阅读说明：本技术 锥形组件及所述组件的制备方法 (Conical assembly and method for preparing said assembly ) 是由 拉尔斯·安德森 里卡德·马滕松 马库斯·贝耶林 于 2019-01-30 设计创作，主要内容包括：本发明提供了一种用于家具或室内配件的锥形组件。多个锥体(C1,C2)以一线性阵列布设以形成所述锥形组件(40),其中一内层锥体(C1)由至少一外层锥体(C2)容纳；以及其中所述外层锥体(C2)由不同于所述内层锥体(C1)的材料的一第一层(L1)材料制成。(The present invention provides a tapered assembly for a furniture or room fitting. A plurality of cones (C1, C2) arranged in a linear array to form said cone assembly (40), wherein an inner cone (C1) is received by at least one outer cone (C2); and wherein the outer layer cone (C2) is made of a first layer (L1) of material different from the material of the inner layer cone (C1).)

1. A taper assembly for a furniture or room fitting, the taper assembly comprising: a plurality of cones (C1, C2) arranged in a linear array to form said cone assembly (40), wherein an inner cone (C1) is received by at least one outer cone (C2); and

wherein the outer layer cone (C2) is made of a first layer (L1) of material different from the material of the inner layer cone (C1).

2. The cone assembly of claim 1, wherein the length of the outer layer cone (C2) and the length of the inner layer cone (C1) are both substantially equal to the length of the cone assembly.

3. The cone assembly according to any one of the preceding claims, characterized in that at least the outer cone (C2) is formed by a plurality of longitudinal ends (8) of the first layer (L1) of material attached to each other.

4. The cone assembly according to any one of claims 1 to 3 wherein the inner cone (C1) has a uniform thickness at each particular longitudinal location.

5. The cone assembly according to any one of claims 1 to 4 further comprising: at least one intermediate layer cone (C3) disposed between the inner layer cone (C1) and the outer layer cone (C2).

6. The cone assembly of claim 5 wherein at least one of said intermediate cone (C3) is made of a material that is the same as or different from said inner cone (C1).

7. The cone assembly according to any one of the preceding claims wherein the outer layer cone (C2) and/or at least one of the intermediate layer cones (C3) is made of a first layer (L1) of material adjacent to a second layer (L2) of material, the second layer (L2) being of a different material than the first layer (L1) of material.

8. The cone assembly of claim 7 wherein the second layer (L2) is made of a substrate material.

9. The cone assembly of claim 8 wherein the backing material is a paper-based material.

10. The cone assembly according to any one of the preceding claims wherein the material of the first layer (L1) comprises one or more of the following materials: wood veneer, cork, paper, hemp, cellulose, laminate, thermosetting resin impregnated paper, thermoplastic board, metal, or Medium Density Fiberboard (MDF).

11. The cone assembly according to claim 3 wherein the plurality of longitudinal ends (8) of the first layer (L1) of material are attached to each other by: (i) applying an adhesive at the plurality of ends (8) prior to laying the outer cones (C2) in the linear array; (ii) -the adhesive is caused to flow along the longitudinal ends (8) due to the adhesive being applied to the outer surface of an inner cone (C1, C3) arranged inside the outer cone (C2); and/or (iii) because an outer surface of the outer cone (C2) is covered with an adhesive surface coating, the surface coating flows along the longitudinal ends (8).

12. The cone assembly according to claim 3 or 11, characterized in that the inner cone (C1) and/or any of the intermediate cones (C3) are formed by attaching longitudinal ends (8) of a material to each other.

13. The cone assembly according to claim 12, characterized in that a connection between the longitudinal ends (8) of the outer cone (C2), a connection between the longitudinal ends (8) of the inner cone (C1), and/or a connection between the longitudinal ends (8) of at least one of the intermediate cones (C3) is spaced apart in a circumferential direction.

14. The cone assembly according to claim 12 or 13 wherein the connections between the longitudinal ends of a cone (C1, C2, C3) are straight.

15. The cone assembly according to claim 12 or 13 wherein the junctions between the longitudinal ends of a cone (C1, C2, C3) are curved.

16. The cone assembly according to any one of the preceding claims wherein at least one of the outer cones (C2) is hollow.

17. The cone assembly according to any one of the preceding claims wherein the innermost cone (C1) is hollow.

18. The cone assembly according to any one of claims 1 to 16 wherein the innermost cone (C1) is solid.

19. The cone assembly according to any one of the preceding claims wherein the innermost cone (C1) extends along an entire length of the at least one outer cone (C2).

20. The cone assembly according to any one of claims 1 to 18 wherein the innermost cone (C1) extends along only a portion of the length of the at least one outer cone (C2).

21. The cone assembly according to any one of claims 1 to 18 wherein the at least one outer cone (C2) extends along only a portion of the length of the innermost cone (C1).

22. The cone assembly according to any one of the preceding claims wherein an outwardly facing surface of the at least one outer cone (C2) is provided with a coating (14, 16).

23. The cone assembly according to any one of the preceding claims wherein the plurality of cones (C1, C2) are attached to each other using an adhesive (28, 38).

24. The taper assembly according to any one of the preceding claims, wherein a first end of the taper assembly has a first cross-sectional shape and a second end of the taper assembly has a second cross-sectional shape different from the first cross-sectional shape.

25. The cone assembly of claim 24 wherein the first cross-sectional shape and/or the second cross-sectional shape is non-circular.

26. A cone assembly according to any one of the preceding claims, characterized in that the cone assembly is provided with a longitudinal slit (60).

27. The cone assembly according to any one of the preceding claims wherein the first layer (L1) of material of the outer layer cone (C2) has a fiber direction that is different from a fiber direction of the material of the inner layer cone (C1).

28. A method of making a tapered assembly for a furniture or room fitting, the method comprising the steps of:

providing a plurality of cones (C1, C2), and

arranging the plurality of cones (C1, C2) in a linear array such that an inner cone (C1) is received by at least one outer cone (C2), wherein an inner surface of the outer cone (C2) covers substantially an entire outer surface of the inner cone (C1).

29. The method according to claim 28, wherein the outer cone (C2) is made of a first layer (L1) of material different from the material of the inner cone (C1).

