120 itself, the top wall 122 is opened downward and the bottom wall 121 is opened upward, and the top wall 122 is adapted to be attached to the top panel 110, and a connecting wall 123 is provided between the top wall 122 and the bottom wall 121. For the truncated cones corresponding to the protrusions, the connecting walls 123 constitute side faces of each truncated cone, the top wall 122 of the bottom panel 120 constitutes a top face of each truncated cone, and the bottom of each truncated cone is open. The bottom wall 121 of the bottom panel 120 constitutes a main body of the bottom panel 120.

[0075] Unlike the bottom panel 120, the top panel 110 comprises a top wall main body formed in a flat plate structure and a top wall extension portion extending downward from the top wall main body and toward the groove 201b, and an end of the top wall extension portion in the D1 direction is formed as an extension flat plate 101. Referring to FIG. 6, at the longitudinal edges 102 of the panel body 100, the main body of the bottom panel 120 and the extension flat plate 101 fit closely together to fit in the groove 201b.

[0076] As may be seen, in the present embodiment, there is a gap between the top wall of the top panel 110 and the bottom wall of the bottom panel 120 at an intermediate position of the panel body 100 except for the pair of longitudinal edges 102 (see FIG. 5). At the pair of longitudinal edges 102 of the panel body 100 (referring to FIG. 6), the top panel 110 and the bottom panel 120 are a flat plate structure with two layers closely adhered to each other, the end 101 of the top panel 110 and the end of the bottom panel 120 are two flat plates closely adhered to each other, and portions at the pair of longitudinal edges 102 of the panel body 100 and the bottom wall of the bottom panel 120 are in the same plane. Also preferably, in other embodiments not shown, the portions of the panel body 100 at the pair of longitudinal edges 102 and the top wall of the top panel 110 are in the same plane.

[0077] As may be seen, in the present embodiment, the top panel 110 and the bottom panel 120 are each structured differently at the pair of longitudinal edges 102 of the panel body 100 than at an intermediate portion of the panel body 100 other than the longitudinal edges 102. However, in other embodiments not shown, the top panel may be a simple flat panel, i.e., it has the same structure at the longitudinal edges of the panel body as at other positions, while the bottom panel has a different structure at the pair of longitudinal edges of the panel body than at an intermediate portion of the panel body other than the longitudinal edges. Alternatively, the bottom panel may be a simple flat panel, i.e., it has the same structure at the longitudinal edges of the panel body as at other positions, while the top panel has a different structure at the pair of longitudinal edges of the panel body than at an intermediate portion of the panel body other than the longitudinal edges. As appreciated, it is feasible as long as the thickness of the panel body formed from at least two layers of panels at the pair of longitudinal edges is ensured less than that at the intermediate position of the panel body.

[0078] Reference is mainly made to FIG. 6 for a preferred arrangement of the frame 200. The frame 200 comprises a hollow frame body 201a and a groove 201b portion defining a groove 201b at the top of the frame body 201a. The frame body 201a defines a hollow portion having a rectangular cross-section by its top wall 2014, bottom wall 2012, outer side wall 2013 and inner side wall 2011. The top wall 2014 extends to form a section of extension wall 2014a at an intersection position thereof with the outer side wall 2013, the outer side wall 2013 extends to form a section of extension wall 2013a at an intersection position thereof with the top wall 2014, the extension wall 2014a of the top wall 2014 and the extension wall 2013a of the outer side wall 2013 are fitted together and extend from the intersection position toward the panel body 100 to form the groove 201b portion above the frame body 201a, and the extension wall 2014a of the top wall 2014 and the extension wall 2013a of the outer side wall 2013 are connected together at an end remote from the intersection position. When the frame 200 is manufactured, the top wall 2014 and the outer side wall 2013 of the frame body 201a may be gathered together at the intersection position thereof and form such extension wall structures abutting each other. In the present embodiment, the frame body 201a protrudes downward beyond the panel body 100, and the bottom side of the frame body 201a (i.e., the bottom side of the bottom wall 2012 thereof) is lower than the bottom side of the panel.

[0079] Preferably, the frame 200 may also be provided with a pivot portion 205 for mounting a pivot extending in the transverse direction D1.

