Abstract:
A composite furniture article comprising a load bearing structural frame including a plurality of load bearing members, wherein the load bearing members are formed from a metal or metallic material; a non-load bearing timber cortex affixed to the periphery of at least a portion of a load bearing member of said structural frame; wherein the timber cortex is affixed to the frame and located such that said structural frame bears substantially all load applied to the furniture article and the timber cortex bears substantially no load.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to articles of furniture, in particularly composite articles of furniture comprising metallic and wooden components. 
       BACKGROUND OF THE INVENTION 
       [0002]    Furniture articles, in the main, have typically been made from timber components which are either glued and/or dowelled together so as to form an article, such as a chair, table or the like. 
         [0003]    Such articles of furniture, if formed from particular timber, may often be expensive and heavy due to increasing demand of such timbers and such timber being of a high density. 
         [0004]    Metallic or plastic articles of furniture exist in the art, typically for applications such as outdoor furniture and budget-type indoor furniture. Such articles are generally not as aesthetically pleasing as traditional articles of furniture, and may be overlooked in preference to traditional timber-type furniture or used as a compromise to timber furniture. 
         [0005]    The increasing demand on timber for manufacturing of furniture places an increasing cost upon furniture which is to be made of such material. 
       OBJECT OF THE INVENTION 
       [0006]    The present invention seeks to address or at least substantially ameliorate at least some of the deficiencies as exhibited by the prior art. 
       SUMMARY OF THE INVENTION 
       [0007]    In a first aspect, the present invention provides a composite furniture article comprising a load bearing structural frame including a plurality of load bearing members, wherein the load bearing members are formed from a metal or metallic material; and a non-load bearing timber cortex affixed to the periphery of at least a portion of a load bearing member of said structural frame. The timber cortex is affixed to the frame and located such that said structural frame bears substantially all load applied to the furniture article and the timber cortex bears substantially no load. 
         [0008]    The timber cortex is preferably comprised of a plurality of timber cladding portions, and the timber cladding portions preferably extend substantially about the periphery of a load bearing member. 
         [0009]    Preferably, the timber cladding portions are affixed to the load bearing member by way of an adhesive material, and the adhesive material is preferably compliant such the timber cortex is substantially insulated load applied to the load bearing member. 
         [0010]    The timber cladding portions of the load bearing member are preferably spaced apart from timber cladding portions of other load bearing members so as to prevent engagement of adjacent timber cladding portions upon application of load to the furniture article. 
         [0011]    The timber cladding portions of the load bearing member are abutted against an adjacent timber cladding member in a manner such that the load bearing member is encapsulated and such that the timber cladding portions collectively provide a visual representation of a unitary solid timber load bearing member. 
         [0012]    Preferably, the load bearing members of load bearing frame have a hollow cross-section, and preferably the load bearing members are formed form aluminium or alloy thereof. 
         [0013]    At least some of the load bearing members are joined to an adjacent load bearing member preferably by way of a weldment. 
         [0014]    The load bearing member may be a leg member of a furniture article, and preferably the article further comprising a stopper member for ground engagement and wherein the stopper member is positioned such that reaction forces from the ground surface applied to the furniture article are transferred to the load bearing member and the timber cortex is insulated from reaction force transfer. 
         [0015]    Alternatively, the load bearing member may be a leg member of a furniture article, and wherein the load bearing member extends beyond the timber cortex such that reaction forces from the ground surface applied to the furniture article are transferred to the load bearing member and the timber cortex is insulated from reaction force transfer. 
         [0016]    The furniture article may be selected from the group including a chair, a stool, a table, a cupboard, a wardrobe or the like. 
         [0017]    In a further aspect, the present invention provides a method of forming a composite furniture article, the method including the step of adhering a plurality of timber cladding portions to the periphery of one of more load bearing member of a load bearing structural frame, said including a plurality of load bearing members, wherein the load bearing members are formed from a metal or metallic material. The plurality of timber cladding portions is adhered about the periphery of the load bearing member to form a timber cortex and are located such that the timber cortex is insulated from load applied to the furniture article and the load bearing members. 