30. The method according to claim 28 or 29, characterized in that the method further comprises the step of: at least one intermediate layer cone (C3) is arranged between the inner layer cone (C1) and the outer layer cone (C2).

31. The method according to any of the claims 28 to 30, wherein at least said outer cone (C2) is formed by laying out a thin sheet of said first layer (L1) in a cone shape.

32. The method of claim 31, wherein before or after arranging the sheet into a conical shape, the method further comprises the steps of: heat treating the sheet.

33. The method according to claim 31 or 32, wherein before or after arranging the sheet into a conical shape, the method further comprises the steps of: bending the sheet.

34. The method according to any of the claims 31 to 33, wherein prior to the step of arranging the plurality of cones (C1, C2, C3) in the linear array, the method further comprises the step of: -connecting the longitudinal ends (8) of the sheet to each other to form a cone shape.

35. The method of claim 34, wherein said plurality of sheets are formed into a plurality of individual cones (C1, C2, C3) by arranging said plurality of sheets in a mold (60).

36. The method of claim 35, wherein the plurality of sheets are arranged in the mold (60) such that each cone (C1, C2, C3) has a circular cross-section along an entire length of the cone (C1, C2, C3).

37. The method according to any one of claims 31 to 36, wherein said sheet is made of said first layer (L1) adjacent to a second layer (L2) of material, said material of said second layer (L2) being different from said material of said first layer (L1).

38. The method according to any one of claims 28 to 37, further comprising the step of: pressing the linear array of cones (C1, C2, C3) into a desired shape.

39. The method according to any one of claims 28 to 38, further comprising the step of: -arranging a fibre direction of the first layer (L1) of the outer layer cone (C2) to be different from a fibre direction of the material of the inner layer cone (C1) and/or a fibre direction of the material of the second layer.

40. The method according to any one of claims 28 to 39, further comprising the step of: closing at least one end of the cone assembly.

41. The method for preparing according to any one of claims 28 to 40, wherein said inner cone (C1) is hollow, then said method further comprising the step of: at least one support member (70) is disposed within the inner cone (C1).

42. The method of claim 41, wherein said support member (70) includes a through hole (72).

43. The method of any one of claims 28 to 42, further comprising the step of: filling the conical assembly with a filler material.

44. The method according to any of the claims 28 to 43, wherein before inserting the cone (C1, C3) into an outer cone (C2, C3), the method further comprises the steps of: attaching the plurality of cones (C1, C2, C3) to each other by applying an adhesive on an outer surface of a cone (C1, C3).

Technical Field

The present invention relates to a tapered assembly, for example for forming a conical shaped furniture leg or other longitudinal parts, and a method of making such a tapered assembly.

Background

A variety of longitudinal components are used for various types of applications; indoor applications typically include a variety of furniture components or other construction components such as a variety of indoor accessories.

One unique application in the furniture industry is to provide a longitudinal member as a furniture leg. Various furniture legs are typically made from a variety of different materials and have a variety of different shapes. In addition to having a structural function, many furniture legs also have an aesthetic factor, and thus most manufacturers tend to choose legs made from a particular, aesthetically pleasing material and shape. Price is also a factor that most furniture manufacturers prefer to make inexpensive furniture legs of many kinds. It is also important that various furniture legs be lightweight for shipping and handling purposes. These factors are of course also important to the customers who purchase the furniture. For some manufacturers, a manufacturing speed of the various legs is also important to enable a large amount of furniture to be produced quickly. Most people would also prefer if the manufacturing and handling processes were non-toxic and environmentally friendly.

Among the many materials in many furniture legs, solid wood and Medium Density Fiberboard (MDF) are two very popular choices; solid wood is generally chosen for robustness and classic aesthetics, while MDF is chosen for inexpensive and fast manufacturing.

It is desirable to provide an alternative to the options listed above, having the sturdiness and aesthetic qualities of solid wood, and the inexpensive and fast to manufacture characteristics of MDF, not only for use in a variety of furniture legs, but also for other applications and products. It would be further beneficial if the alternative also had a light weight and was non-toxic and environmentally friendly to manufacture.

An example is described in US patent US5,438,812, which is a technique for forming longitudinal parts. A rod is composed of a hollow inner core formed by adhering a plurality of wood strips edge to edge and a plurality of veneer sheets adhered to the outside of the wood strips. The rod thus obtained is difficult to manufacture, since it requires a plurality of manufacturing steps to form the core, and an outer cover. Furthermore, an outer surface will have a plurality of radial steps, namely: the arrangement of high level steps at multiple longitudinal locations on an outer envelope surface makes it extremely unsuitable for interior design applications.

Accordingly, it is desirable to provide an improved assembly that is adaptable to a variety of indoor applications, such as a variety of furniture components.

Disclosure of Invention

Accordingly, the present invention seeks to combine several of the advantageous features of the prior art to remove some of the disadvantages of the prior art, while also adding several new advantageous features. One aspect of the present invention is a tapered assembly for use as a furniture component, such as a furniture leg, or other component of various indoor accessories. The cone assembly comprises a plurality of individual cones arranged in a linear array to form a cone shaped assembly (e.g. a furniture leg) with an inner cone received by an outer cone, preferably an outermost cone. The outermost cone may preferably be formed from a single plate by attaching longitudinal ends of the single plate to each other. At least one of the plurality of cones is provided with a substrate material.

Various embodiments of a plurality of tapered assemblies, and various embodiments of methods of making a plurality of tapered assemblies, are described herein.

The cone assembly is formed by a plurality of individual cones arranged in a linear array; an inner cone is received by the hollow interior of an intermediate cone, or an outer cone.

At least the outer layer cones, and any intermediate layer cones, are formed from a sheet of material folded over and by bringing together longitudinal ends of the sheet to form a tapered shape (i.e., a cone). The inner cone may be formed in a similar manner or, in some embodiments, may be formed as a solid body since the inner cone need not accommodate other cones. A solid body is understood to include solid materials, such as a piece of hardwood or softwood, and a composite unit, such as a bonded wood.

The plurality of cones are laid out in the linear array and attached to each other by an adhesive (or similar material). A junction between two adjacent cones is disposed between an inner surface of one cone and an outer surface of the intermediate cone.

