Method for producing objects, volumes, furniture modules and furniture, and articles produced by said method

[0001] This application is a divisional of prior filed copending application application Ser. No. 10/451,973, filed Jun. 30, 2003, currently pending, which is incorporated herein in its entirety and which claims the benefit of priority of International Application PCT/DE01/04865, which in turn claims the benefit of priority of German Patent Application Serial No. 101 01 120.2, filed Jan. 5, 2001 and German patent Application Serial No. 101 64 559.7 filed Dec. 14, 2001, pursuant to 35 U.S.C. 119(a)-(d), the subject matter of which is incorporated herein by reference.

[0002] The invention relates to a method for producing objects, volumes, furniture modules and furniture that are composed of individual elements, such as walls, panels, struts, support beams, legs, or the like.

[0003] The invention also relates to objects for interior and exterior design, such as objects, volumes and furniture modules, especially office furniture, consisting of individual elements.

[0004] There are well-known methods for the manufacture of furniture and furniture elements whose initial basis is a flat material. These methods use single-layered material whose plastic and elastic qualities are the same throughout the cross-section of the material. This single-layered material is then cut and folded, so that the individual parts, such as table plates, table legs or table beams, form furniture modules.

[0005] For example, GB 1 196 445 describes a table construction built from a flat material using the method described above. But this construction requires the insertion of a common wall between the furniture elements in order to achieve the requisite stability for the construction. GB 1 205 275 describes a method for furniture manufacture using cardboard or another plastic material which is combined to form closed modules. In these well-known furniture modules, the requisite stability is achieved through a common wall between two furniture elements standing next to each other.

[0006] Other known furniture designs are described in EP 0 221 342 A1 and DE 3 906 936 A1, which also do not have sufficient rigidity and stability.

[0007] With this prior art, the aim of the invention is to provide a method and articled produced according to said method that allow to provide objects, volumes, furniture modules and furniture that are highly stable and yet have a low weight, require a minimum of material and have a characteristic design.

[0008] This aim is realized through a method of the type specified above and by items of the specified type with the features including objects, volumic elements, modules and furniture made from modules composed of individual structural elements that are made from a flat composite material of uniform thickness having a plurality of layers from which a blank for the structural element is cut and desired fold lines are applied to the blank including angular end portions for forming an angled connecting site into which the fold lines are cut, wherein the blank is folded along the cut-in fold lines, thereby realizing outer edges that are joined such that they a closed folded thin-walled shell of a structural element having weight bearing capacity, and wherein two or more structural elements are connected via a fixing nodal element at the angled connecting site for joining two or more structural elements via the fixing nodal element.

[0009] Each individual element is cut from a flat material which has uniform thickness and has a plurality of layers. The layers of the material are selected so that the outer layers and the inner layer have different plastic qualities, stability and malleability. While the individual elements are being cut out, the multi-layered flat material is slit along the fold lines, creating inner and outer edges to fold the unwound section, forming a folded, thin-walled shell for the furniture element after the outer edges are stuck together. The furniture elements produced in this manner are connected by a fixing element, which is a nodal element so that the individual elements, which are cut at a specific angle, can be mounted and stuck to the three solid sections of the fixing element and the outer edges meet at a single point.

[0010] A furniture element results which is shaped as a folded, thin-walled shell and is composed of one leg and two support beams. The fixing element is composed of three solid sections, which are positioned at a 90 degree angle to one another and have a common peak, so that each of the solid sections has a cross-section which corresponds with the outlines of the element it connects, which is shaped to a folded, thin-walled shell. The fixing element has legs angularly oriented for inserting into the corresponding shell of the structural element such that the angled sites of each element are joined to form a single point and the inserted fixing nodal element is thus no longer visible.

[0011] The furniture module, which is formed as a folded, thin-walled shell, and the furniture manufactured using this method are comprised of a multi-layered flat material, such as aluminum outer layers, with a middle layer of a hard material, such as plywood. The individual furniture elements can have a triangular, rectangular or polygonal cross-section.