         [0018]    A load bearing member may be a leg of the furniture article, and a stopper member for engagement and load transfer between the leg and a ground surface may be affixed to the load bearing member and spaced apart form the timber cortex such that load is transferred between the load bearing member and the ground. 
         [0019]    Preferably, the load bearing members are formed from aluminium or aluminium tubular members. 
         [0020]    The plurality of timber cladding portions may be adhered to the load bearing member by way of an adhesive, and the adhesive material is preferably compliant such the timber cortex is substantially insulated load applied to the load bearing member. 
         [0021]    Preferably, the timber cladding portions are abutted against an adjacent timber cladding member in a manner such that the load bearing member is encapsulated and such that the timber cladding portions collectively provide a visual representation of a unitary solid timber load bearing member. 
         [0022]    Subsequent timber cladding portions may be adhered to further load bearing members and are spaced apart from timber cladding portions of other load bearing members so as to prevent engagement of adjacent timber cladding portions and load transmission therebetween upon application of load to the furniture article. 
         [0023]    The composite furniture article may be further received application of upholstery. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0024]      FIG. 1(   a ) is an exploded view depiction of an exemplary embodiment of a chair according to the present invention; 
           [0025]      FIG. 1(   b ) is an assembled view of the embodiment as depicted in  FIG. 1(   a ); 
           [0026]      FIG. 1(   c ) is an exploded view of a leg of the embodiment as depicted in  FIG. 1(   a ); 
           [0027]      FIG. 1(   d ) is an enlarged view of a portion of the embodiment as depicted in  FIG. 1  ( a ); 
           [0028]      FIG. 1(   e ) is a partial schematic cross-sectional view A-A of  FIG. 1(   a ); 
           [0029]      FIG. 1  ( f ) depicts a partial schematic cross-sectional view of an alternate embodiment of a leg for a furniture article in accordance with the present invention; 
           [0030]      FIG. 2  depicts an embodiment of a load bearing member according to the present invention partially clad by timber cladding portions in a partially assembled state; 
           [0031]      FIG. 3  depicts load bearing member and timber cladding portions of  FIG. 2  in an assembled state; 
           [0032]      FIG. 4  depicts load bearing member and timber cladding portions of  FIG. 2  in a finished state; 
           [0033]      FIG. 5  depicts a perspective view of an embodiment of a furniture article according to the present invention including load bearing members as depicted in  FIG. 4 ; 
           [0034]      FIG. 6  depicts a perspective view from below of the embodiment as depicted in  FIG. 5 ; 
           [0035]      FIG. 7  shows the embodiment as depicted in  FIG. 5  and  FIG. 6  in a further assembled state; 
           [0036]      FIG. 8  shows the embodiment of the invention as depicted in  FIG. 5 ,  FIG. 6  and  FIG. 7  in an assembled state; 
           [0037]      FIG. 9  shows a cross-sectional view of a timber veneer chair leg as exhibited by the Prior Art; 
           [0038]      FIG. 10  ( a ) shows a cross-sectional view of an exemplary embodiment of a chair leg according to the present invention; and 
           [0039]      FIG. 10  ( b ) shows a cross-sectional view of an exemplary embodiment of a chair leg according to the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0040]    Referring to  FIGS. 1(   a ) to ( d ), there is shown an exemplary embodiment of a furniture article  10  according to the present invention. In the depicted embodiment, the exemplary embodiment is that of a chair. The article comprises a load bearing structural frame  12  which is formed by a plurality of load bearing members  14 , and a non-load bearing timber cortex  16  which is affixed to the periphery of load bearing members, in this embodiment those load bearing members being legs of the chairs. 
         [0041]    In the present embodiment, the furniture article also includes a plurality of panel members  19  which are adhered to the load bearing members  14  of the structural frame  12  so as to form a base  11 , arm rest  13  and a back rest  15 . 
         [0042]    The timber cortex  16  is formed from a plurality of timber cladding portions  18  which are affixed to the structural member  14  of the chair leg. In the present embodiment, the timber cladding portions  18  are affixed to the structural member  14  by way of an adhesive material such as a glue, epoxy resin or the like. The material is suitably compliant such that upon load being applied to the load bearing member  14  of the leg, substantially no load or strain is transmitted to the timber cortex  16 , such that the load bearing member  14  takes all of the load when the chair is in use. 
