U.S. patent application number 15/868091 was filed with the patent office on 2020-02-20 for intensive use shelf.
This patent application is currently assigned to Norix Group, Inc.. The applicant listed for this patent is Richard Karl, Scott Karl, Kurt Staskon. Invention is credited to Richard Karl, Scott Karl, Kurt Staskon.
Application Number | 20200054135 15/868091 |
Document ID | / |
Family ID | 67140311 |
Filed Date | 2020-02-20 |
View All Diagrams
United States Patent
Application |
20200054135 |
Kind Code |
A9 |
Karl; Richard ; et
al. |
February 20, 2020 |
INTENSIVE USE SHELF
Abstract
The invention is directed to an intensive use furniture
component having a sealing connection on a mounting surface for
sealingly attaching to a floor or wall to prevent liquid from
seeping under or behind the furniture component. The furniture
component is formed by an outer shell having a side wall extending
generally perpendicular to the mounting surface. A mounting flange
is disposed adjacent the sidewall. A bolt hole is formed in the
mounting flange. The sealing connection comprises a caulk channel
formed as a channel in the mounting surface for receiving a bead of
caulk to fill the seam between the mounting surface and the wall or
floor to prevent fluid from seeping past the caulk channel to a
space adjacent the interior mounting surface.
Inventors: |
Karl; Richard; (Naples,
FL) ; Karl; Scott; (Geneva, IL) ; Staskon;
Kurt; (Orland Park, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Karl; Richard
Karl; Scott
Staskon; Kurt |
Naples
Geneva
Orland Park |
FL
IL
IL |
US
US
US |
|
|
Assignee: |
Norix Group, Inc.
West Chicago
IL
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 20190208908 A1 |
July 11, 2019 |
|
|
Family ID: |
67140311 |
Appl. No.: |
15/868091 |
Filed: |
January 11, 2018 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
15583955 |
May 1, 2017 |
10507150 |
|
|
15868091 |
|
|
|
|
13450508 |
Apr 19, 2012 |
9661933 |
|
|
15583955 |
|
|
|
|
13186853 |
Jul 20, 2011 |
|
|
|
13450508 |
|
|
|
|
11868308 |
Oct 5, 2007 |
8007059 |
|
|
13186853 |
|
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47B 55/00 20130101;
A47C 19/00 20130101; A47B 61/003 20130101; A47C 16/02 20130101;
A47B 21/00 20130101; A47B 63/00 20130101; A47B 96/021 20130101;
A47B 23/06 20130101; A47B 57/10 20130101; A47B 2200/12 20130101;
A47B 7/00 20130101; A47B 13/00 20130101; A47B 96/20 20130101; A47B
91/08 20130101; A47C 21/00 20130101 |
International
Class: |
A47B 96/20 20060101
A47B096/20; A47B 61/00 20060101 A47B061/00; A47B 96/02 20060101
A47B096/02 |
Claims
1-45. (canceled)
We claim:
46. An intensive use shelf comprising: a molded hollow outer shell
having a ligature resistant top, a bottom, a back wall, a first
side wall and a second side wall, the top on the back wall, the
bottom on the back wall spaced from the top, the first side wall on
the back wall integrally molded to the top and bottom, the second
side wall on the back wall integrally molded to the top and bottom,
the first side wall spaced from the second side wall.
47. The intensive use shelf of claim 46, further comprising an open
front between the first side wall and the second side wall.
48. The intensive use shelf of claim 46, wherein the ligature
resistant top further comprises a sloping top surface.
49. The intensive use shelf of claim 46, wherein the ligature
resistant top is integrally molded to the back.
50. The intensive use shelf of claim 46, wherein the first side
wall and second side wall further comprise rounded corners.
51. The intensive use shelf of claim 46, wherein the top extends
from the first side wall to the second side wall.
52. The intensive use shelf of claim 48, wherein the top extends
from the first side wall to the second side wall.
53. The intensive use shelf of claim 48, wherein the bottom extends
from the first side wall to the second side wall.
54. The intensive use shelf of claim 46, herein the bottom further
comprises a sloping bottom shelf surface whereby the sloping bottom
shelf surface prevents fluid collection in the intensive use
shelf.
55. The intensive use shelf of claim 46, further comprising a
ligature resistant clothes hangar support in the bottom.