The adhesive for interconnecting a plurality of cones may be applied to the inner surface, the outer surface, or both the inner and outer surfaces of the two cones for interconnection. Alternatively, an impregnated film is provided as the adhesive, the impregnated film being disposed between the two adjacent cones, or an intermediate cone may be made of an adhesive material, such as a thermoplastic film or a thermosetting resin impregnated paper.

In some preferred embodiments, the process of joining individual cones into a cone assembly will also determine the final shape of the cone assembly.

Each cone is preferably manufactured with a circular cross-section over the entire length of each. However, the final cone assembly may have other cross-sectional shapes. This may be achieved by using a mould when manufacturing the conical assembly. When each cone is inserted into the mold (either in contact with the mold or an intermediate layer cone), it will allow the plurality of cones to deform and conform to the shape of the mold. The die may be a male die for use with a mating female anvil or a female die for use with a mating male anvil. For example, many of the dies may have a rectangular cross-section, or a circular cross-section continuously transitions into a rectangular cross-section along a length. A wide variety of options are possible.

Each cone is preferably formed by sealing or otherwise joining the longitudinal ends of a sheet.

At least the longitudinal ends of the outer cone are glued together to provide a tight connection. This is extremely advantageous for non-circular cross-sections, such as the following: elliptical, triangular or polygonal; and tapered elements that include a slightly convex or completely flat envelope surface and a plurality of cross-sectional shapes that vary along a longitudinal axis of the element, such as elliptical at a wider end and rounded at a narrower end.

It is also possible to glue together the longitudinal ends of the inner cone, or of a plurality of intermediate cones. This reduces the risk of sheet separation at the joint.

The glue for connecting the longitudinal ends may be provided in a number of ways. One option is to apply glue at a plurality of ends and to connect the ends of the sheet when forming the cone. Another option is to use the glue for connecting the plurality of cones to each other, namely: flowing the glue on an inner and/or outer surface of the plurality of cones into a connection region of the plurality of longitudinal ends. A further option is to apply a surface coating to the outer/inner surface and to let the adhesive coating flow into an area of the joint.

The glue is preferably coloured to match the colour of the outer cone and hence also the colour of the cone assembly.

For all the bonding schemes mentioned above, the resulting joint will be uniform along the longitudinal axis and flush with a circumferential envelope surface of the cone. Thus, the bond formed by the adhesive/glue will not constitute any topographical change to the tapered assembly.

In a preferred embodiment, it is desirable to reduce material waste and to ensure that the material of the tapered elements has a uniform thickness. Thus, the plurality of sheets used to form the plurality of individual cones can be adapted to a plurality of specific dimensions, whereby the sheets used to form the outer cones will be slightly different from the plurality of sheets used to form the plurality of intermediate and/or inner cones. In particular, each lamina has a particular thickness. This means that each cone formed by a lamina will have an inner diameter slightly smaller than its outer diameter. The outer cone has a specific inner diameter that will accommodate the intermediate or inner cone having a specific outer diameter. In order for the intermediate layer cone/inner cone to fit well into the outer cone without protruding outside the outer cone, the lamellae used to form the intermediate layer/inner cone need to be slightly smaller than the lamellae used to form the outer cone. Thus, if the cone assembly is formed of four separate cones, the plurality of sheets used to form the plurality of cones may vary in size. The sheet used to form the outer cone will be the largest and the sheet used to form the inner cone will be the smallest. The dimensions of the plurality of sheets used to form the plurality of intermediate layer cones will be between the dimensions of the plurality of inner and outer sheets, respectively. A longitudinal dimension, i.e., the length of each cone, may be equal for all cones of a cone assembly and gradually decrease for a circumferential dimension of each intermediate and/or inner cone.

If there are any protruding cones in the assembly step of the cone assembly, the ends of the cone assembly may be cut to remove any uneven thickness of material.

The conical member may be reinforced in some embodiments. Preferably, such reinforcement is provided within the interior of the conical assembly by routing one or more plugs within the interior of the conical assembly. The plugs may be arranged at one or both ends, or somewhere in between. The plugs may be hollow or provided with a through hole to allow a plurality of cables or other external devices to pass through the plugs.

Reinforcement may also be provided by short cones that are shorter than the cones of a cone assembly body, disposed on the inside of the inner cone or the outside of the outer cone of the cone assembly. The short taper may, for example, be disposed at a higher and wider end of the tapered element, at an intermediate position between the ends, or at a bottom end to provide a local reinforcement to the tapered element.

At least one of the outer cones is preferably made of a wood veneer sheet, thereby providing a wood appearance to the entire cone assembly. In case a plurality of wood veneers is used, it is preferred to provide said wood veneers with a backing material, such as paper or a nonwoven material. The plurality of wood veneers used to form the plurality of cones are preferably softened and may also be softened by directly subjecting the wood veneers to a heat treatment prior to the operation of forming the wood veneers into the plurality of cones.

In one embodiment, the taper assembly comprises at least two tapers, wherein a first taper is linearly inserted into a second taper, an inner envelope surface of the first taper being connected to an outer envelope surface of the second taper. An inner circumferential dimension of an end of the first cone is substantially the same as an outer circumferential dimension of an end of the second cone, the end of the second cone being disposed substantially at the same linear (or longitudinal) position as the first cone. Cutting the sheet of the inner cone to a smaller size than the sheet of the outer cone.

The outermost joints (i.e. a longitudinal joint formed by the two longitudinal ends of a sheet, or the ends of a plurality of veneers touching each other) may be fixed, i.e. the longitudinal ends of the sheet or veneer may be attached to each other. Preferably, the junction is flush with a circumferential outer surface of the cone.

The advantage of this aspect is that the plurality of cones give the cone assembly strength, while the plurality of cones are themselves easy and cheap to manufacture. The linear array is easy and cheap to manufacture, just as the plurality of cones can be manufactured to help them fit well into each other. The backing material will provide strength and accommodate the higher-level shaping of the tapered assembly. The plurality of cones may be made of a variety of flexible materials that allow furniture manufacturers some freedom to adjust the shape of a side of the cone assembly without sacrificing the strength of the cone array prior to securing the cone assembly to an associated furniture member.