[0012] This method enables the manufacture of tables, chairs and cabinets, with or without doors, which can be used from either side. The table consists of a furniture module, shaped to a folded, thin-walled shell (table frame with legs), with a table plate on top, supported by elements placed in the four corners of the table frame, creating a distance between the table plate and the supporting table frame.

[0013] The chair consists of a furniture module formed as a folded, thin-walled shell, on which an arm- and backrest is placed, which lies on two elements fastened in the rear corners of the module, creating a distance between it and the supporting module. Four x-shaped consoles formed as a folded, thin-walled shell are mounted on the legs of the chair at ⅔ ground level, which serve as supports for the seat.

[0014] The cabinet without doors consists of elements formed as folded, thin-walled shells and combined into a supporting furniture module, so that two u-shaped furniture elements rest on this furniture module which are also manufactured using this method and are joined together on the inner vertical walls, e.g. with glue. The outer edges of the two u-shaped elements are also formed as folded, thin-walled shells and a plate is mounted on the open end facing upwards. The back side of the cabinet is closed. The space between the plate, the rear element and the horizontal wall is divided into four sections by vertical elements.

[0015] The cabinet, which is accessible from both sides, is composed of individual elements manufactured as folded, thin-walled shells according to the said method. A u-shaped element is fastened onto the supporting furniture module, so that a plate can be positioned on the vertical walls. The space between the plate and the horizontal wall can be closed by two elements moving vertically. When one element is up, the other is down. Thus, the opposite sides of the cabinet are closed above and below.

[0016] Objects, volumes, furniture modules and furniture manufactured according to the said method are characterized, above all, by their lightness and stability, since the supporting structure is a closed, folded, thin-walled shell and the individual elements are stuck together with a solid connection. The sparing use of materials, the simple production method, the potential for altering the thickness of the individual layers of the composite material depending on the necessary spread and the customization of the flat composite material as required are of particular advantage. In addition, the folded, thin-walled shell is characterized by its characteristic design, making objects volumes, furniture modules or furniture manufactured according to the said method unmistakable.

[0017] Another substantial advantage of this method is that by combining multiple materials with differing characteristics, qualities arise in the objects, volumes, furniture elements and furniture which are far superior to the qualities of the individual materials.

[0018] For example, the outer layers can be made of metal, plastic, paper, textiles, fiber or leather, depending on interior or exterior design requirements, while remaining within the framework of the invention.

[0019] Further advantages and details can be found in the description below, referring to the attached drawings.

[0050] In FIGS. 1 through 6, the method is explained in greater detail on the example of the manufacture of a furniture module. The basic element in the furniture module, which was selected by way of example, is a folded, thin-walled shell which is combined into nodal points.

[0051] FIG. 1 depicts the composition of such a nodal point from a table leg (1), a beam assigned to the long side of the table (2) and a beam assigned to the short side of the table (3), which are connected by a solid fixing nodal element (4). In FIGS. 1, 2 and 4 the cross-section of beams 2 and 3 is recognizable. The cross-section surfaces are at a specified angle to each other. The cross-sections have triangular outlines. The solid fixing nodal element (4), with its branches positioned in axes x, y and z, attached at a 90.degree. angle, and having a common peak, is introduced into the beams (2 and 3) and table leg 1, which are shaped to folded, thin-walled shells. The elements are cut out in such a manner that the outer edges can be combined into a single point at the peak of the solid section. All sections of the nodal point are then stuck together. Preferably, a polyurethane glue is used as an adhesive. The table leg (1) ends with a foot (5).

[0052] In FIGS. 3 and 5, the characteristic design is recognizable in the form of the triangular profile of table leg 1 and beams 2 and 3. Table leg 1 is an equilateral triangle changing with the height and all three sides of beams 2 and 3 have equal length. These elements are connected. The edge at the peak of the equilateral triangle of table leg 1 is positioned vertically. The edges at the base of the triangle are positioned at a certain angle to the vertical elements.

[0053] FIG. 6 shows the development of table leg 1 with fold lines (K) and outer edges (L), as well as the outline of the element, the folding process (M), and a view of a folded leg element (N).