56. The intensive use shelf of claim 55, wherein the ligature
resistant clothes hangar support further comprises a J-bar
configuration.
57. The intensive use shelf of claim 56, wherein the J-bar
configuration comprises an upper indentation adapted to receive a
clothes hangar hook.
58. The intensive use shelf of claim 54, further comprising a
recessed pocket formed on the sloping bottom shelf surface, the
recessed pocket adapted to support a clothes hangar hook.
59. The intensive use shelf of claim 58, further comprising a
ligature resistant J-bar configuration wherein the recessed pocket
formed on the does not extend through the bottom.
60. The intensive use shelf of claim 46, further comprising a
contraband barrier on the back.
61. An intensive use shelf comprising: a molded hollow outer shell
having a top, a bottom, a back wall, a first side wall and a second
side wall, the top on the back wall, the bottom on the back wall
spaced from the top, the first side wall on the back wall
integrally molded to the top and bottom, the second side wall on
the back wall integrally molded to the top and bottom, the first
side wall spaced from the second side wall; and a ligature
resistant hangar support integrally molded on and extending from
the back wall.
62. The intensive use shelf of claim 61, further comprising a
ligature resistant top surface on the top.
63. The intensive use shelf of claim 61, further comprising a first
shelf on the back wall, the first shelf further comprising a shelf
top and a shelf bottom, the ligature resistant hangar support
integrally molded into the shelf top,
64. The intensive use shelf of claim 61, wherein the ligature
resistant hangar support further comprises a recessed pocket molded
in the hollow outer shell.
65. The intensive use shelf of claim 63, wherein the ligature
resistant hangar support further comprises a J-bar configuration on
the shelf top.
66. An intensive use shelf comprising: a rotationally molded hollow
outer shell having a top, a bottom, a back wall, a first side wall
and a second side wall, the top on the back wall, the bottom on the
back wall spaced from the top, the first side wall on the back wall
integrally molded to the top and bottom, the second side wall on
the back wall integrally molded to the top and bottom, the first
side wall spaced from the second side wall; a ligature resistant
top surface on the top, the ligature resistant top surface having a
sloping configuration; and a recessed pocket, the recessed pocket
comprising a concave opening, a ligature resistant hangar support
in the recessed pocket, the ligature resistant hangar support
having a J-bar configuration in the hollow outer shell whereby the
J-bar configuration has a closed indentation adapted to receive a
clothes hangar hook while resisting supporting a ligature.
Description
FIELD OF THE INVENTION
[0001] Present invention relates generally to intensive use
furniture for use in institutional settings such as prisons, jails,
detention centers and psychiatric facilities. And more particularly
to furniture for use by individuals where using a contraband barier
to secure the furniture components to each other, and to the floor
or wall, sealing close seams at the interface is important to
prevent urine and other liquids from penetrating into and under the
product and prevent concealment of contraband.
BACKGROUND OF THE INVENTION
[0002] Intensive use furniture is designed for use in demanding
environments. Facilities housing individuals for rehabilitation
from health or legal problems require furniture for safely
furnishing living quarters while being durable.
[0003] Intensive use furniture was formerly made of steel or wood.
In previous years, fiberglass construction was used to replace wood
and metal. Fiberglass offered a more appealing aesthetic than steel
or wood, and more resistant to damage by the user and damage by
bodily fluids. Wood furniture, for example is known to have
problems with bed bugs in these settings. Fluids can rot and damage
wood furniture resulting in weakness and creating odors. Fiberglass
however, had several limitations. Fiberglass cracked and splintered
if a direct force was applied. Manufacturing fiberglass furniture
was very slow and involved custom production.
[0004] Intensive use furniture for such facilities requires
durability and ease of cleaning. Furthermore, it is desired that
furniture used in such intensive use facilities prevent improper
use of that furniture by the user such as concealing items within
or underneath the furniture. Typically, an inmate in a correctional
or psychiatric facility may try to conceal drugs, weapons or other
contraband in the furniture. The structure of the furniture must
avoid all of these problems.
[0005] In addition, intensive use furniture is usually fixed to the
floor or walls. This fixture must be relatively simple, secure and
preferably sealing the seams between the furniture and the
adjoining surface. Preferably, the fixation method is provided with
a means for preventing tampering by the user of the furniture.