It is to be understood that the term "cone" is to be interpreted as a three-dimensional object having a cross-section in its longitudinal direction, said cross-section having one or more two-dimensional shapes, the width of the cross-section at one end of said cone being larger than the width of the cross-section at the other end of said cone. Individual cones are used to form a cone assembly, i.e., the cone assembly exhibits a conical profile. According to the invention, a cone is solid or hollow; the outer cone and any intermediate cones will be hollow, while an innermost cone may be solid or hollow. Assuming a hollow cone, the inner width of a larger end of the cone is larger than the outer width of a smaller end to facilitate insertion. The cones may be pointed or truncated, having a linear or a non-linear increase in width, the cross-section may have a variety of different shapes along a length of the cone, in particular non-circular shapes, such as polygonal or elliptical shapes with rounded corners, and the cones do not have to have a same shape.

Preferably, the inner cone is provided such that it has a uniform thickness at each specific longitudinal position. At each cross-section, the thickness of the inner cone is the same along its circumferential extension.

In one embodiment, the cone assembly has a bottom end and a top end, whereby during an intended use, the term "top" and the term "bottom" refer to a location. At any given longitudinal position of the tapered assembly, a radius is equal to or less than a radius above the particular longitudinal position. In an alternative embodiment, the increase in radius is helical so that the conical element can be unscrewed from a die, whereby at a given twist angle it may have a same, or even larger, diameter at a lower longitudinal position relative to a diameter straight above.

Preferably, the sheet material used to form a single cone may have longitudinal ends under an angular cut, such that the splicing of the ends to some extent ensures that the thickness of the sheet material across the longitudinal join is constant, or close to constant. Both end portions may be cut at an angle inwardly from the outer surface of the single plate to the inner surface of the single plate. This ensures that a plurality of said outer cones are in contact on said outer surface, which may be particularly important for some veneers that are thicker, e.g. some veneers have a thickness of more than 1mm, even more than 2 mm.

The plurality of dimensions of the plurality of cones used to form the cone assembly are configured to improve the final product. In particular, an inner diameter of the outer cone may be matched to an outer diameter of one or more of the inner cones, so that the inner cones may fit well within the outer cone.

If there is a situation where one end of one cone projects outside of another, it may be desirable to reduce a length of the end to ensure that a substantial portion of the tapered assembly has a uniform thickness.

The length of the end portion may for example be no more than 20 times, preferably no more than 10 times, the thickness of the sheet material used to form the one or more cones. The thickness of the sheet may include a backing material, and any adhesive used to attach the backing material to the sheet.

All of the cones made of a wood material may be provided with a backing material. This has the advantage of increasing a robustness of the leg, but also allows the cones to be more highly formed into a predetermined shape of a final cone assembly.

The backing material may be a paper-based material. This is easy and cheap to manufacture.

At least one cone may be made of a sheet material. The sheet may for example be a single sheet, i.e. a thin sheet of deformable material. In a preferred embodiment, at least one of the cones may be made of a single sheet of any one or more of the following materials: paper, plastic, hemp, cellulose, wood, cork, non-woven material, thermosetting resin impregnated paper, or Medium Density Fiberboard (MDF). Even metals such as steel or aluminum are conceivable. This makes a manufacturing process more flexible, since in some cases these materials may be easier to manufacture than wood veneers, and depending on the particular use of the leg they may have some desirable characteristics.

In a preferred embodiment at least one cone, e.g. the outer cone, is made of a wood veneer, even more preferably a wood veneer having a fiber orientation along the longitudinal axis of the cone.

At least the outer cone may be made of a wood veneer, the longitudinal ends of the wood veneer being attached to each other. This has the advantage of giving the tapered assembly a "wooden" appearance, without the use of solid wood.

The outwardly facing surface of at least one outermost cone may be provided with a coating. The coating may be applied before or after a process of connecting individual cones in an array. The coating can be hardened in a fixed process, for example due to high temperature and/or pressure. The coating may be a sheet forming the outermost pyramid. As an alternative, a sheet-like coating may be attached to a single sheet before the sheet-like coating forms a cone. The sheet-like coating may for example be a covering paper for use in laminate floors, such as a pure cellulose board impregnated with melamine formaldehyde resin and with aluminium oxide particles, for example with 18-50g/m²A weight of (a). This makes a surface very durable. This is also advantageous in that the coating may impart other properties to the cone assembly that may not be present in itself, such as water resistance, gloss, and the like.

An adhesive may be used to attach the plurality of cones to each other. This increases a robustness of the cone assembly and reduces the risk of separation of the individual cones. The adhesive may be applied to the sheet prior to forming the cone; this is advantageous in that the adhesive may be dry before the formation of the cones, but activated by high temperature and/or pressure when manufacturing an array of cones.

The binder, or glue, may be a thermosetting resin such as melanine formaldehyde, phenolic resin, urea formaldehyde and combinations thereof. It may partially or completely penetrate within the veneer. It may be colored. It may be added through a resin impregnated sheet. The sheet may be saturated or supersaturated. This may be a solution: when a linear continuous array of cones is connected to form an elongated rod, in particular an outdoor rod supporting a plurality of cables or the like. The adhesive or glue is then preferably applied to a lower portion of the rod, which lower portion may be grounded. By using the adhesive, the pole will be particularly resistant to water, abrasion and corrosion, and thus suitable for outdoor use, for example a support pole, such as for supporting cables, balconies, lights and flags.

According to one aspect of the invention, an elongated rod is provided. As noted above, the rod may be fabricated using one or more unsaturated, saturated, or supersaturated resin impregnated sheets. The pole, preferably constructed for outdoor use and for supporting cables, lamps, etc., comprises a plurality of cones arranged in a linear continuous array such that each cone protrudes from an adjacent cone and such that the linear continuous array forms a hollow cylinder. For this particular aspect, one or more cones may be fabricated as described herein. When manufacturing the linear continuous array of cones, resin (or any other adhesive) may be applied to an inner surface of one cone to accommodate another cone, or to an outer surface of one cone to accommodate an outer surface of one cone within another cone, or to be disposed internally. Thus, a rod may be manufactured by providing a plurality of single plates of the same size, each single plate forming a separate cone. For example, the plurality of veneers may be a plastic material, or a wood material. In case a plurality of wood veneers are used, these wood veneers may be provided with a backing material.

Another aspect of the invention is a method of making a tapered assembly. In a most preferred embodiment, the method is performed as a two-step process. As a first step, individual cones are manufactured by folding a sheet so that its longitudinal ends are in contact, and applying glue along these ends to form a longitudinal seam. The folded sheet is kept in a folded state until the glue is hardened. The first step may be performed, for example, by clamping the longitudinal ends and forcing them against each other, or by inserting the sheet into a preferably conical mould. After the preparation of the individual cones, in a second step, preferably 3-5 cones are laid out on a male mold and then pressed from a female mold into the cone assembly of the desired shape. Alternatively, the individual cones may be inserted into a female mold, and a male mold inserted into the inner cone to form the cone assembly.

For both alternatives, when rotating a cone on the male die, the cone may be sprayed with a glue, one by one before laying the next cone on top of the previous one. It is also possible to apply the glue on the plurality of cones in a separate operation, even on the flat single plate before forming the cones.

According to another aspect, the conical assembly is manufactured in a single operation. In this embodiment, the sheet may be inserted directly into a master mold and then pressed into its conical shape. This method is most suitable for the tapered elements requiring less of the longitudinal connection, for example, a plurality of tapered elements cut longitudinally.

In a further embodiment, a combination of the above aspects is provided. In a first step, the outer cones are bonded along the longitudinal seams or joints. The other of the plurality of cones is then placed within a hollow interior of the outer cone. It may be that the outer cone is made of a single plate and the inner cone is made of solid material and will act as a male mould. In a multi-piece product this may also be suitable as a means of reducing the number of operations, i.e. the cones that need to be preformed.

When forming more advanced shapes, such as elliptical shapes, e.g. triangular, quadratic, pentagonal, etc. polygonal shapes, and in particular shapes having little or no convexity or even flat envelope surface, it is best accomplished using any of the above-described aspects/embodiments, most preferably an outermost cone having an adhered longitudinal end.

For example, at least one cone may be formed by a sheet made of a single plate. In the array of cones, at least one cone is preferably formed by a sheet provided with a substrate material. This is preferred for a plurality of cones made of wood veneer. Further steps may include forming the plurality of sheets into a plurality of individual cones, and inserting one or more cones into the outermost cone, thereby forming a cone assembly by means of a linear array of the plurality of cones.

During the manufacture of a cone, the sheet is inserted into a female mold using a longitudinally distributed pressure (e.g., by using a male mold to provide the pressure) such that the longitudinal ends meet. The joint, i.e. the area where the longitudinal ends of the sheet meet, may not only be heated, but also have an adhesive, such as a thermosetting glue.

The advantage of this aspect is that the plurality of cones are themselves simple to manufacture and cheap to manufacture. The plurality of sheets are easily transported and the manufacturing process is made more flexible by cutting the plurality of sheets into a plurality of suitable shapes and rolling them into a plurality of cones at a time. A cone manufacturing system can manufacture multiple cones of different materials, and the cone manufacturing system can freely select the number and materials of the multiple cones to fit a desired product. The cone assembly is easy and cheap to manufacture, precisely because the individual cones can be manufactured to help them to fit better to each other. The backing material provides strength and flexibility and provides an aesthetically pleasing wood appearance if the outermost cones are made of wood veneer. The plurality of tabs may be made of a variety of flexible materials to allow the furniture manufacturer some freedom to adjust the shape of one side of the cone without sacrificing the strength of the cone array before inserting the cones into each other.

The method may further comprise attaching the plurality of cones to each other by applying an adhesive on an outer surface of a cone before inserting a cone into an outer cone. Alternatively, as mentioned above, the adhesive may be applied to one surface of the sheet before the cone is formed.

According to an embodiment, the step of manufacturing a plurality of laminae for forming a plurality of independent cones comprises providing a substrate material to each lamina.

According to an embodiment, the method further comprises a step of heat treating and/or softening at least one sheet made of veneer before shaping the at least one sheet into a single cone. In particular, the veneer may be softened by heating the sheet, and/or by softening the veneer before folding it into a cone. In this case, a term "softening" should be interpreted to mean sharply bending the veneer in a fiber direction, making the bending more uniform.

According to one embodiment, the step of forming the plurality of sheets into a plurality of individual cones is performed by arranging the plurality of sheets in a mold. The mold may typically be a master mold that can receive the sheet during folding of the sheet into a desired pyramidal shape; since the flap is curved as far as possible radially outwards, it can conform to an internal shape of the master. However, in some embodiments, it may also be desirable to use a male mold that is inserted into the female mold such that the flap is compressed between the male mold and the female mold. This may be particularly advantageous when the cone is of a small size, such as in the range of 0.5cm-2 cm.

According to an embodiment, the step of arranging the plurality of lamellae in the mould is performed such that each cone has a circular cross-section along an entire length of the cone.

According to an embodiment, the method further comprises a step of pressing the linear array of cones into a desired shape. The pressing step is performed using a male die.

According to one aspect, a furniture leg is provided. The furniture leg comprising a plurality of cones arranged in a linear array to form the leg, wherein an inner cone is received by at least one outer cone; and wherein at least one of the plurality of cones has a substrate material.

At least the outermost cone may be formed of a single plate by attaching the longitudinal ends of the single plate to each other.

All of the cones may be provided with a substrate material.

The backing material may be a paper-based material.

At least one cone may be made of any one or more of the following materials: veneer, paper, plastic, hemp, cellulose, laminate, metal, or Medium Density Fiberboard (MDF).

Each cone may be formed from a single plate by attaching the longitudinal ends of the single plate to one another.

At least the outwardly facing surface of the outermost cone may be provided with a coating.

The plurality of cones may be attached to each other using an adhesive.

According to one aspect, a method of manufacturing a furniture leg is provided. The method comprises a plurality of steps: providing a plurality of sheets to form a plurality of individual cones, wherein at least one cone is made of a sheet provided with a substrate material; forming the plurality of flakes into a plurality of individual cones; and mutually inserting one or more cones to form a furniture leg in a linear array of the plurality of cones.

The method may further comprise attaching the plurality of cones to each other by applying an adhesive on an outer surface of the cones prior to inserting a cone into an outer cone.

