U.S. patent application number 11/729055 was filed with the patent office on 2008-10-02 for furniture, home decor, and other items of manufacture formed of cellular material.
Invention is credited to Cathy Hensey, Vahid Pourkay.
Application Number | 20080237319 11/729055 |
Document ID | / |
Family ID | 39792515 |
Filed Date | 2008-10-02 |
United States Patent
Application |
20080237319 |
Kind Code |
A1 |
Hensey; Cathy ; et
al. |
October 2, 2008 |
Furniture, home decor, and other items of manufacture formed of
cellular material
Abstract
Articles of furniture and home decor formed of a single panel of
unfinished honeycomb cardboard cut in a compressed state along a
first plane to have a predefined shape and expanded along a second
plane; and fixing means for fixing the cut honeycomb cardboard in
an expanded state. In preferred embodiments, the compressed
honeycomb cardboard may be cut in the first plane to have the
profile of a sofa, a chair, a table, a vase, or a tray, such that
when the honeycomb cardboard is expanded it takes on a
three-dimensional form thereof.
Inventors: |
Hensey; Cathy; (New York,
NY) ; Pourkay; Vahid; (Cliffside Park, NJ) |
Correspondence
Address: |
Cathy Hensey
Apt. 6C, 375 South End Avenue
New York
NY
10280
US
|
Family ID: |
39792515 |
Appl. No.: |
11/729055 |
Filed: |
March 27, 2007 |
Current U.S.
Class: |
229/103 |
Current CPC
Class: |
A47B 3/00 20130101; A47B
2230/0085 20130101; A47B 2220/0086 20130101; A47B 43/02
20130101 |
Class at
Publication: |
229/103 |
International
Class: |
B65D 5/00 20060101
B65D005/00 |
Claims
1. A cardboard table, comprising: a base constructed of one or more
panels of honeycomb cardboard; a top member having a substantially
planar upper surface provided on the base and comprising a panel of
honeycomb cardboard; a fixing member provided on a lower surface of
the top member and comprising a panel of honeycomb cardboard for
fixing the top member to the base member to prevent lateral
movement therebetween; and a shelf member comprising a panel of
honeycomb cardboard provided below the top member and having slots
formed therein for engaging the base.
2. A cardboard table according to claim 1; wherein each panel of
honeycomb cardboard comprises first and second substantially planar
outer sheets and an inner core of material having a honeycomb
construction secured to the first and second planar sheets.
3. A cardboard table according to claim 1; wherein the base
comprises a pair of leg members each constructed of a single panel
of honeycomb cardboard and the slots are formed in the shelf to
engage the leg members.
4. An article of cardboard furniture, comprising: a single panel of
honeycomb cardboard cut in a compressed state along a first plane
to have a predefined shape and expanded along a second plane; and
fixing means for fixing the cut honeycomb cardboard in an expanded
state.
5. An article of cardboard furniture according to claim 4; wherein
the honeycomb cardboard comprises a honeycomb structure comprised
of a plurality of laminated paper materials shaped to form
honeycomb cells.
6. An article of cardboard furniture according to claim 4; wherein
the compressed honeycomb cardboard is cut in the first plane to
have a profile of a sofa, such that when the honeycomb cardboard is
expanded it takes on a three-dimensional form of a sofa.
7. An article of cardboard furniture according to claim 4; wherein
the compressed honeycomb cardboard is cut in the first plane to
have a profile of a chair, such that when the honeycomb cardboard
is expanded it takes on a three-dimensional form of a chair.
8. An article of cardboard furniture according to claim 4; wherein
the compressed honeycomb cardboard is cut in the first plane to
have a profile of a table, such that when the honeycomb cardboard
is expanded it takes on a three-dimensional form of a table.
9. An article of cardboard furniture according to claim 4; wherein
the compressed honeycomb cardboard is cut in the first plane to
have a profile of a vase, such that when the honeycomb cardboard is
expanded it takes on a three-dimensional form of a vase.