Securing the furniture to the floor or wall further reduces the
safety concerns on both the prisoners or patients and staff
resulting in a safer environment.
[0006] It is desirable to provide furniture for such facilities
having durability, aesthetically pleasing characteristics and
design for comfortable use. Therefore there is a need to provide an
intensive use furniture product without using assembly fasteners
and having more impact-resistance, less weight and with much
greater load-bearing capacity than fiberglass, wood or metal
construction furniture. The furniture must sealingly attach to a
mounting surface such as a wall or floor.
BRIEF SUMMARY OF THE INVENTION
[0007] One embodiment of the present invention is directed to a
line of furniture for use in demanding environments, comprising
components for use in individual's cell or room, as well as use in
common areas such as a bed, night stand, wardrobe, desk, footstool
and wall shelving units. The individual components are rotationally
molded using a flame retardant linear low-density polyethylene with
a hollow or honeycomb interior and may be filled with polyurethane
foam for increased durability and sound absorption. The components
comprise a shell having a mounting surface, the mounting surface
having an outer edge surrounding the shell. The mounting surface is
adapted for sealingly attaching to a structural element such as a
wall or floor. The shell is attached to the wall or floor by an
attachment means such as threaded fastener extending though a bolt
hole in the mounting surface wherein an insert of metal or hard
plastic may be inserted in the bolt hole for support. Generally
horizontal surfaces on shelves, wardrobes, and the like are formed
to gently slope downward away from a support wall to prevent the
user from placing items on top of the furniture and to resist
supporting a ligature or climbing on top of the furniture. The
mounting surface includes a contraband barrier for sealing seems
between the mounting surface of the shell and the wall, floor or
furniture component by a caulk channel formed around the entire
perimeter of the mounting surface to isolate the interior portion
of the mounting surface from fluids, contraband, weapons or other
materials and contraband at the outer edge. The caulk channel in
the mounting surface is adapted to receive a bead of caulk for
forming a fluid resistant barrier between the furniture and the
adjoining wall or floor surface. The bolt holes may be concealed by
covers affixed over the bolt holes by adhesive or the like forming
a smooth or recessed outer surface of the shell over the fasteners
protecting the structural attachment to the floor or wall.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0008] FIG. 1 is a perspective view of an first embodiment of an
intensive use bed
[0009] FIG. 2 is a perspective view of the underside of the
intensive use bed of FIG. 1.
[0010] FIG. 3 is a perspective view of an second embodiment of an
intensive use bed
[0011] FIG. 4 is a perspective view of the underside of the
intensive use bed of FIG. 3.
[0012] FIG. 5 is a front plan view of a first embodiment of a
fastener cover of FIG. 1.
[0013] FIG. 6 is a section view taken at 6-6 of FIG. 5 of the first
embodiment of a fastener cover.
[0014] FIG. 7 is a perspective view of the first embodiment of a
fastener cover of FIG. 5.
[0015] FIG. 8 is a front plan view of a second embodiment of a
fastener cover of FIG. 3.
[0016] FIG. 9 is a section view taken at 9-9 of FIG. 8 of the
second embodiment of a fastener cover.
[0017] FIG. 10 is a perspective view of the second embodiment of a
fastener cover of FIG. 8.
[0018] FIG. 11 is a front top perspective view of an intensive use
nightstand.
[0019] FIG. 12 is a front bottom perspective view of an intensive
use nightstand.
[0020] FIG. 13 is a section view taken at 13-13 of FIG. 11.
[0021] FIG. 14 is a section view taken at section 14 of FIG.
13.
[0022] FIG. 15 is a front plan view of an intensive use three shelf
wall shelf.
[0023] FIG. 16 is a section view taken at 16-16 of FIG. 15.
[0024] FIG. 17 is a perspective view of an intensive use desk.
[0025] FIG. 18 is a section view taken at 18-18 of FIG. 17.
[0026] FIG. 19 is a section view taken at 19 of FIG. 18.
[0027] FIG. 20 is a top perspective view of an intensive use
footstool.
[0028] FIG. 21 is a bottom perspective view of an intensive use
footstool.
[0029] FIG. 22 is a bottom plan view of the intensive use
footstool.
[0030] FIG. 23 is a section view taken at 23-23 of FIG. 22.
[0031] FIG. 24 is a section view taken at 24-24 of FIG. 22.
