TECHNICAL FIELD OF THE INVENTION

This invention relates to a flexible laminate material, and a method of manufacturing the flexible laminate.

BACKGROUND ART

Laminate materials are composed of a number of layers of sheet material such as wood or metal, which are bonded together with a thin layer of glue.

Laminates are widely used for manufacturing inexpensive pieces of furniture. The materials include plywood, which includes a number of thin layers of wood bonded together and chipboard having a wood veneer bonded to its surface.

There is a growing market for furniture that is "flat-packed" in a ready to assemble form. This furniture is cheaper for the average consumer and also requires less warehouse space. In addition, furniture that is exported to other countries is often required to be sent in flat pack form in order to save container space. However, the requirement of ready-to-assemble, flat pack furniture can prove limiting in terms of furniture designs and shapes.

It is an object of this invention to provide a flexible laminate material which, at least partially, alleviates some of the abovementioned problems.

SUMMARY OF THE INVENTION

In accordance with this invention, there is provided a flexible laminate material comprising at least one layer of flexible sheet material bonded to at least one layer of rigid sheet material with a flexible adhesive.

There is further provided for at least at least one slot/groove to be cut through the rigid sheet material, but not though the flexible sheet material, allowing for flexing of the laminate.

There are preferably a number of slots cut through the rigid sheet material. The slots may be cut in any of a number of geometric configurations and patterns including but not limited to straight slots, curved slots, circular slots and shaped slots. The slots may be cut individually or in sets, and the slots in a set may be cut parallel to one another, to allow for flexing of the laminate along a particular plane.

One or more slots may be cut at an angle to at least one other slot, to allow for flexing of the laminate along another plane.

Slots may additionally intersect one another.

The layer of flexible sheet material is preferably sandwiched between two layers of rigid sheet material with opposing slots cut through opposing layers of the rigid sheet material, but not through the flexible sheet material.

The flexible material may be a fairly floppy material, alternatively the material may be resiliently flexible and capable of resuming its former shape after flexing, further alternatively the flexible material may be capable of retaining its flex once it has been bent. The slots may be filled with an adhesive that bonds to both the rigid sheet material and the flexible sheet material.

The laminate may be flexed in the required direction prior to the application of the adhesive into the slots, in which case the laminate may retain its flexed shape once the adhesive has set.

Alternatively, a flexible adhesive may be applied to the slots in the laminate while the laminate is still in the flat plane, in which case the laminate may be flexed away from the position in which the flexible adhesive originally set.

The degree of flexibility of the laminate is a function of the flexibility of the adhesive and the shape and width of the slots and the distance between the slots cut in the laminate.

The rigid sheet material may be of any rigid substance, including but not limited to plywood, and the flexible sheet material may be a strong fabric, alternatively a thin sheet of metal or further alternatively a bendable plastics material.

The method of manufacturing a flexible laminate includes the steps of bonding at least one layer of rigid sheet material to at least one layer of flexible material, cutting one or more slots in the rigid material, and filling the slots with a flexible adhesive.

The method preferably includes the steps of sandwiching a layer of flexible material between two layers of rigid sheet material and bonding the three layers together, and cutting opposing slots through opposing layers of rigid material, but not through the flexible material. BRIEF DESCRIPTION OF THE DRAWINGS

A preferred embodiment of the invention is described below by way of example only and with reference to the following drawings, in which;

Figures 1 to 4 illustrate the various steps involved in manufacturing the flexible laminate;

Figures 5 to 6 is a representation of the flexible laminate in use as a piece of furniture.

DETAILED DESCRIPTION OF THE INVENTION

Referring to figures 1 to 5 in which like features of the invention are indicated by like numerals,

Referring to figure 1 , the flexible laminate 10 includes a layer of flexible material 12 such as a strong fabric, sandwiched between two layers of rigid sheet material 14 such as plywood or like material, and bonded to both layers of rigid sheet material with a flexible adhesive (not shown).

Referring to figure 2, a series of opposing slots 16 are cut through opposing layers of the rigid sheet material 14, but are not cut through the flexible material 12. A number of slots 16 are generally spaced apart equidistant from other to form a set (20 figure 5) to allow for flexing of the laminate 10 along a particular plane.

Referring to figure 3, the slots16 are filled with an adhesive 18 that bonds to both the rigid sheet material 14 and the flexible material 12. In this embodiment, the flexible adhesive 18 is applied to the slots 16 in the laminate while the laminate is still in the flat plane. In this instance, the laminate 10 may be flexed away from the position in which the flexible adhesive originally set, as long as the adhesive used is flexible, and the bond between the adhesive and the adjacent material remains intact.

Referring to figure 4, and in an alternative embodiment of the invention, the laminate 10 may be flexed in the required direction prior to the application of the adhesive 8 into the slots 6, in which case the laminate 10 will retain its flexed shape once the adhesive 18 has set.

The degree of flexibility of the laminate 10 is a function of the flexibility of the adhesive 18 and the shape and width of the slots 16 and the distance between the slots 16 cut in the laminate.

Referring to figure 5, a number of sets 20 of parallel slots 16 may be cut at appropriate positions on a sheet of laminate to allow for flexing of the laminate at those positions. Furthermore, other sets 22 of parallel slots 16 may be cut at an angle to the first set of slots, to allow for flexing of the laminate along another plane. These different sets of slots 20, 22 may also intersect one another.

Additionally, individually shaped slots 24 and 26 may be cut to define specific zones, such as the chair seat 28 or backrest 30.

In this manner a piece of furniture 32 such as the chair depicted in figure 6 can be manufactured and transported in a flat-pack arrangement, and then deformed into a three dimensional shape on assembly once it has reached its destination.

Numerous modifications to this embodiment are possible, without departing from the scope of the invention. For example, various types of rigid sheet material and flexible material may be used to create the flexible laminate. In addition, various patterns of shaped slots may be cut into the flexible laminate to allow for flexing along various planes, for example, concentric circular slots could be cut to allow for a rounded effect.

The invention therefore provides a novel flexible laminate material, and a method of manufacturing the flexible laminate.