10. An article of cardboard furniture according to claim 4; wherein
the compressed honeycomb cardboard is cut in the first plane to
have a profile of a tray, such that when the honeycomb cardboard is
expanded it takes on a three-dimensional form of a tray.
11. An article of cardboard furniture according to claim 4; wherein
the compressed honeycomb cardboard cut in the first plane is
expanded such that opposite ends thereof are brought into contact
with each other; and the fixing means fixes the oppose ends to each
other.
12. An article of cardboard furniture according to claim 4; wherein
the fixing means comprises adhesive.
13. An article of cardboard furniture according to claim 4; wherein
the fixing means comprises a mechanical fixing element.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to articles of
manufacture having a lightweight cellular construction and, more
particularly, to articles of furniture and home decor formed
substantially or entirely of one or more panels of lightweight
cellular material.
[0003] 2. Description of Related Art
[0004] There has long been a need for articles of furniture and
home decor that are lightweight, inexpensive to manufacture, easily
transported, stored, assembled and disassembled, and inexpensive
enough to purchase so that they may be discarded after a desired
period of use.
[0005] Although the manufacture of furniture with lightweight
materials that are stable and strong is generally well known, the
materials used in such constructions have been somewhat limited.
For instance, lawn furniture formed of hollow-core aluminum members
or resin materials are well known. Likewise, the concept of
providing easily assembled furniture formed of fiberboard or other
composite materials is generally well known.
[0006] Although cardboard has found widespread use in many storage
and delivery applications, the use of cardboard or other heavy,
wood-based types of paper in furniture construction has been
somewhat limited. Some cardboard furniture constructions utilize
cardboard arranged in the form of an egg crate divider structure
made from a crisscross pattern of interlocking, flat sheets or
strips of cardboard. Cardboard materials arranged in such an egg
crate pattern have been used to form core members of various
articles of furniture, such as desktop work surfaces and seat
portions of chairs and sofas. In the case of such constructions,
the cardboard core members are generally concealed by decorative
surface materials such as fiberboard, composite or laminate
surfaces, plastics, leather or textiles.
[0007] The use of cardboard egg crate divider core members or
laminated corrugated cardboard in furniture construction is known
to decrease the weight and manufacturing cost of such furniture
while providing sufficient structural integrity to enable use of
the furniture for its intended purpose. However, aside from a
modest decrease in the manufacturing cost over the use of wood or
other conventional materials, the use of cardboard core structures
does not result in an appreciable difference in the structure of
the furniture from the viewpoint of the purchaser and/or user of
the furniture. Such furniture is no easier to transport, store,
assemble and disassemble, and dispose of than furniture formed of
more conventional materials. Nor is such furniture significantly
less costly to purchase than other traditional constructions.
[0008] The use of cardboard as an element of furniture design
(rather than core structure) has been limited. Some design efforts
have involved the use of corrugated cardboard to form structural
furniture members such as legs, seats, seat backs and working
surfaces with enhanced strength and rigidity.
[0009] For example, a currently-available line of cardboard-based
modern furniture designed by renowned architect Frank Gehry is
constructed of multiple laminated layers of corrugated cardboard
held together by hidden screws and fiberboard surfaces. In one
commercial embodiment of this furniture line, a chair is fabricated
of sixty layers of corrugated cardboard and held together by
concealed screws and fiberboard edging. Although the strength of
the corrugated cardboard is significantly enhanced by laminating
multiple layers, the resulting furniture is costly and is not
lightweight or easily transported. Nor can it be disassembled or
easily stored.
[0010] Other efforts at producing furniture with reinforced paper
or cardboard constructions have been generally unsuccessful. Many
of the resulting articles of cardboard furniture have proven to be
of unstable construction and unable to support adequate weight to
serve their intended or desired purposes. Purchasers of many of
these articles of furniture are required to exercise caution in
their use to avoid bumping into them and causing them to
collapse.