[0032] FIG. 25 is a bottom perspective view of an intensive use
Wardrobe.
[0033] FIG. 26 is a top perspective view of an intensive use
wardrobe.
[0034] FIG. 27 is a front elevation view of the intensive use
wardrobe of FIG. 25.
[0035] FIG. 28 is a section view taken at section 28-28 of FIG.
27.
[0036] FIG. 29 is a section view taken at 29-29 of FIG. 27.
[0037] FIG. 30 is a section view taken at 30-30 of FIG. 27.
[0038] FIG. 31 is a detail section view taken at section 31 of FIG.
30.
[0039] FIG. 32 is a detail section view taken at section 32 of FIG.
30.
[0040] FIG. 33 is a detail section view taken at section 33 of FIG.
29.
[0041] FIG. 34 is a top plan view of the intensive use wardrobe of
FIG. 26.
[0042] FIG. 35 is a bottom perspective view of an intensive use
table base.
[0043] FIG. 36 is a bottom perspective view of a second embodiment
of an intensive use table base
[0044] FIG. 37 is a top perspective view of a third embodiment of
an intensive use table base.
[0045] FIG. 38 is a top perspective view of a fourth embodiment of
an intensive use table base.
[0046] FIG. 39 is a bottom plan view of the second embodiment of an
intensive use table base of FIG. 36.
[0047] FIG. 40 is a perspective view of an intensive use table
having a tabletop attached to a table base.
[0048] FIG. 41 is a perspective view of a first embodiment of an
intensive use bookshelf.
[0049] FIG. 42 is a perspective view of a second embodiment of an
intensive use bookshelf.
DETAILED DESCRIPTION OF THE INVENTION
[0050] FIGS. 1 through 4 illustrate an intensive use furniture
component shown as a first and second embodiment of a bed 20.
Referring to a FIGS. 1 and 3, the bed 20 is rectangular having a
top surface 22, a pair of end side walls 24 and a front and rear
side walls 26. The bed 20 has an attachment means 27 formed in the
end, rear and front walls 24, 26. The attachment means may comprise
a plurality off fastener pockets 32 disposed in spaced relation on
the end surfaces and front and rear surfaces for receiving
fasteners (not shown) therein for extending through the shell to
attach the bed 20 to the floor F (FIG. 5). The top surface 22 has a
ridge 33 surrounding the support portion 35 forming a recessed
pocket on the top of the bed. The ridge and support surface form a
recessed pocket as a means for locating a mattress (not shown) as
well as containing the seepage of bodily or other undesirable
fluids within the ridge 33. Each of the surfaces may have a
contoured or smooth non-penetrable outer shell for resisting
penetration by fluids. A cover 25 may be placed over the fastener
pockets 32 to protect the fasteners from the user and to prevent
fluid from seeping into the pockets or contraband being placed in
the fastener pocket 32. Referring to FIGS. 2 and 4, the intensive
use bed 20 is shown in a bottom perspective view. The intensive use
bed 20 has a bottom surface 34 forming the mounting surface for
attaching the bed to a floor F (FIG. 5). The bottom surface is
formed comprising a plurality of openings 36 forming a honeycomb
structure 38 to improve strength and reduce the weight of the bed
20. A bottom plate 39 may be plastic welded or adhesively attached
over the bottom surface 34 to cover the openings 36 to increase
strength and to prevent contraband or fluid from residing in the
openings, for example if the bed is not attached to the floor. The
honeycomb structure 38 comprises a plurality of end support beams
40 extending between the end walls 24. The honeycomb structure 38
further comprises the plurality of edge support beams 42 extending
between the front walls 26 and the rear walls forming a plurality
of chambers 43 (FIG. 6) enclosed in the shell of the bed and open
recesses 36 opening to the bottom surface 34.
[0051] As illustrated in FIGS. 1 to 4, the outer walls 24, 26 may
have contoured ridges 37 formed in the surface to provide ridges
for support of the walls and improve the aesthetic appearance of
the bed. The fastener pockets 32 formed in the outer walls 24, 26
are generally scalloped shaped. A fastener hole 40 is formed in the
fastener pocket 32 to accommodate a fastener such as a bolt or the
like being inserted into the mounting location and attached to the
floor under the bed. The fastener pockets 32 of the bed also accept
tie down buckles 45 for use in psychiatric applications.