         [0043]    The panels  19  may also be affixed to the load bearing frame  12  by way of an adhesive or by other fixation means, however as such panel members  19  may in fact take load in some applications as load will be directly applied to the base  11 , arm rest  13  and back rest  15 , it is not pertinent that the panel members  19  be isolated from the load bearing structural frame  12  in the manner that the timber cortex  16  is situated. 
         [0044]    In the present embodiment, the load bearing structural frame  12  is formed from elongate aluminium members of a square and hollow cross section. The load bearing members  14  in the present embodiment are joined together by way of weldments  17 , however those skilled in the art will appreciate that other manners of a fixing the load bearing members  14  together may be used, such as by way of joining members which may be concealed within the inside of the load bearing structural frame  12 . 
         [0045]    Referring to  FIG. 1(   e ), a partial schematic cross-sectional view of the load bearing member  14  of the chair leg is shown with the timber cladding portions 18  affixed to the load bearing member  14 . As shown, there is provided a stopper member  21  which is inserted within the hollow load bearing leg member  14  and which abuts with the lower portion of the load bearing member  14 . 
         [0046]    As will be noted, in the present embodiment, the timber cladding portions  18  are not engaged with the stopper member  21  such that upon application of the furniture article to the ground  23  and loading, reaction force from the ground  23  is transmitted to the load bearing member  18  to the frame  12 , without any substantial load being imparted to the timber cladding portions  18 . 
         [0047]    As also shown, the upper portions of the timber cladding portions  18  do not engage with load bearing member  14   a  and as such, the timber cladding portions  18  do not share any of the axial load imparted to the load bearing structural frame  12  from the ground  23  reaction force. 
         [0048]    Furthermore, the adhesive utilized in adhering the timber cladding portions  18  to the load bearing member  14  is substantially in compliant such that minimal strain from axial compression of the load bearing member  14  is transferred to the timber cladding portions  18 . As such, the timber cladding portions  18  do not assist in any load bearing capacity during use of the furniture article  10 . 
         [0049]    Although the load bearing member  14  is depicted as extending beyond the cladding portions  18 , those skilled in the art in alternate embodiments such as different stopper member shapes and geometries, the cladding portions  18  could extend beyond the load bearing member or be in line with the load bearing member  14 , provided the stopper member  21  engaged only with the load bearing member  14  and did not contact or engage with the cladding portions in use, by way of a sufficient gap being provided between the upper face of the stopper member and the lower portions of the cladding, again without any substantial load being imparted to the timber cladding portions  18 . 
         [0050]    Referring to  FIG. 1  ( f ), a partial schematic cross-sectional view of an alternate embodiment of load bearing member  14   c  suitable for a chair as described with reference to  FIGS. 1(   a )-( e ). In this embodiment, as is shown, the load bearing member  14   c  is depicted as being a leg for a furniture article. In this embodiment, the load bearing member  14   c  extends beyond the timber cladding portions  18   b  so as to engage with the ground surface. Similarly, as described in reference to  FIG. 1(   e ), the load induced from the ground reaction force is carried by the load bearing member  14   c  without any substantial load being imparted to the timber cladding portions  18   b.    
         [0051]    Referring to  FIGS. 2-8 , there is shown an exemplary embodiment of a furniture article  100  as a chair in accordance with the present invention. A load bearing structural frame  120  is comprised by a plurality of load bearing members  122  which are welded together to form the load bearing structural frame  120 . In the present exemplary embodiment, there is shown the assembly process of forming the non-load bearing timber cortex  130  by a plurality of timber cladding portions  132  which are affixed to the leg load bearing member  122   a  by way of an adhesive. In the present embodiment, the load bearing members  122  are square in cross-section. However, those skilled in the art will appreciate that other cross-sectional geometries are equally as applicable, without departing from the scope of the invention. 
         [0052]    The timber cladding portions  132  are pre-formed to a requisite shape so as to have a “wedge-type” geometry such that when adhered to the leg load bearing member  122 , a tapered timber cortex  130  is formed. Upon suitable finishing including sanding, staining if necessary and lacquering if required, the timber cortex extending around the periphery of the leg load bearing member  122 , provides a visible impression of being a solid timber leg. 
         [0053]    Upon affixing the timber cladding portions  132  to the leg load bearing members  122   a , base member  142 , arm rest members  144  and back rest member  146  may be affixed to the load bearing frame  120  in a similar manner as described with reference to  FIGS. 1(   a )-( c ). Subsequently, upholstery  150  may be applied to the seat member  142 , arm rest member  144  and back rest member  146  so as to provide a completed chair as shown in  FIG. 8 . 
         [0054]    Referring to  FIG. 9  and  FIGS. 10(   a ) and ( b ), as shown in  FIG. 9  in accordance with the prior art, there is shown an exemplary embodiment of a chair leg  200  in accordance with the prior art, which comprises a central core  210  and an outer layer of a timber venire  220 . In the prior art, a relatively inexpensive core  210  may be used, which may be a wooden-particulate substance or alternatively, other less expensive timbers or other synthetic or natural occurring materials. 
         [0055]    By comparison, as shown in  FIG. 10  ( a ), there is shown an exemplary embodiment of a chair leg  300  in accordance with the present invention, which includes a load bearing member  310 , in this embodiment a tubular aluminium central member, having a timber cortex  320  formed from a plurality of timber cladding portion in accordance with the present invention and as described above in reference to  FIGS. 1-8 . As shown in  FIG. 10  ( a ), the timber cortex includes a plurality of recesses  322 , which extend radially inward part way through the timber cortex  320  and toward the load bearing member  310 . Such recesses  322  may be formed by way of a lathe, and by turning the leg member  300  prior to incorporation of the chair leg member  300  with the rest of an article of furniture. 
         [0056]    As will be appreciated by those skilled in the art, the solid timber cortex, supported by the load bearing member  310 , allows a significant depth of cut into the cortex  320 , which allows ornate design to be imparted to the chair leg  300  in a manner such that the timber material from which the timber cortex  320  is formed provides a visual as well. as tactile sensation and impression of being a solid timber member. 
         [0057]    Similarly, referring to  FIG. 10(   b ), there is shown a further exemplary embodiment  400  of a chair leg having a load bearing member  410  and a timber cortex  420 , in accordance with the present invention. As shown, rebates  420  are provided within the chair leg  400 , by way of turning the chair leg  400  on a lathe prior to use of the chair leg in conjunction with an article of furniture. 
         [0058]    Those skilled in the art will appreciate in comparison with  FIG. 10  of the prior art, the present invention allows intricate and detailed shape geometry to be applied to the article whilst still providing a continuous outer surface of the requisite timber material from which the article is made. 
         [0059]    Further, those skilled in the art will appreciate that a relatively thin timber venire cannot be shaped to a complex outer surface geometry as a single piece, and inherently the prior art will show discontinuity and joints within the timber at areas of change of angle or the like. 
         [0060]    Furthermore, those skilled in the art will appreciate that any attempt to provide an ornate shape to the prior art as shown in  FIG. 10(   a ) so as to emulate the visual characteristics of the articles of  FIG. 10(   a ) and  FIG. 10(   b ) will result in tooling cutting full-way through the timber venire  220  thus resulting in an article not of continuous out of service and showing the internal core material  210  from the outside of the article. 
         [0061]    As will be appreciated and understood by those skilled in the art, the present invention allows for visual and tactile impression of a solid timber leg, whilst providing the advantages as described with reference to the present invention. 
         [0062]    As will be appreciated by those skilled in the art, a classical type chair may be formed as a seemingly wooden-frame construct, typical as those as seen in the art, however the present invention provides a furniture article having significant advantages over existing furniture article. 
         [0063]    Advantages as provided by the present invention include the construction of furniture articles which have less reliance on real timber materials, which provides a cost advantage in view of depleting supplies of timber, in particular classic type timbers utilized in furniture articles. 
         [0064]    Furthermore, by use of significantly thinner timber portions to provide the timber cladding portions, off-cuts and smaller pieces of stock material may be utilized, rather than relying on thick sections to form the construct of the furniture article. Still further, by utilizing a load bearing frame formed from a metal or metal alloy, in particular, aluminium, there is not the necessity to provide a full timber frame for the construction of the articles of furniture. Furthermore, such a load bearing frame formed from an aluminium alloy provides the significant advantages of being relatively cheap, easy to assemble, increased strength, resistance to wood rot, and a decrease in weight in comparison to solid timber articles. 
         [0065]    Thus, the present invention provides a chair which is formed so as to provide the visual characteristics of classical timber appearance whilst also providing the advantages as discussed above. 
         [0066]    The present invention allows the use of timbers such as Hardwood, Oak, Mahogany, Beech or the like to be used, so as to provide the visual appearance, as well as appearance to touch, as being a solid timber member, in comparison to the effect derived by the use of timber veneer as utilised on the prior art. 
         [0067]    As will be appreciated by those skilled in the art, other cross-sectional geometries of the load bearing structural frame may be used, such as circular, triangular, hexagonal or the like without departing from the scope of the invention. Furthermore, as will be appreciated by those skilled in the art, the shape of the cladding utilized may be varied depending on the visual or ornate requirement of the load bearing member of the furniture article. For example, as providing a tapered leg by wedge-shaped timber cladding portions, as described in reference to the present embodiment. 
         [0068]    Furthermore, those skilled in the art will appreciate that in other or alternate embodiments, should the need be required, prior to fixation of the load bearing member to the furniture article, the timber cladding portions may be affixed to the load bearing member in a general shape as required, and the composite load bearing member and timber cortex may be “worked” to provide a requisite geometry, such as turning on a lathe so as to provide an ornate and desirable shape from a suitable material for post-furnishing and which also is a desired timber for the construction of furniture articles. 
         [0069]    Again, by providing an internal load bearing member with an outer non-load bearing cortex, multiple timber cladding portions may be utilized so as to utilize timber of smaller cross-sections which normally would need to be discarded or used for other applications, thus ameliorating the necessity to utilize more expensive thick timber cross-sectional stock timber. 
         [0070]    Furthermore, by the use of timber cladding portions, should there be a defect in the stock material, only a timber cladding member having such a defect would need to be replaced or discarded, rather than a whole stock material. As such, an ornate and visually acceptable load bearing member may be provided whilst being formed a lower cost, at a lower weight or mass, and more efficiently, whilst utilizing off-cuts of wood or timber which would normally be discarded. 
         [0071]    In addition to the commercial advantages provided by the present invention, environmental advantages are also realized by the non-reliance on old-growth timber forests and the minimization of timber waste in the timber furniture manufacturing industry. 
         [0072]    As will be also appreciated by those skilled in the art, although the present embodiment are depicted in the form of a chair-article, other articles of furniture having load bearing members such as rungs of chairs, stools, wardrobes, tables and the like, are equally as applicable and will be considered to also being embodiments of the present invention. 
         [0073]    Typical adhesives suitable for use in accordance with the present invention are those including, epoxy resins, contact cements, urthethane glues, hot-melt glues or adhesive, pressure sensitive adhesives and the like. By way of example, adhesives such as Cascamite One Shot Adhesive are suitable for use in the present invention. 
         [0074]    Furthermore, although in the present embodiments the use of adhesive to affix the timber cladding portions to the load bearing members has been described in reference to the present embodiments. Those skilled in the art will appreciate that fixation methods and devices may be equally applicable in other applications, such as internal fasteners, spurs, ridges, screws or the like, without departing from the present invention. 
         [0075]    While the present invention has been explained by reference to the examples or preferred embodiments described above, it will be appreciated that those are examples to assist understanding of the present invention and are not meant to be restrictive. Variations or modifications which are obvious or trivial to persons skilled in the art, as well as improvements made thereon, should be considered as equivalents of this invention. 
         [0076]    Furthermore, while the present invention has been explained by reference to a chair, it should be appreciated that the invention can apply, whether with or without modification, to other articles of furniture without loss of generality.