[0011] To the extent previous designs have satisfied the need for
reduced cost, ease of assembly/disassembly, storage, and the like,
the resulting designs are aesthetically unappealing. For example,
one attempt to meet the foregoing needs involves constructions in
which multiple sheets of solid flat or corrugated cardboard are
stacked or folded atop each other to achieve increased structural
strength. The resulting furniture has a visual appearance similar
to that of a corrugated cardboard crate or box and is generally
unacceptable from an aesthetic standpoint.
[0012] Heretofore, there have been very few articles of furniture
or home decor formed using bare, unlaminated cardboard as a
structural material because of the lack of rigidity, structural
stability and low level of consumer acceptance of cardboard as an
aesthetic element of design. There have also been very few articles
of furniture and home decor formed using bare cardboard as an
element of design because of the displeasing appearance of bare
cardboard.
SUMMARY OF THE INVENTION
[0013] In view of the foregoing, it is an object of the present
invention to provide articles of manufacture including but not
limited to furniture and home decor formed of a material which has
relatively great rigidity and structural strength, which is capable
of bearing relatively large loads and stress, and which has an
attractive and desirable aesthetic appearance.
[0014] It is another object of the present invention to provide
articles of manufacture such as furniture and home decor that are
easily manufactured and transported.
[0015] Still another object of the present invention is to provide
articles of manufacture such as furniture and home decor that that
are lightweight, inexpensive to manufacture, easily transported,
easily stored, easily assembled and disassembled, and inexpensive
enough to purchase so that they may be discarded after a desired
period of use.
[0016] Yet another object of the present invention is to provide
articles of manufacture such as furniture and home decor having
components that are formed substantially or entirely of a single
panel of bare honeycomb cardboard that is pre-cut and expanded to
take on the shape of a desired article of furniture or home
decor.
[0017] Still yet another object of the present invention is to
provide articles of manufacture such as furniture and home decor
having components that are formed substantially or entirely of
multiple panels of laminated honeycomb cardboard that are preformed
to be fitted together in combination to form secure and
structurally sound articles of furniture or home decor such as
dining tables, coffee tables, drafting tables, desks, bookcases,
vases, and the like.
[0018] A further object of the present invention is to provide
articles of furniture and home decor of the type described above in
collapsed or kit form, wherein individual components may be quickly
and easily assembled and joined in a solid and strong
construction.
[0019] Still yet a further object of the present invention is to
provide articles of furniture and home decor of the type described
above in collapsed or kit form, wherein individual components are
light in weight, compact for easy storage, and inexpensive to
purchase.
[0020] Other objects and advantages of the invention will become
apparent upon reading the following detailed description and upon
reference to the drawings. Throughout the drawings, like reference
numerals refer to like parts.
[0021] The foregoing objects of the invention, and others, are
achieved in accordance with the present invention by providing
inexpensive, lightweight, structurally sound articles of furniture
and home decor out of nothing but honeycomb cardboard.
[0022] According to the present invention, articles of furniture
and home decor can be inexpensively manufactured because they are
formed substantially or entirely of pre-cut panels of finished or
unfinished honeycomb cardboard. The articles of furniture and home
decor can be easily assembled without the use of special tools,
fasteners, adhesives or the like. In accordance with a first aspect
of the present invention, articles of furniture or home decor
formed of multiple pre-cut panels of finished honeycomb cardboard
can also be sold as a kit and assembled by merely sliding the
individual, pre-cut panels together. Because of the use of finished
honeycomb cardboard, the resulting furniture is rigid and
structurally sound. In accordance with a second aspect of the
present invention, articles of furniture or home decor having
components formed of a single panel of unfinished honeycomb
cardboard can be sold as a kit and assembled by merely unfolding or
expanding the single panel of unfinished honeycomb cardboard and
securing its ends together to form the completed component.
[0023] More specifically, in accordance with the first aspect of
the present invention, an article of furniture, such as a table or
a desk, is formed of a plurality of panels of finished honeycomb
cardboard and comprises: a base constructed of one or more panels
of finished honeycomb cardboard; a top constructed of one or more
panels of finished honeycomb cardboard and provided on the base; a
fixing member constructed of one or more panels of finished
honeycomb cardboard adhered to the top member for fixing the top to
the base and preventing lateral movement therebetween; and a shelf
constructed of one or more panels of finished honeycomb cardboard
provided below the top and having slots formed therein for engaging
the base.