[0080] Preferably, at least two layers of panels of the panel body 100 are all formed by blow molding. A method of blow molding each layer of panel comprises the following steps: placing a frame on top of a mold having a shape matching the shape of the frame, wherein a protruding portion is formed on an outer edge of the frame, the protruding portion protruding outwards in an extension direction of the formed panel and protruding outwards from the mold; placing a plastic blank plate onto a top surface of a mold mounted with the frame, and applying a suction force in a direction perpendicular to the extension direction of the panel, so as to form the plastic blank plate using a suction molding process, so that the plastic blank plate covers the frame and the mold; moving the mold in a direction perpendicular to the extension direction of the panel to disengage from the frame and the plastic blank plate; trimming the plastic blank plate to ensure that the trimmed plastic blank plate covers at least an outwardly-facing surface of the protruding portion of the frame to ensure that the frame is embedded within the trimmed plastic blank plate.

[0081] Preferably, a bottom edge of the mold is provided with a step around a main body of the mold, and the frame is configured to be adaptively placed on the step around the main body of the mold.

[0082] FIG. 7 through FIG. 9 illustrate a table 340 that comprises the composite panel 300 shown in FIG. 1 through FIG. 6. The table 340 is a foldable table 340 comprising a table panel and legs 400, wherein the table panel comprises table panel units that can be pivoted and folded relative to each other about an axis X, and each of the table panel unit is made of one composite panel 300. The legs 400 are configured to be folded to abut against and parallel to a bottom surface of the table panel unit and folded with the table panel unit relative to the other table panel unit.

[0083] When the table 340 needs to be folded and stored, the four legs 400 may be first folded to a state where they abut against and parallel to the bottom surface of the table panel unit and can be folded together with the table panel unit with respect to the other table panel unit, as shown in FIG. 8; thereafter, the two table panel units are folded and pivoted relative to each other about the pivot portion 205 to a state shown in FIG. 9.

[0084] Preferred embodiments of the present invention also provide a method of manufacturing the composite panel according to FIGS. 1-6. The method comprises: providing at least two layers of panels and attaching the at least two layers of panels to each other to form a panel body having a pair of opposed longitudinal edges, the thickness of the panel body at the pair of longitudinal edges being less than that at an intermediate position of the panel body; providing a frame capable of surrounding the panel body and engaging with each edge of the panel body, wherein a groove opening towards the panel body and extending along an extension direction of the longitudinal edges is provided at a position of the frame corresponding to the pair of longitudinal edges of the panel body, and the height of the groove is consistent with the thickness of the panel body at the pair of longitudinal edges; inserting the pair of longitudinal edges of the panel body into corresponding grooves of the frame, and sliding the panel body relative to the frame in an extension direction of the longitudinal edges until the panel body and the frame are assembled together.

[0085] With reference to FIG. 6, the step of providing the frame comprises a step of providing a plurality of beams and a step of connecting the plurality of beams into the frame, wherein the step of providing the beams comprises: providing a rectangular blank plate having a pair of first edges extending in a length direction and a pair of second edges extending in a width direction; connecting the pair of first edges together to allow the blank plate to form a tubular structure; shaping the tubular structure such that the tubular structure comprises a hollow beam body portion and a beam extension portion extending upwardly from the body portion, wherein the beam extension portion is jointly formed by two walls that abut against each other and are joined at an end away from the beam body portion; bending the beam extension portion relative to the beam body portion to define the groove open to one side between the beam extension portion and the beam body portion.

[0086] The composite panel according to the present invention has a preferred thickness as well as a smaller weight as compared to conventional panels with equal thickness. Thus, the composite panel according to the present invention has advantages such as good stability, unlikelihood to bending and damages, and light weight and portability.

[0087] The above depictions of various embodiments of the present invention are provided to those having ordinary skill in the art for depiction purpose, and are not intended to exclude other embodiments from the present disclosure or limit the present disclosure to a single disclosed embodiment. As described above, various alternatives and modifications of the present disclosure will be apparent to those of ordinary skill in the art. Accordingly, although some alternative embodiments have been described in detail, those having ordinary skill in the art will understand or readily develop other embodiments. The disclosure is intended to cover all alternatives, modifications and variations of the present disclosure described herein, as well as other embodiments falling within the spirit and scope of the present disclosure described herein.