[0054] Under this method, each furniture element is produced in a specific sequence of processes: the multi-layered, e.g. three-layered flat material of uniform thickness is cut out based on a specified model, while the material is slit in order to define the trim lines (outer edges) (L) and the fold lines (K), the flat material is folded along the slits, creating inner and outer edges, and the outer edges (L) are stuck together, forming a closed, folded, thin-walled shell which is to be used as a furniture element. The furniture elements produced in this manner are then attached to elements produced in the same manner. The furniture elements produced according to the said method can have different profiles depending on their use, e.g. the horizontal elements have the same cross-section as an equilateral triangle throughout their length, while the cross-section of the vertical elements (the table legs) changes depending on their height. The horizontal elements are used as support beams and the vertical elements as furniture legs.

[0055] Under the invention, the profile can also be any other polygonal shape. The individual furniture elements are connected by a fixing element. The sections, which are cut at a specified angle, are connected by mounting the three elements, which are formed as folded, thin-walled shells, on the three solid sections of the fixing element so that the outer edges meet at a single point and all sections are stuck together. In this sequence, the furniture elements, which are shaped to folded, thin-walled shells, are created and combined with a fixing element, e.g. two horizontal beams and a vertical leg, to form a furniture module.

[0056] FIGS. 7 through 9 depict a table manufactured according to the said method. The four table legs (1) and the four table beams (2 and 3) are shaped to a folded, thin-walled shell and connected by the solid fixing nodal element (4). The table plate (7) is positioned on four buffers 6, i.e. each positioned in a corner of the table, which guarantees a distance between the table plate (7) and the table beams (2 and 3).

[0057] The table produced according to the said method can serve as a conference table, a work table or a side table, depending on the need.

[0058] FIGS. 10 through 12 depict a chair manufactured according to the said method. The four legs (1.1), a beam (2.1), and two beams (3.1) on both sides, which are connected by the fixing nodal elements (4), which are composed of a folded, thin-walled shell. The support structure of the chair has four nodal points. Solid fixing elements (4) are used in each nodal point.

[0059] The back- and armrest section (8) is fastened to the rear by two buffers. On the four legs (1), at a distance of about ⅔ from the bottom of the legs, an x-shaped construction is mounted consisting of four thin-walled, folded consoles (9), on which the seat (10) is fastened.

[0060] FIGS. 13 through 15 depict a cabinet without doors which is produced using the said method. The cabinet has four legs (1.2) and a frame consisting of two beams (2.2) and two beams (3.2). The legs and beams are shaped to folded, thin-walled shells, serving as a support construction. Two u-shaped furniture elements (11) are mounted on this construction. They have edges (13), which are also shaped to folded, thin-walled shells. A common plate (12) is positioned on the two u-shaped elements (11) which are stuck together. The rear of the cabinet has a back element (15). The space between the plate (12), the back element (15) and the horizontal wall is divided into four sections by vertical elements (14). The furniture element (11) has edges which are formed accordingly (13).

[0061] FIGS. 16 through 18 depict a cabinet accessible from both sides which produced according to the said method. A u-shaped element (20) is mounted on the support structure consisting of four legs (1.3) and a frame consisting of two beams (2.3) and two beams (3.3). On this element, (20) a plate (16) is positioned. The space between the plate (16) and the horizontal wall of element 20 is divided into two sections by a horizontally-positioned element (17). The vertical sliding doors (18 and 19) are connected by a rope structure (not shown). By moving the sliding door (18) upwards, the other sliding door (19) moves downwards. The furniture element (20) also has the characteristic edges, which are formed as folded, thin-walled shells (21).

[0062] FIG. 19 shows the flat material after it has been cut and before the folds are made to produce the hollow structural element. FIG. 20 is a flow chart in which the materials and the possibilities for use of the materials are shown.

[0063] While the invention has been illustrated and described as embodied in a piece of furniture, it is not intended to be limited to the details shown since various modifications and structural changes may be made without departing in any way from the spirit of the present invention. The embodiments were chosen and described in order to best explain the principles of the invention and practical application to thereby enable a person skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated.