Plastic and plywood laminate table with drop corner

A light-weight, folding table has a plurality of folding legs coupled to a table top. The table top includes a laminate with a plastic sheet bonded to a plywood layer. A perimeter edge channel encloses a perimeter edge of the laminate along the sides without enclosing corners of the laminate. Corner caps cover the corners of the laminate. The corner caps overlap ends of the edge channel at the corner.

BACKGROUND

1. Field of the Invention

The present invention relates generally to light-weight, foldable tables.

2. Related Art

Folding tables are often used in applications where numerous tables are intermittently required. Therefore, such folding tables are provided with legs that fold towards the table top to provide a compact volume for storage. In addition, it is desirable that such tables have a reduced weight to facilitate handling and transportation. It is also desirable, however, that such tables remain robust, and provide a solid, flat working surface. To this extent, tables have been proposed that have a wood frame disposed between upper and lower shells of plastic; and which the upper plastic shell is laminated to an inner plywood sheet. For example, see U.S. Pat. No. 5,271,338 and U.S. Pat. No. 5,311,825. Some tables have been proposed with corner pieces. For example, see U.S. Pat. Nos. 3,219,401; 5,173,348 and 5,947,037.

SUMMARY OF THE INVENTION

It has been recognized that it would be advantageous to develop a folding table with a robust working surface and damage resistant and/or replaceable corners.

The invention provides a light-weight, folding table with a plurality of folding legs coupled to a table top and pivotal between an extended position maintaining the table top in an elevated position, and a collapsed position towards the table top. The table top includes a laminate with a plastic sheet bonded to a plywood layer. The plastic sheet defines an upper working surface of the table top. A perimeter edge channel encloses a perimeter edge of the laminate along the sides without enclosing corners of the laminate. Corner caps cover the corners of the laminate. The corner caps overlap ends of the edge channel at the corner.

The invention also provides a light-weight, folding table with a plurality of folding legs coupled to a table top and pivotal between an extended position maintaining the table top in an elevated position, and a collapsed position towards the table top. The table top includes a laminate with a plastic sheet bonded to a plywood layer. The plastic sheet defines an upper working surface of the table top. The plywood layer has a bottom surface with at least a majority exposed. At least one runner is coupled under the table top and directly to the bottom surface of the plywood layer. The runner includes a channel with an open side of the channel coupled to the table top.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENT(S)

As illustrated inFIGS. 1a-3b, a light-weight, folding table device, indicated generally at10, in an example implementation in accordance with the invention is shown. The table can be configured as a conference table, as discussed more fully below, that can be folded and stored and moved about as needed. Several such tables can be placed end to end to form a row; and several rows can be provided. The table can be long and narrow, or wide and shallow, to accommodate configurations with many rows. In addition, the table can provide a hard flat working surface, while remaining light-weight for portability. Furthermore, the table can have impact resistant corners or corners that absorb impact or corners that can be replaced to avoid damage that from such impacts that might occur during folding, unfolding, stacking and/or moving or arranging the table.

The table10includes a table top14with a plurality of folding legs or leg assemblies18coupled to the table top and pivotal between an extended position and a collapsed position. In the extended position, the legs maintain the table top in an elevated position (as shown). In the collapsed position the legs pivot towards the table top. Thus, the legs or leg assemblies can be pivotally coupled to the table top. As described above, several such tables can be configured as desired in the open position with the leg assemblies unfolded and the table top elevated. Such tables can be stacked for storage and/or transportation with the leg assemblies folded towards or against the table top. The tables can be stacked one on top of another with the tables in a horizontal orientation and the stack in a vertical configuration. Alternatively, the tables can be stacked laterally adjacent one another with the tables in a vertical orientation and the stack in a horizontal configuration.