[0024] The term "finished honeycomb cardboard" refers to honeycomb
cardboard material that has continuous planar opposing surfaces. In
a preferred embodiment, the planar surfaces comprise first and
second substantially planar outer sheets formed of flat paper,
cardboard, plastic, or the like, which may be in a laminated or
bare form. A honeycomb core structure is prepared, for example, by
laminating a plurality of paper materials shaped to form honeycomb
cells to provide a honeycomb core material, then forming honeycomb
units by cutting the laminate of the paper materials in a direction
perpendicular to the honeycomb cells while the latter are closed to
form an open panel of desired height, and successively connecting
the honeycomb units, with upper and lower faces bonded together, to
provide an elongated honeycomb core. The planar sheets are bonded
to one or both cut faces (front and rear sides) of the elongated
honeycomb core to provide the "finished honeycomb cardboard"
structure.
[0025] In a preferred embodiment, the base of the article of
furniture comprises a pair of vertically oriented leg members each
constructed of a single panel of finished honeycomb cardboard.
Slots formed in the shelf member are spaced apart so as to
respectively engage the leg members. The fixing member comprises a
panel of honeycomb cardboard affixed to a lower surface of the top
to fit within opposing upper side portions of the leg members so as
to maintain the top in place and prevent lateral movement between
the top and the leg members. Assembling the finished honeycomb
cardboard panels in the foregoing manner results in furniture that
is rigid and structurally sound.
[0026] In accordance with the second aspect of the present
invention, an article of manufacture which may be furniture or home
decor, such as a table, a desk, or a vase, comprises: a single
panel of "unfinished honeycomb cardboard," and comprises: a single
panel of unfinished honeycomb cardboard cut along a given plane to
a predefined shape plane and expanded in a direction to the plane
to expand the honeycomb structure.
[0027] The term "unfinished honeycomb cardboard" refers to
honeycomb cardboard material that has open surfaces. In a preferred
embodiment, a honeycomb structure is prepared by laminating a
plurality of paper materials shaped to form honeycomb cells, then
forming honeycomb units by cutting the laminate of the paper
materials in a direction perpendicular to the honeycomb cells while
the latter are closed and successively connecting the honeycomb
units, with upper and lower faces bonded together, to provide an
elongated honeycomb core off desired height. Unlike finished
honeycomb cardboard, planar sheets are not bonded to opposing
surfaces of the honeycomb structure, thereby providing an
unfinished honeycomb structure that may be easily compressed and
expanded due to the flexible nature of the individual honeycomb
cells.
[0028] In a preferred embodiment, a panel of unfinished, compressed
honeycomb cardboard is cut along a given plane to have the profile
of an article of furniture. When the compressed honeycomb cardboard
is expanded, it becomes elongated to take on the three-dimensional
shape of the article of furniture. The shape taken on by the
expanded honeycomb cardboard depends upon the shape into which the
compressed honeycomb cardboard is cut and the way it is expanded.
If the compressed honeycomb cardboard is cut in the given plane to
have the side profile of a sofa, it will take on the
three-dimensional form of a sofa when expanded. If expanded
somewhat less, it will take on the three-dimensional shape of a
chair. Alternately, the compressed honeycomb cardboard may be cut
in the given plane to have the side profile of a table. When
expanded, it will take on the three-dimensional shape of a table.
By cutting the compressed honeycomb cardboard in the appropriate
manner, it can acquire the three-dimensional shape of any desired
article of manufacture.
[0029] In accordance with a third aspect of the present invention,
a panel of unfinished compressed honeycomb cardboard is cut along a
given plane and expanded such that opposite ends of the cut
honeycomb cardboard are attached to each other to provide a
resulting article that has a generally cylindrical shape. Articles
such as round tables, desks, stools, round benches, vases, baskets,
placemats, and the like, may be produced in this manner.