[0052] Referring to FIGS. 3 and 4, the bed 20 illustrated as a
second embodiment has a pair of storage openings 28 opening into
the front surface 26. The storage surface 26 has a gently sloped
storage cavity floor 27 to prevent fluid collection and ease spray
cleaning and drying.
[0053] Referring to FIGS. 5 and 8, the fastener pocket 32 is shown
having a contoured surface 45 extending to a bolt hole 40 formed
from through the mounting surface, shown as mounting flange 46. The
mounting flange 46 is formed in each of the fastener pockets 32
having a top side 39 in the fastener pocket 32 adjacent the
contoured surface and a bottom side 41 on the bottom surface 34.
The fastener hole 40 extends from the top side 39 to the bottom
side 41 and is adapted to receive a fastener such as a bolt
extending through the mounting flange for attachment to a structure
such as the floor F. A metallic or plastic insert 50 may be
inserted in fastener hole 44 to provide additional support for the
mounting flange 46 to prevent crushing the flange when the bolt is
tightened. As illustrated in FIG. 5, contoured cover 49a and in
FIG. 8, flat cover 49b are used to hide the bolt to prevent
tampering. The cover 49a, 49b is attached by plastic welding or
adhesive 51, forming a slightly recessed surface with respect to
the walls 24, 26.
[0054] Referring to FIGS. 6 and 7 the contoured cover 49a has a
shape for being received in fastener pocket 32 as shown in FIG.
5.
[0055] Referring to FIGS. 9 and 10, the contoured cover 49b has a
generally planar shape having a contoured outer edge to fit into
and cover the fastener pocket 32 as illustrated in FIG. 8.
[0056] Continuing to refer to FIGS. 5 and 8, foam 52 is injected
into the generally hollow chambers of the honeycomb structure of
the bed 20. A caulk channel or groove 54 is shown intermediate the
outer edge 56 of the bottom surface 34 and the fastener hole 40.
The caulk channel 54 extends around the entire perimeter of the
lower surface. The caulk channel 54 is preferably semicircular in
cross sectional shape and preferably has a radius of between 0.07
inches and 0.25 inches.
[0057] Referring to FIGS. 11-14, an alternate embodiment of an
intensive use furniture component is illustrated as an intensive
use nightstand 60. The intensive use nightstand 60 has a top
surface 62, a pair of side surfaces 64 and a front surface 68.
Front surface 68 is shown having two openings 70 for holding items
such as books. Or clothes. Nightstand 60 has rounded corners 72 and
a smooth outer surface on the top 62 and sides 64. The nightstand
60 may have a mounting surface on the base 78 and/or the back
surface 79. The nightstand is shown having a plurality of fastener
holes 76 formed in the base 78.
[0058] Referring to FIG. 13, a section view of the nightstand 60 is
illustrated showing two openings 70 and a generally horizontal
lower surface 80 and fastener holes 76 extending from the lower
opening 70 through the base 78. An insert may be molded into
fastener holes 76 to prevent crushing the base 78 when fasteners
are tightened.
[0059] Referring to FIG. 14, a caulk channel 77 is illustrated on
lower surface 81 of base 78 and the back surface 79. Caulk channel
77 extends around the entire perimeter of base 78 and spaced from
the outer edge of the base 78, to sealingly attach the nightstand
to the floor in conjunction with fasteners (not shown) extending
through fastener holes 76. The caulk channel 77 is preferably
formed intermediate the fastener holes 76 and the outside perimeter
of the base 78. Alternately, the nightstand may be adapted having a
mounting surface on the back surface 79 for attachment to a wall W.
Referring to FIG. 14, a detailed view taken from view 14 of FIG. 6
is illustrated showing a caulk channel 82 on the vertical rear
surface 79. The caulk channel 82 extends around the entire
perimeter of the vertical rear surface 79 for sealingly attaching
the nightstand 62 adjacent wall W. The nightstand 60 has gently
sloped storage cavities 73 to prevent fluid collection and ease
spray cleaning and drying.