The table top14includes a laminate22with an upper layer of plastic sheet26, such as an ascrylonitrile butadiene styrene (ABS) plastic sheet, bonded to a lower layer or plywood layer30of plywood. The plastic sheet can have a thickness of approximately 0.050 inches and the plywood layer can have a thickness of approximately ⅝ inches. The plastic sheet26has an upper exposed surface defining an upper working surface34of the table top. The plywood layer30can have a bottom surface38with at least a majority exposed, or that is substantially exposed, without being covered by a bottom shell or plastic layer. Leaving a bottom of the laminate exposed can reduce the cost of the table and facilitate fabrication. The plastic sheet and plywood layer can share a common perimeter and have essentially the same planar surface area. The laminate, and the table, can be rectilinear, i.e. can have a square or rectangular shape with straight edges or sides meeting at corners. In addition, the laminate and table can have other polygon shapes with straight sides which meet at corners. The corners can have a slight curvature, or can be rounded, so that they are not sharp.

The opposite sides of the table or laminate can be longer than the opposite ends to form a rectangular shaped table top with the long sides designated as sides and the short sides designated as ends for convenience. It will be appreciated that all sides of the table can be of equal length to form a square shaped table (which is intended to be described by the term rectangular as well). The opposite sides can also designate front and back sides, as described in greater detail below. In the case of a conference table that is relatively long and shallow, tables can be configured end to end to form a longer row with users seated at the front side.

A perimeter edge channel42, such as a J-channel or J-shaped channel, or C-channel or C-shaped channel, can be disposed along the edges or sides of the laminate. The channel can be straight to match straight edges of the laminate, or rolled to match curved edges of the laminate, as discussed in greater detail below. The edge channel42can enclose a perimeter edge of the laminate along the sides, but without enclosing corners of the laminate. Thus, several perimeter edge channels can have lengths shorter than the corresponding or respective side of the table or edge of the laminate so that the corners of the laminate are exposed with respect to the edge channel. The edge channel42can have distal ends that terminate short of the corners. Leaving the corners exposed with respect to the edge channel facilitates manufacture of the table by eliminating the precision required for cutting and attaching the edge channel. In addition, it is not necessary to form a corner in the edge channel.

The edge channel42can have a bottom flange50and a top flange54(FIG. 2e). The bottom flange can be longer than the top flange. Thus, the bottom flange50extends into the laminate a greater distance than the top flange; and the top flange leaves a greater surface area of the top working surface exposed. The distal edges of the flanges can be tapered towards the laminate to eliminate sharp edges. A bur can be formed on the proximate edge of the bottom flange to create a drip edge. The edge channel can be formed of aluminum by extrusion. Alternatively, the edge channel can be formed of plastic.

The outermost perimeter of the laminate or plywood layer can be interrupted only at corner voids58(FIGS. 2hand2i) that are cut-out or chamfered in each corner. The corner voids can extend into the plywood sheet and/or plastic sheet. The corner voids can be formed by cutting the corner voids out of the plywood layer and/or plastic sheet, such as by cutting or stamping.

Corner caps62are removably disposed on and cover the corners of the laminate. In addition, the corner caps62overlapping the distal ends of the edge channel42at the corner. Each corner cap has opposite channels66(FIGS. 3aand3b) (or a pair or orthogonal channels in the case of a rectangular or square table) receiving the opposite adjacent edges of the laminate and opposite ends of adjacent edge channel. Each channel66of the corner cap can have a bottom flange70longer than a top flange74of the corner cap (FIGS. 3aand3b). In addition, each corner cap can have a bottom web78and a top web82each extending between opposite sides.

The opposite channels66of the corner caps62can have a notch or enlarged cavity86(FIGS. 3aand3b) to receive the opposite ends of adjacent edge channels. Thus, an interior of the corner caps can abut to the top and bottom of the laminate, top and bottom of the edge channels, the perimeter side of the laminate, and the perimeter side of the channel, to provide a snug fit. The cross-section (perpendicular to a longitudinal axis of the edge channel) at the notch or enlarged cavity86provides an enlarged recess with a reduced opening to enclose the distal ends of the edge channel. The opposite channels66or flanges70and74can have lower and upper lips90and94disposed on the respective bottom and top flanges70and74of the corner caps, defining the reduced opening. The upper lip94can extend over a distal edge of the top flange74, and can abut to the upper surface34of the plastic sheet26. The lower lip90can extend over a distal edge of the bottom flange70, and can abut to the bottom surface38of the plywood layer30. Similarly, the lips can extend along the top and bottom webs. Thus, the corner caps provide a finished edge along the surfaces of the table.