The step of providing a plurality of laminae to form a plurality of individual pyramids may comprise providing a substrate material to each lamina.

At least one cone may be made of any of a variety of materials, alone or in combination: veneer, paper, plastic, hemp, cellulose, laminate, metal, or Medium Density Fiberboard (MDF).

The method may further comprise the step of heat treating and bending at least one sheet of veneer before shaping the at least one sheet into a single cone.

The step of forming the plurality of sheets into a plurality of individual cones may be performed by arranging the plurality of sheets in a mold.

The step of arranging the plurality of sheets in the mold may be performed such that each cone has a circular cross-section along an entire length of the cone.

The method may further comprise the step of pressing the linear array of cones into a desired shape.

Drawings

These and other aspects, features and advantages which may be achieved by the present invention will be apparent from and elucidated with reference to the following description of embodiments of the invention, with reference to the accompanying drawings.

Fig. 1a shows a rectangular sheet that will form a cone.

FIG. 1b shows a cut sheet that will form a cone.

Fig. 1c shows a cut sheet that will form a cone, and a cone obtained from the sheet by shaping.

Figures 2a to 2c show a square sheet cut to form a cone.

Fig. 2d to 2g show a manufacturing process for preparing a tapered assembly.

Fig. 3 shows three foils with different combinations of substrate and coating.

FIG. 4 shows different arrangements of the plurality of cones in the plurality of linear arrays of the plurality of cones.

FIG. 5 shows a plurality of cones coated with coating and adhesive in a plurality of linear arrays of cones.

Fig. 6a shows a mould for shaping the sheets into cones.

Fig. 6b shows a mold with a thin sheet inside, and an alternative male mold.

FIG. 7a shows a perspective view of a finished cone assembly.

FIG. 7b shows a perspective view of a plurality of finished cone assemblies having different shapes.

FIG. 8 shows a flow chart with steps for manufacturing the cone assembly.

FIG. 9 shows another flow chart with steps for manufacturing the cone assembly.

Detailed Description

Various embodiments of the present invention will be described herein with reference to the several figures. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In the detailed description of the various specific embodiments illustrated in the various figures, the terminology used is not intended to be limiting of the invention. In the drawings, like numerals refer to like parts throughout the several views.

Fig. 1a, 1b, and 1c, as well as fig. 2 a-2 c, illustrate that sheets 10 may be optionally cut to form a tapered shape suitable for rolling into cones. The plurality of sheets 10 may be laid out in a flat configuration to form a sheet. The sheet may for example be a single sheet, i.e. a thin deformable sheet. For fibrous substrates, such as wood, etc., a fiber direction may not be perfectly aligned with a longitudinal direction of a cone, but it may be different to some extent, such as ± 45 ° or less. Furthermore, the fiber direction is not meant to refer to the direction of all fibers, but should be interpreted as the general direction of a plurality of fibers, or the horizontal direction.

In a preferred embodiment, at least one cone is made of a wood veneer. At least one of the cones may be made of a single sheet of any one or more of the following materials: paper, plastic, hemp, cellulose, wood, cork, non-woven material, thermosetting resin impregnated paper, or Medium Density Fiberboard (MDF). Even metals such as steel or aluminum are conceivable. The sheet may be formed into a three-dimensional shape, for example by wrapping or rolling/folding without damaging the material.

FIG. 1a shows a rectangular sheet 10; fig. 1b shows a corresponding cut segment and a rolling direction to obtain a truncated cone from said cut segment. In this embodiment, the corner pieces cut from the sheet 10 are discarded. The longitudinal ends 8 of the cut sheet 10 are folded towards each other and optionally attached to each other to maintain a conical shape.

In fig. 1c, another sheet 10 is shown, which is cut in such a way as to create two different angles at the longitudinal ends of the sheet. The angle to be formed at a top end of the cone is less than the angle to be formed at a bottom end. When formed into a cone, a width of the cone will decrease in a non-linear manner, since an abrupt change in a cutting angle will result in an abrupt change in how a thickness decreases.

FIG. 2a shows a square foil 10; fig. 2b shows a corresponding cut segment after initial cutting, while fig. 2c shows additional cut lines 9 to form a final shape and a rolling direction to obtain a truncated cone from the cut segment. In this embodiment, smaller portions of the sheet 10 are discarded due to the cut lines 9. The fibres are preferably directed substantially along a longitudinal extension of the cone, and the longitudinal ends 8 of the cut pieces are folded towards each other and attached to each other as required to maintain the conical shape. The flakes 10 can have any desired shape and the flakes 10 can be cut to a desired shape as desired during any manufacturing step prior to rolling the flakes 10 into cones. The embodiment shown in fig. 2a to 2c is advantageous when using a plurality of veneers, since a longitudinal axis of the pyramid will not exactly correspond to a fibre direction of the veneer, the fibres being angled with respect to the longitudinal axis of the pyramid, whereby a staggered texture of cones is achieved, each cone of the cones being configurable with a different fibre angle with respect to the closest cone in an assembly. A cone is a very simple shape that can be made from almost any flat surface, depending on its way of folding. This has the advantage that a plurality of sheets 10 of a size and shape that is easy to manufacture or transport can be used, as well as waste from other types of manufacturing.

As one example, a cone may be much shorter than the final cone assembly. A shorter taper may be provided to form a connecting structure or to reinforce existing connecting structures. The shorter cone may for example be made of wood or metal, and the longitudinal ends may even have a mutual overlapping structure. Such overlap may be in the range of 5-10mm, or greater.

The longitudinal ends 8 of the sheets 10 may be straight or curved. They may be, for example, sinusoidal or saw-toothed to improve the conformity of the ends to each other. The width of the plurality of sheets may be different.

Turning now to fig. 2d, another example is shown. Here, a roll 11 of a sheet-like material is provided and cut into individual sheets 10 in a continuous manner. Preferably, the rollers 11 are oriented such that the fiber direction of the sheet-like material is in a transverse direction. Based on a cutting process, a series of sheets 10 is thus provided. The plurality of lamellae 10 may be made of the same size, thereby forming the same plurality of cones. However, in a preferred embodiment, the plurality of lamellae 10 have a size that differs, such that one lamella 10a will be used to form an outer layer cone C2, a slightly smaller lamella 10b to form an intermediate layer cone C3 to fit inside the outer layer cone C2, and a lamella 10C slightly smaller than lamella 10b to form an inner layer cone C1 to fit inside the intermediate layer cone C3. In practice, this is achieved for each cone by using a constant cut angle and length, but reducing the width of the continuous plurality of sheets (for subsequent formation of the continuous plurality of cones).