[0060] Referring to FIGS. 15 and 16, a third embodiment of an
intensive use furniture component is illustrated as a wall shelf
90. Wall shelf 90 is illustrated as a three-shelf 92 wall shelf,
however additional configurations may also be manufactured having
more or fewer shelves 92. The wall shelf 90 as a top 94, a bottom
96 and two sides 98. Each shelf 92 extends between the two sides 98
and is defined by the opening between adjacent shelves. The wall
shelf 90 is preferably formed by rotational molding forming a
hollow outer core 97 that is filled with structural foam 100. A
mounting flange 99 is formed around the perimeter of the wall shelf
90 having a plurality of spaced fastener holes 95 for accepting
threaded fasteners to attach wall shelf 90 to a wall.
[0061] Referring to FIG. 16, a section view of the wall shelf of
FIG. 8 is illustrated having shelves 92 defining openings 106. The
wall shelf 90 of FIGS. 15 and 16 is generally mounted vertically
having a longer vertical length and shorter horizontal width. Top
94 and bottom 96 are formed having non-horizontal surfaces to
prevent items from being placed on top of the wall shelf 90 or to
resist climbing thereon by the users. A flat rear surface 108 forms
a mounting surface adapted to mount against a wall W by fasteners
extending through the fastener holes 94. The shelves 92 are gently
sloped and form storage cavities to prevent fluid collection and
ease spray cleaning and drying.
[0062] A caulk channel 110 is formed on the mounting flange 99 for
accepting a bead of caulk (not shown) to sealingly attach the wall
shelf to the wall W and eliminate any gaps between the wall shelf
and the wall.
[0063] Referring to FIGS. 17-19 an additional embodiment of an
intensive use furniture component is shown as a desk 120. The desk
120 has an upper surface 122 having rounded corners and a pair of
support legs 124 and a rear support panel 126. The support legs
have a mounting surface 121 on the bottom for attaching to the
floor F, the mounting surface having a perimeter surrounding bolt
holes 125. A plurality of fastener openings 128 are shown formed in
the lower portion of the support legs 124 having the bolt holes
extending through the mounting surface to the floor with the head
of the bolt adapted to be recessed in the fastener opening 128. As
illustrated in FIGS. 18 and 19, the desk 120 may be rotationally
molded forming a hollow shell having a core 130 which may be filled
with foam 132 such as polyurethane. The upper surface 122 comprises
a separately manufactured hard writing surface constructed from one
of a high pressure laminate, thermo laminate, wood, plastic sheet
or other planar material which may be separately manufactured and
attached to the support legs 124. It is anticipated the support
legs may further comprise a caulk groove on the top mounting
surface 123 attached to the upper surface 122 to provide a
contraband barrier between the legs and the writing surface. The
writing surface may also be integrally molded with the legs
124.
[0064] Referring to FIGS. 17 and 18, the fastener openings 128 are
generally scallop shaped openings in the support legs 124. The
fastener openings 128 provide a recessed mounting for fasteners
extending through fastener hole 134. Referring to FIG. 12, the
support legs 124 are preferably formed by a molding process to
create a hollow shell 130 which may be filled with the structural
foam 132. A caulk channel 138 is formed on the lower surface 140 on
each support leg on 24. The caulk channel extends around the
perimeter of the floor surface 140 of the support leg. The caulk
channel is adapted to receive the bead of caulk for sealing and
attaching the desk 120 to the floor. As discussed with respect to
the bed 20 above, the fastener openings may be closed with covers
to conceal the bolts B (FIG. 6).
[0065] Referring to FIGS. 20-24, an alternative embodiment of an
intensive use furniture component is shown as a footstool 150. The
footstool 150 has a mounting flange 152 surrounding a foot support
154 having a top surface 156. Footstool 150 is secured to a floor
surface 158 by fasteners 159 extending through each of a plurality
of fastener holes 156 formed in the base. A foam fill hole 157 is
formed in the bottom 155 to provide access for blowing in or
inserting foam in the footstool hollow shell.
[0066] As illustrated in FIG. 20, the footstool 150 has a bottom
158 and a hollow interior cavity 160. The footstool 150 may be
formed by rotational molding or similar process to form a
substantially hollow shell 164 that may be filled with foam 166
(FIG. 15) for support and sound deadening. A central cavity 162
extending from the bottom 158 reduces the amount of material used
for forming the footstool 150. Bottom 158 may also comprise a
plurality of support ridges 172 adding structural integrity to the
mounting flange on 52. The support ridges 172 extend from the
central cavity 162 to a position adjacent caulk channel 174.
Fastener holes 156 are formed in a circumferential position with
respect to the bottom 158. Caulk channel 174 is formed in the
bottom 158 intermediate the fastener holes 158 and the outer
perimeter 176.
[0067] Referring to FIGS. 23 and 24, foam 166 is used to support
the hollow shell 164. The caulk channel 174 is disposed on the
bottom 158 adjacent the outer perimeter 176 for receiving a bead of
caulk 178 for sealingly attaching the footstool 152 to a floor
surface F. The support ridges 172 are molded into the bottom 158 to
provide structural support for the base.
[0068] Referring to FIGS. 25 to 34, an alternate embodiment of an
intensive use furniture component is illustrated as a wardrobe 190
comprising cabinet 191 having a top 192, sides 194, a base 196, a
back panel 197 and an optional, at least one door 198 attached to
the cabinet 191. The wardrobe 190 is adapted for mounting to a
floor surface or an adjacent wall surface of both. The wardrobe 190
has a plurality of fastener openings 200 formed on the top 192 for
receiving fasteners to attach to an adjacent wall W. An integrally
molded sloped top surface 193 is used to prevent storage and
concealment of contraband and further resist climbing. The sloped
surfaced could be a separate piece and attached during
manufacturing or installation by fasteners or adhesive as is well
known n the art of fastening plastic components together.
[0069] The hinged door illustrated in FIG. 25, preferably uses a
piano style hinge 202 to create the strongest and most secure
attachment to the wardrobe 190 as illustrated in FIGS. 25, 26 and
28-33. The door may also be reversible as a left or right hinge
depending on the installation requirements. A tambour door option
may also be considered unique in the field. The door can be molded
the same as the other components in the product line or may be
different such as HPL (high pressure laminate) laminate,
thermoformed laminate, MDF or wood. The door is positioned to allow
for complete 270 degree opening around the piano hinge as necessary
to prevent overstressing the hinges as shown in FIG. 34. Metal
inserts 204 (FIGS. 25, 26 and 28) are used throughout the product
to attach the hinges to increase attachment strength and security.
A locking means 206 may be included through integrated or separate
latch features.
[0070] Referring to FIGS. 26 and 28, the clothes hanging feature
210 is molded as an integral J-bar 212 feature to prevent a
traditional bar being used as a ligature support. The geometry of
the J-bar 212 is preferred to be integrated into the part, but may
be a separate piece fastened into the cabinet 191. A removable
piece could be used as a weapon in these intended environments. The
cabinet 191 has recessed pockets 214 at the upper portion having
internal j-bar 212 on the lower front surface for securely
supporting the hook of a standard clothes hangar. The upper portion
of the wardrobe 190 is filled to resist hiding contraband or other
material above the j-bar 212. A hangar recess 216 is formed between
the j-bar 212 and the back 218 of the cabinet 191 to accommodate
the hangar. Fastener holes 220 are formed in the back 218 and
extend through the back panel 197 which is adapted to be a mounting
surface for attachment to a wall W. Fasteners 224 are extending
from inside the cabinet through the back panel to the wall W.
Additional fasteners 224 are disposed in fastener pockets 226 on
the top of the cabinet 191 as illustrated in FIG. 34. As discussed
above, covers may be used to conceal the fasteners and close the
fastener pockets 226. A lower shelf 230 is formed in the cabinet
191 forming a storage opening 228 between the shelf 230 and the
base 196.
[0071] Referring to FIGS. 35-40 an intensive use table 240 is
illustrated. The table 240 has a base 242a-d having a vertical wall
243 having an outer surface 244, a floor end 246 and a table top
end 248. The tabletop end 248 comprises a mounting surface for
attachment to a tabletop 250 (FIG. 20). The mounting surface may
have a caulk groove 251 formed therein for acting as a contraband
barrier 252. The table base 242a-d may have a contoured outer
surface defined by ridges 260 for additional support. The ridges
may be linear, parallel, curved or otherwise formed to provide
structural support for the As illustrated in FIGS. 37 and 38, the
top of the base has a hollow cavity 262 that may be filed with sand
during installation. The tabletop 250 is attached by fasteners
extending through the base 242 at bolt holes 263 and attaching to
the underside 264 of the top 250. The top may be formed as the
writing surface of the desk 120 described above.