The corner caps62can be formed of a plastic material that can be flexible to protect the corner of the laminate and the table. The corner caps can snap fit over the edge channel. In addition, one or more mechanical fasteners, such as screws, can extend through a bottom of the corner caps and into the plywood layer. Alternatively, the corner caps can be sacrificial to break upon impact. The corner caps can be removable to allow for replacement of damaged or marred caps.

A lateral gap or space100can be formed between a lateral corner edge of the laminate and an inner lateral side of the corner cap62. The corner cap can be deflectable into the lateral gap or space under impact. In addition, top and bottom gaps or spaces104and106can be formed between the top web80and the upper working surface30and the bottom web76and the bottom surface34of the plywood layer, respectively. Again, the corner cap can be deflectable into the top and bottom gaps or spaces under impact.

One or more runners120can be coupled under the table top14to provide stability and support to the laminate, and help maintain the strength and flatness of the upper working surface. The runner can include a channel with an open side of the channel coupled to the table top. Lateral flanges124can extend from the channel through which mechanical fasteners, can extend, such as screws, or chemical fasteners, such as adhesive, to attach the channel to the plywood layer. The runners120can be coupled directly to the bottom surface38of the plywood layer30; thus facilitating manufacture. The runners can be formed of aluminum and can be fabricated by extrusion. A pair of runners can be disposed along the long ends of the table and can extend substantially the entire length of the table.

Runner caps140can be coupled to open opposite ends of the runner120. The runner140can include an insert portion disposed in the channel of the runner, and an enlarged portion that covers distal edges of the runner. Covering the distal edges of the runner protects adjacent tables or the working surfaces thereof when stacked together. The enlarged portion can include wings that match the lateral flanges of the runners. In addition, a bumper160(FIG. 2j) can be coupled to the runner cap140, and can extend beyond the runner to abut to an adjacent stacked table.

The leg assemblies18can further include one or more legs170attached to a pivot174coupled to the bottom surface38of the plywood layer30. A foot178can be disposed on the opposite end of the legs, opposite the pivot. Such a foot can have a similar width to that of the table top to resist tipping. A linkage182, as known in the art, can be coupled between the plywood layer30and the legs170. The linkage can include two pivotal links and a locking member that can removably cover the pivot between the links to selectively maintain the legs in the open position.

As stated above, the table10can be configured as a conference table, i.e. can be long and narrow or shallow to accommodate numerous rows. In addition, the legs170or leg assemblies18can be off-center with respect to a longitudinal axis of the table. Such a configuration positions the legs170and linkage nearer a back of the table top, providing more leg room at the front of the table top and resisting user's kicking their knees into the legs or linkages.

A method for fabricating a table as described above includes bonding an ABS plastic sheet to a plywood layer to form a laminate. Perimeter sides of the laminate are enclosed with an edge channel, but corners of the laminate are left exposed with respect to the edge channel. Corners of the laminate and ends of adjacent edge channels are covered with corner caps, but a gap or space is left between the lateral edge of the corner of the laminate and the corner caps and/or between upper and lower surfaces of the laminate and the corner caps. Runners can be directly coupled to the plywood layer under the table top.

A method for protecting a table includes obtaining a folding table with a laminate formed by a plastic sheet bonded to a plywood layer and a perimeter edge of the laminate enclosed by an edge channel without enclosing corners of the laminate and corner caps removably disposed over the corners of the laminate. A damaged corner cap is removed and replaced with a new corner cap.

Referring toFIGS. 4a-d, another table10bis shown that is similar in most respect to that described above, and which description is herein incorporated by reference. The table10bcan be configured as a rectangular table for use with users sitting all around the table, as opposed to one side. Thus, the legs170band leg assemblies18bcan be aligned with the longitudinal axis of the table.

Although the tables above have been described as having rectangular shapes, it will be appreciated that the tables can have other shapes, such as polygonal, hexagonal, octagonal, circular, semi-circular, etc. Referring toFIGS. 5a-e, another table10cis shown that is similar in most respect to that described above, and which description is herein incorporated by reference. The table10cand table top14ccan be circular. The perimeter edge channel42ccan also be circular and can circumscribe the laminate which can also be circular. A pair of leg assemblies18ccan be coupled to the table top.

The table tops described above can also be used with fix leg(s).