[0030] In accordance with another aspect of the present invention,
the article of furniture or home decor of the second and third
aspects of the invention further comprises fixing means for fixing
the single panel of expanded honeycomb cardboard in the expanded
state. The nature of the fixing means depends upon the shape in
which the panel of cut honeycomb cardboard is expanded. In articles
having a generally cylindrical shape in which the opposite ends of
the honeycomb cardboard are held in contact with each other, the
fixing means may comprise a mechanical element such as a clip or
other fastening device for maintaining opposite ends of the
expanded honeycomb cardboard together, or an adhesive or
Velcro.RTM. layer or member for serving this purpose. In articles
in which the opposite ends of the honeycomb cardboard are not held
in contact with each other, such as sofas, chairs, tables, and the
like, the fixing means may comprise one or more solid elements such
as a rod or wire extending through the expanded honeycomb
cardboard, or any additional structure that serves this purpose,
such as a removable or fixed covering structure, including a
hardened laminated coating.
[0031] Fulfillment of the foregoing and other objects of the
invention will become apparent upon complete reading of the
specification and claims taken in conjunction with the attached
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1A is a perspective view showing a completely assembled
embodiment of a typical cardboard table in accordance with the
present invention
[0033] FIG. 1B is a view of the individual components of the
cardboard table of FIG. 1A;
[0034] FIG. 2 is a perspective view showing a completely assembled
embodiment of a typical project table in accordance with the
present invention;
[0035] FIG. 3 is a perspective view showing a completely assembled
embodiment of a typical coffee table in accordance with the present
invention;
[0036] FIGS. 4A and 4B are fragmentary exploded perspective views
of honeycomb cardboard panels used in various embodiments of the
present invention;
[0037] FIG. 5 is a perspective view showing a completely assembled
embodiment of a cardboard room divider in accordance with the
present invention;
[0038] FIG. 6A is a perspective view showing a completely assembled
embodiment of a typical cardboard shelf unit in accordance with the
present invention;
[0039] FIG. 6B is a view of the individual components of the
cardboard shelf unit of FIG. 6A;
[0040] FIG. 7 is a perspective view showing a length of honeycomb
cardboard in a compressed state;
[0041] FIG. 8A is a side plan view showing compressed panels of
honeycomb cardboard cut in the profile of a chair or sofa;
[0042] FIG. 8B is a perspective view showing the compressed panel
of cut honeycomb cardboard of FIG. 8A expanded to form a sofa;
and
[0043] FIGS. 9A and 9B are perspective views showing compressed
panels of cut honeycomb cardboard expanded to form various articles
of furniture or hime decor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0044] The honeycomb cardboard furniture according to the present
invention, how it can be provided and assembled by a purchaser or
user, and how it differs from previously known cardboard furniture
can be best explained and understood with reference to the attached
drawings.
[0045] As will be described below, various articles of furniture
and home decor can be inexpensively manufactured according to the
present invention because they are formed substantially or entirely
of pre-cut panels of finished or unfinished honeycomb cardboard.
The articles of furniture and home decor can be easily assembled
without the use of special tools, fasteners, adhesives or the like.
Thus, articles of furniture or home decor having components formed
of a single panel of unfinished honeycomb cardboard can be sold as
a kit and assembled by merely unfolding or expanding the single
panel of unfinished honeycomb cardboard and optionally securing its
ends together to form the completed component. Articles of
furniture or home decor formed of multiple pre-cut panels of
finished honeycomb cardboard can also be sold as a kit and
assembled by merely sliding the individual, pre-cut panels
together. Because of the use of honeycomb cardboard, the resulting
furniture is rigid and structurally sound.
[0046] A first aspect the present invention will now be described,
in which a plurality of panels of honeycomb cardboard are pre-cut
to be fitted together in combination to form secure and
structurally sound articles of furniture or home decor such as
dining tables, coffee tables, drafting tables, desks, shelf units,
and the like.
[0047] FIG. 1A is a perspective view illustrating a typical table
according to the present invention. The table is generally
designated by the reference numeral 10. The table 10 is formed of a
plurality of individual pre-cut panels of finished honeycomb
cardboard, including a base comprised of a pair of long legs 12,
12', short legs 13, 13' and a shelf 14, each constructed of one or
more panels of finished honeycomb cardboard, and a top member 16
constructed of a single panel of finished honeycomb cardboard and
provided on the legs 12, 12'.
[0048] In this embodiment, the top member 16 and base members
including tall legs 12, 12', small legs 13, 13' and shelf 14 of the
table 10 are each formed entirely of pre-cut panels of finished
honeycomb cardboard. The individual members of the table base,
which in this embodiment includes the pair of tall legs 12, 12',
the pair of small legs 13, 13' and the shelf 14, are slotted
periodically to slide together to form the table base in the manner
described below and shown in the drawings.
[0049] Further, a fixing member 18 comprised of a single panel of
finished honeycomb cardboard is adhered to a bottom surface of the
top member 16 for fixing the top member 16 to the base and
preventing lateral movement therebetween. More specifically, the
fixing member 18 is dimensioned to fit within opposing sides 20,
20' of the tall legs 12, 12' at an upper portion thereof so as to
prevent lateral movement between the top member 16 and the tall
legs 12, 12'.
[0050] In accordance with the present invention, the manufacture of
lightweight and inexpensive furniture is facilitated by
constructing the table top 16, base members (legs 12 and 12', 13
and 13' and shelf 14) and fixing member 18 entirely of individual
panels of pre-cut, finished honeycomb cardboard.
[0051] FIG. 1B illustrates the individual components of the table
10, including the small tall legs 12, 12', the small legs 13, 13',
the shelf 14, the top member 16 and the fixing member 18 (shown by
dotted lines). As illustrated, the individual members of the table
base, which in this embodiment includes the tall legs 12, 12', the
small legs 13, 13' and the shelf 14, are periodically slotted 22 to
allow the legs 12 and 12', 13 and 13' and the shelf 14 to slide
together to form a stable table base.
[0052] As best seen in FIGS. 4A and 4B, the construction of the
honeycomb cardboard employed in the present invention includes
first and second substantially planar outer sheets 102, 104 formed
of flat cardboard, as in FIG. 4B, or having a posterboard-type
construction 116, as in FIG. 4A. A honeycomb core structure 108 is
prepared by laminating a plurality of paper materials for forming
honeycomb cells to provide a honeycomb core material, then forming
honeycomb units by cutting the laminate of the paper materials in a
direction perpendicular to the honeycomb cells while the latter are
closed, successively connecting the honeycomb units, with upper and
lower faces bonded together, to provide an elongated honeycomb core
108, and bonding the planar outer sheets 102, 104 to a cut face
(front and rear sides) of the elongated honeycomb core 108 to
provide the honeycomb cardboard structure.
[0053] To enhance the substantial and solid appearance of the item,
an outer sheet (102, 104) may have an overlay of simulated wood, or
other material. Alternatively, the outer surface may be finished in
a fiberboard or laminate material such as Formica.RTM. or other
rigid material which is able to withstand liquids and the shocks of
normal bumps, nicks, and scrapes.
[0054] FIG. 2 illustrates another embodiment of a table according
to the present invention. The table is generally designated by the
reference numeral 10B. The table 10B is formed of a plurality of
individual pre-cut panels of finished honeycomb cardboard,
including a base comprised of legs 12B, 12B' and a shelf 14B, each
constructed of one or more panels of finished honeycomb cardboard,
a top member 16B constructed of a single panel of finished
honeycomb cardboard and provided on the legs 12B, 12B'. The table
10B is generally similar in construction to the table 10 of FIG.
1A. However, as can be seen, the project table 10B further includes
a back brace 24 having spaced apart slots for engaging
corresponding slots formed in the legs 12B, 12B'.