[0072] Referring to FIGS. 49 and 50, an alternate embodiment of an
intensive use furniture component is shown as a book shelf 270.
Referring to FIG. 49, the bookshelf 272 has a base 273 adapted to
support a pair of vertical ends 272 and a support leg 274.
Bookshelf 270 may be formed with more or fewer legs 274 depending
on its intended use and the size of the shelf 276. Ends 272 and
support leg 274 are formed with rounded corners 278 to prevent
supporting clothes being hung thereon, a ligature or the like. The
shelf 276 is formed with a gently sloping surface angle to allow
liquids to run off and facilitate cleaning. Bolt holes 280 are
formed in the base 273 to attach the book shelf to the wall W. A
caulk bead is formed on the base at the back opposite the shelf 276
as a contraband barrier sealing between the wall W and the
base.
[0073] Referring to FIG. 50, the bookshelf 290 has upper support
legs 292 supporting shelf 276 on base 273. Fastener pockets 294 are
formed at the junction of the shelf 276 and base 273. Bolt holes
280 are formed through the base and disposed in the fastener
pockets 294. The fastener pockets 294 are adjacent the outer edge
of the base 273 facilitating closure of the fastener pocket with a
cover as described above regarding the intensive use bed 20.
[0074] Referring generally to FIGS. 1 to 17, the intensive use
furniture products are preferably rotationally molded in flame
retardant, plastic resin with a hollow interior. In the preferred
embodiment, the plastic resin may be High Density Polyethylene
(HDPE) or Linear Low Density Polyethylene (LLDPE). The resin may
contain additives such as flame-retardants to meet government
standards. As a means to increase product strength and durability,
a secondary material is used to fill the hollow cavities left
during the molding process. Molding plastic could be done by
rotational, blow, injection, thermo forming or compression molding
where one or more pieces may be used to create the hollow
cavity.
[0075] The secondary material filling the cavities of the molded
products may be structural polyurethane foam selected for increased
durability and sound absorption. The filler may be injected under
pressure and may consist of urethane foam or other material that
can conform to the irregular cavities created during the molding
process. The filled, rotationally molded products are significantly
more impact-resistant, with much greater load-bearing capacity,
than the fiberglass predecessors. Because the products are produced
from molds, the production capacity increases allow more efficient
manufacturing and a product that is less expensive to ship and
install.
[0076] A fire retardant additive is added to the linear low-density
polyethylene and molded into the intensive use furniture products
to meet fire rating standards such as the State of California,
Technical Bulletin No. 133, Flammability Test Procedure for Seating
Furniture for Use in High-Risk and Public Environments.
[0077] In the molding process, nylon may be added to the plastic
mix for molding the forming the substantially hollow shell to
reduce de-lamination between the polyethylene walls and
polyurethane foam filler.
[0078] Due to the intensive-use nature of the products, the
individual components preferably include a means of securely
fastening the product to a floor, wall or other desired mounting
surface. In the preferred embodiment, the components are typically
bolted to a structurally sound mounting surface such as a floor
(bed, nightstand, stool) or a wall (Wardrobe, wall shelf, wall
storage units) through molded-in bolt hole locations. Additionally
each mounting position may be reinforced with metal inserts
disposed in the bolt holes by insertion during the molding process
or during finishing operations, to prevent crushing of the plastic
surrounding the bolt holes or on a mounting flange.
[0079] To facilitate a tighter fit to the floor and eliminate gaps,
each product features a semicircular shaped, hidden caulk channel
on the underside of the unit, along the outer edge and preferably
around the entire mounting surface forming a closed circuit of
caulk adjacent the perimeter of the mounting surface. The caulk
channel has a diameter profile to accommodate a standard bead of
sealant such as caulk to seal any seams between the intensive use
furniture and the mounting surface, the size of which may vary with
the particular components. This allows the end-user to seal the
floor and back edges of wall or floor mounted products to prevent
concealment of contraband, prevent fluids from penetrating the
surface mounting areas and facilitate cleaning of the component and
surrounding areas.
[0080] The present invention has been shown and described with
reference to the foregoing exemplary embodiments. It is to be
understood, however, that other forms, details, and embodiments may
be made without departing from the spirit and scope of the
invention which is defined in the following claims.
* * * * *