After the sheets 10 are formed, they may be stacked on top of each other and laid in a gluing station. Here, a plurality of rollers GA are arranged to be in contact with the plurality of longitudinal end portions of the plurality of sheets. Since the plurality of rollers GA have an adhesive, such as glue, the adhesive will be transferred to the ends of the plurality of sheets 10 since the plurality of rollers GA move along the longitudinal ends of the plurality of sheets.

Each lamina 10 is then inserted into a master mold 60 as shown in fig. 2 f. When the sheet 10 is inserted, the sheet 10 will automatically fold such that the longitudinal ends of the sheet come into contact. This will eventually harden to fix a pyramidal shape by applying glue, or other adhesive, to the longitudinal ends of the sheet 10. Once extracted from the mold 60, the sheet 10 is in the shape of a cone C1, C2.

Thus, the longitudinal ends of the sheet may be joined using an adhesive, and also optionally using high temperature and/or pressure. The adhesive may be wet or dry and pressure and/or elevated temperature may be applied in a variety of ways. Examples of suitable binders include thermosetting glues such as urea formaldehyde, melamine formaldehyde, phenol formaldehyde based or thermoplastic glues, melt glues used as PVA-c.

Once a plurality of cones C1, C2 are fabricated, these cones are used to form a cone assembly. For this purpose, a mold 60 is again used. The mold 60 used to form the cone assembly may be the same mold used to make the individual cones, or may be another mold. In particular, if the cone assembly is to have another shape than the plurality of individual cones, another mold will be required.

Inserting the plurality of cones in a sequential manner; an inner layer taper C1 is inserted into an intermediate layer mold C3, which in turn is inserted into an outer layer taper C2 as mold C3. The plurality of cones C1-C3 may be attached to each other using an adhesive, and the plurality of cones C1-C3 may be further pressed into a desired shape using a male die. Preferably, the plurality of cones are rotated at least 5 degrees or more relative to each other such that a longitudinal seam/joint of an outer cone is offset from a longitudinal seam/joint of an inner cone. The seams/joints of a wood cone and an inner paper cone may be aligned, while the seams/joints of a third inner cone are offset relative to the first seams. The plurality of seams may have different angles relative to the longitudinal axis of the cone assembly such that the plurality of seams intersect one another.

A plurality of the molds 60 may be constructed of two or more parts so that they can be separated. This facilitates both the plurality of cones C1-C3 and the extraction of the cone assembly from the mold 60.

As can be seen from fig. 2g, the cones C1-C3 are rotated relative to each other to ensure that the junctions, i.e. the junctions of the longitudinal ends of the lamellae, are separated in a circumferential direction.

When the plurality of cones C1, C2 are arranged in a linear array such that an inner cone C1 is received by at least one outer cone C2, an inner surface of the outer cone C2 covers substantially the entire outer surface of the inner cone C1.

Fig. 3 shows a plurality of sheets 12,14,16 having different materials and coatings. The plurality of sheets are shown as a first sheet 12 having a substrate material 12 but no coating, a sheet 14 having a coating but no substrate material, and a sheet 16 having a combination of both a substrate material and a coating. Other types of substrates and combinations of coatings are possible for the plurality of sheets 12,14,16, such as the addition of an adhesive layer, and the plurality of substrates and coatings may be provided before or after the plurality of sheets 12,14,16 are cut or rolled into the plurality of cones. Different ones of the sheets 12,14,16 and cones may have different substrates and coatings in a same linear array, and the same sheet may have substrates or coatings that may be applied in different manufacturing steps before or after rolling the sheet into a cone. Not only is the choice of materials for the various substrates and coatings freely available, but also the choice of when to apply them in view of a flexible production system, where certain process steps may be outsourced to a third party or produced at a different plant.

A cross-sectional view of a sheet used to form a cone is also shown at the bottom of fig. 3. The sheet 10 has a first layer L1 disposed adjacent a second layer L2. In one embodiment, the first layer L1 is a wood veneer and the second layer L2 is a backing material. It should be readily understood that in some embodiments, the second layer L2 is omitted and the materials of the first layer L1 and the second layer L2 may be selected depending on the particular application.

In one embodiment, the sheet may include a plurality of strips on its outer surface to form a visually striped design. Still further, the sheet may be dyed and/or painted, but since the sheet is flat, the sheet may also be embossed and/or brushed and then effectively painted, for example with an acrylic paint. The embossing may be formed by embossing an embossing roller or plate onto the veneer, preferably by heat treatment, preferably between 60-200 ℃, and preferably by resin impregnation, to have resin on the back or inside of the veneer. The embossments may contact and mate with each other along the longitudinal ends so that the seam, or joint, is even further concealed. By matching is meant that at least 30%, more desirably at least 50%, of the plurality of projections and the plurality of indentations on the surface of a side of an end of a single sheet will substantially correspond in height to the plurality of projections and the plurality of indentations of an adjacent longitudinal end of the single sheet.

Referring to FIG. 4, various substrates, various coatings, and various non-limiting combinations of materials will be discussed herein. Any number of cones may be combined within the scope of the technical concept described herein, as long as there are at least two cones and at least one outermost cone C2 is made of a first layer L1 of material. The material of the first layer L1 is preferably different from the material of the inner cone. In a preferred embodiment, at least one of the plurality of cones C1-C3 has a substrate material. The inner cone C1 may be made of a solid material, such as softwood or hardwood or glued wood, i.e. forming a solid cone. The outermost cone may be formed by folding a paper-based substrate or a non-woven substrate reinforced wood veneer into a cone and bonded along the longitudinal ends, and the inner envelope surface has glue thereon. The inner cone may have an elliptical or a polygonal cross-sectional shape, which may vary with a longitudinal extension of the cone assembly.