[0055] The top member 16B, base members including legs 12B, 12B'
and shelf 14B, and the back brace 24 of the table 10B are each
formed entirely of pre-cut sheets of honeycomb cardboard. The
individual members of the table base, which in this embodiment
includes the legs 12B, 12B' and the shelf 14B are slotted
periodically 22B to slide together to form the table base. A fixing
member 18B comprised of a single panel of finished honeycomb
cardboard is adhered to a bottom surface of the top member 16B for
fixing the top member 16B to the base and preventing lateral
movement therebetween. More specifically, the fixing member 18B is
dimensioned to fit within opposing sides 20B, 20B' of the legs 12B,
12B' at an upper portion thereof so as to prevent lateral movement
between the top member 16 and the leg members 12B, 12B'.
[0056] FIG. 3 illustrates another embodiment of a table according
to the present invention. The table is generally designated by the
reference numeral 10C. The table 10C is formed of a plurality of
individual pre-cut panels of finished honeycomb cardboard,
including a base comprised of legs 12C, 12C' and a shelf 14C, each
constructed of one or more panels of finished honeycomb cardboard,
a top member 16C and a fixing member 18C constructed of a single
panel of finished honeycomb cardboard and provided on the legs 12C,
12C'. The table 10C is generally similar in construction to the
table 10 of FIG. 1A.
[0057] The top member 16C, base members including legs 12C, 12C',
26, 26' and top member 16C, of the table 10C are each formed
entirely of pre-cut sheets of honeycomb cardboard. The individual
members of the table base, which in this embodiment includes the
legs 12C, 12C' and the shelf 14C are slotted periodically 22C to
slide together to form the table base.
[0058] FIG. 5 illustrates a cardboard room divider in accordance
with the present invention. The room divider is generally
designated by the reference numeral 30. The room divider 30 is
formed of a plurality of individual pre-cut panels of finished
honeycomb cardboard. The room divider includes end members 32, 34
which are cut in the same way, a first center member 36 and a
second center member 38. By providing additional center members 36,
38, a room divider of any desired length may be formed.
[0059] FIGS. 6A and 6B illustrate a cardboard shelf unit in
accordance with the present invention. The shelf unit is generally
designated by reference numeral 40. The shelf unit is formed of a
plurality of individual pre-cut panels of finished honeycomb
cardboard. The shelf unit 40 includes leg members 42 provided with
spaced apart slots 44, a top member 46 with a fixing member 48
adhered to the lower surface thereof, and a bottom member 50 with a
fixing member 52 adhered to the lower surface thereof. A plurality
of shelves 54 are provided with slots 56 to slide together with the
leg members 42 to form the shelf unit. The leg members 40, 42, top
member 46, bottom member 50, shelves 54 and fixing members 46, 48
of the shelf unit 40 are each formed entirely of pre-cut sheets of
honeycomb cardboard.
[0060] As illustrated by the foregoing embodiments, the present
invention facilitates the manufacture of lightweight, inexpensive
furniture by constructing the individual elements entirely of
individual panels of pre-cut finished honeycomb cardboard.
[0061] Further embodiments of the invention are formed of a single
panel of unfinished honeycomb cardboard. In the preferred
embodiments, the unfinished honeycomb cardboard has the
construction of the honeycomb core structure 108 shown in FIGS. 4A
and 4B. Unlike the finished honeycomb cardboard shown in the
drawings, no planar sheets are bonded to opposing surfaces of the
honeycomb core structure, thereby providing an unfinished honeycomb
structure that is collapsible and expandable.
[0062] FIG. 7 is a perspective view showing a length of unfinished
honeycomb cardboard 60 in a compressed state with opposite ends 62,
64 urged toward each other. As will be seen below, the honeycomb
cardboard 60 is expandable from its compressed state in a flexible
manner so that it may take on any desired elongated shape.
[0063] FIG. 8A is a plan view showing a compressed panel of
honeycomb cardboard 66 cut along a first plane to have the profile
of a chair or sofa. As shown in FIG. 8B, when the compressed
honeycomb cardboard panel 66 is expanded, it becomes elongated to
take on the shape of a chair or sofa 68, depending upon the amount
of expansion.
[0064] The shape taken on by the expanded honeycomb cardboard
depends upon the manner in which the compressed honeycomb cardboard
is cut and expanded. Thus, when the panel of compressed, unfinished
honeycomb cardboard 62 cut in the first plane to have the side
profile of a chair or sofa is expanded, it takes on the
three-dimensional form of a chair or sofa. If the panel compressed,
unfinished honeycomb cardboard 62 were cut to have the side profile
of a table, it would take on the three-dimensional shape of a table
when expanded.
[0065] In the embodiments shown in FIGS. 9A and 9B, various
articles are formed with a generally cylindrical shape by expanding
the cut panel of unfinished honeycomb cardboard such that opposite
ends thereof are attached to each other. For instance, as shown in
FIG. 9A, the unfinished honeycomb cardboard is cut to have the side
profile of a round bench. When expanded such that opposite ends of
the honeycomb cardboard are attached, the finished article has the
three-dimensional shape of a round bench 70. Similarly, FIG. 9B
shows an expanded article with the shape of a stool or table
base.
[0066] Thus, as shown in FIGS. 8A-8B and 9A-9B, when compressed
panels of unfinished honeycomb cardboard are cut in a desired
manner and expanded, they take on the shape of a desired article of
manufacture. The shape taken on by the expanded honeycomb cardboard
depends upon the manner in which the compressed honeycomb cardboard
is cut and expanded. Thus, when a panel of compressed, unfinished
honeycomb cardboard cut in the first plane to have the side profile
of a chair is expanded, it takes on the three-dimensional form of a
chair or sofa. When the panel of compressed, unfinished honeycomb
cardboard cut in the first plane to have the side profile of a
table is expanded, it takes on the three-dimensional form of a
table. In a like manner, when the panel of compressed, unfinished
honeycomb cardboard cut in the first plane to have the side profile
of a tray is expanded, it takes on the three-dimensional form of a
tray. Similarly, when the panel of compressed honeycomb cardboard
cut in the first plane to have the side profile of a vase or round
table is expanded, it takes on the three-dimensional form of a vase
or round table.
[0067] Thus, as will be appreciated, when a compressed honeycomb
cardboard panel of appropriate height is cut in an appropriate
manner, it can acquire the three-dimensional shape of any desired
article of manufacture.
[0068] Fixing means may be used for maintaining or fixing the
single panel of expanded, unfinished honeycomb cardboard in an
expanded state. The nature of the fixing means depends upon the
shape in which the panel of cut honeycomb cardboard is expanded. In
cylindrical articles such as stools, benches, table bases, vases,
baskets, and the like, in which the opposite ends of the honeycomb
cardboard are held in contact with each other, the fixing means may
comprise a mechanical element such as a clip or other fastening
device for maintaining opposite ends of the expanded honeycomb
cardboard together, or an adhesive layer or Velcro.RTM. member for
serving this purpose. In articles in which the opposite ends of the
honeycomb cardboard are not held in contact with each other, the
fixing means may comprise one or more solid elements such as a rod
or wire extending through the expanded honeycomb cardboard, or any
additional structure that serves this purpose, such as covering
structure, such as a hardened laminated coating.
[0069] The embodiments of the invention described above are
illustrative of the principles of the invention and are not
intended to limit the invention to the particular embodiments
described. For example, in other embodiments, the honeycomb
cardboard may be utilized to form articles of manufacture other
than furniture or items of home decor. Accordingly, as used herein,
the term "cardboard furniture" is intended to refer to articles of
furniture and home decor formed partly, substantially or entirely
of cardboard or heavy wood-based types of paper. However, as used
herein, the term "cardboard furniture" includes other utilitarian
objects that are typically constructed of wood, plastics, composite
materials, metal, or a combination of these and/or other materials.
The embodiments described can be easily modified by those skilled
in the art without undue experimentation. Accordingly, the
embodiments of the invention described above are illustrative of
the principles of the invention and are not intended to limit the
invention to the particular embodiments described. While the
preferred embodiment of the invention has been illustrated and
described, it will be appreciated that various changes can be made
therein without departing from the spirit and scope of the
invention.
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