Patent Abstract:
The invention is directed to a rotary molded bed having a sleeping surface surrounded by a raised edge, storage compartments molded into the side of the bed and a means for attaching a base of the bed to a floor. The rotationally molded bottom may comprise a flat surface or a honeycombed configuration. The hollow bed body may be filled with structural foam to provide support. The base is attached to a floor surface preferably having fastener openings in the base adapted to hold fasteners recessed in the base, the fasteners extending through a floor mount surface in the base. The fastener openings may have covers adapted to close the fastener openings to prevent tampering with the fasteners.

Full 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&#39;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 contrband 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.  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  49   a  and in  FIG. 8 , flat cover  49   b  are used to hide the bolt to prevent tampering. The cover  49   a,    49   b  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  49   a  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  49   b  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  242   a - 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  242   a - 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 meetfire 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.

Technology Classification (CPC): 0