According to one embodiment, the outer cone C2 is made of a class a wood veneer made of a kraft paper substrate weighing 80-150 grams, the middle cone C3 is made of a low value wood veneer, such as fir or pine, and is made of a kraft paper substrate, and the inner cone C1 is made of a low grade veneer and is made of a kraft paper substrate. The resulting cone assembly may be provided with one or more end plugs, or one or more intermediate plugs. A plurality of said intermediate plugs are preferably provided with a bore and said plurality of intermediate plugs taper inwardly towards said bore.

At the top of FIG. 4, an outer cone C2 is made of, for example, a wood veneer of a non-backing material that houses an inner cone C1, the inner cone C1 being of a non-wood veneer material (e.g., paper, plastic, hemp, cellulose, plywood or Medium Density Fiberboard (MDF) or equivalent) and backing is applied only to the inner cone C1. Under this array, an identical assembly is shown, additionally having an intermediate layer taper C3 of non-single sheet material and no substrate, the intermediate layer taper C3 being inserted into the array.

Below this array, a combination of three single plate cones C1-C3 each provided with a substrate is shown. On the top, an array is shown with two non-single plate cones without substrate C1, C3, the cones C1, C3 being inserted into a single plate cone with substrate C2. The benefit of being able to combine a number of materials, a number of substrates and a number of coatings somewhat freely, and a number of tapers, is to allow for a tapered assembly that can have different ancillary characteristics, price, size, and manufacturing speed without substantially changing its production system.

For some embodiments, in which an outermost cone C2 is made of a single sheet or equivalent material, the resulting cone assembly will have a classic aesthetic appearance, and the stability of the cone assembly is further enhanced by requiring at least one cone C1-C3 to have a backing material. These characteristics make the tapered assembly particularly suitable for use in a furniture leg. Further combinations, different substrates and coatings, multiple new combinations of multiple substrates and multiple coatings, and more than three pyramids in an array are also possible.

Reference is now made to fig. 5, which illustrates various substrates, various coatings, and other non-limiting combinations of various materials within the scope of the present invention. The top array of multiple cones shows a cone C2 made of a sheet or equivalent non-single sheet material with a substrate into which cone C2 is inserted cone C3 provided with one or more intermediate layers of adhesive, said cone C3 being made of a non-single sheet material (e.g. paper, plastic, hemp, cellulose, laminate or Medium Density Fiberboard (MDF) or equivalent). Further inserted into the array is an inner layer veneer cone C1 provided with adhesive. A bottom array of multiple cones shows an outer layer veneer cone C2 with a coating. The array further includes one or more intermediate layer non-veneer cones C3 with a coating, and an inner layer veneer cone C1 with a backing material. Applying an adhesive to the plurality of cones C1, C3 in the array has the advantage of maintaining the structural integrity of the array, ensuring that the array cannot be torn apart or that the plurality of cones can be separated. This can also provide further advantages depending on the adhesive used. By using an adhesive that is malleable for the first application and rigid after drying, the adhesive can help maintain a shape of an array that is a new shape that has been pressed before the adhesive dries. Examples of such adhesives are glues, heat treated or melted plastics and other types of curable resins.

The advantage of applying a coating depends on the coating used. Certain oils or chemicals may be used to help the cone assembly withstand a variety of environmental conditions, further increasing the life of the product. Aesthetic advantages can also be achieved through the use of various coatings such as wood stains or paints. In this case, it may be beneficial for the coating to cover only the outermost cones.

The adhesive may be applied to the plurality of sheets prior to taper formation. The adhesive may be selected from a type of adhesive that is normally dry and activated by high temperature and/or pressure.

With the embodiments described above, it should be mentioned that the inner cone C1 may not necessarily be manufactured by folding a sheet as described above. Alternatively, the inner cone C1 may be a solid cone disposed on the intermediate and outer cones C2, C3.

An embodiment of fig. 6a and 6b shows a mould 60 for receiving the plurality of lamellae 10 and forming individual cones. The mold 60 may be any shape or size and may have a variety of different shapes in one mold. In view of a process of quickly and easily attaching the ends 8 of the sheet 10 to each other, the mold 60 may preferably be configured such that the longitudinal ends 8 of the sheet 10 come into contact when the sheet is inserted. The benefits of using a mold 60 are that it is easier to make the shape and size of the plurality of cones consistent, the shape and size of the sheet 10 can be inconsistent while still keeping the shape and size of the plurality of cones the same, the ends are easier to attach to each other, and the coating can be applied more easily using the mold. Alternatively, as shown in FIG. 6b, the sheet is pressed to conform to the shape of a female mold by means of a male mold 61. When the male die 61 is inserted into the female die 60, the taper is shaped.

As previously described, a tapered member may be formed using a similar die concept. It is not necessary to insert a sheet of material but a series of multiple cones C1-C3. If the inner cone C1 is hollow, a male mold may be used.

Fig. 7a shows a first embodiment of a cone assembly, while fig. 7b to 7c show further embodiments of a cone assembly. In fig. 7, a linear array 40 of a plurality of cones is shown, which is formed by the plurality of cones. The cone assembly 40 has a circular cross-section 50 along an entire length of the linear array of cones 40. Further, the array 40 has been cut or the plurality of cones forming the array have been sized so that there are no protruding cones protruding from the ends of the array. This may be beneficial because a flat end is easier to secure to a piece of furniture. This also increases the stability of the cone assembly if all of the plurality of cones can extend to the plurality of ends of the array. The circular cross-section is easy to manufacture and transport and also has a predictable response when formed.

In fig. 7a, three embodiments of support members 70 are schematically shown, each of which may be used alone or in combination with one or more support members. These can of course also be used with the described cone assembly of figures 7b to 7 c. A support member 70 is at a top end, a support member 70 is at a bottom end, and a support member 70 is disposed between the top end and the bottom end. A through hole 72 may be provided in one or more of the support members 70.

Figure 7b shows another form of a cone assembly. The linear array of cones 40 is formed in a similar manner to that of figure 7a except that in this embodiment the array of cones 40 has been embossed to change at least one of the circular cross-sections 50 at both ends of the array to another, possibly more desirable shape 52. This new shape 52 can be maintained if desired by using suitable materials, substrates and coatings, and possibly further manufacturing steps. The new shape may be desirable for a variety of aesthetic reasons, for a variety of functional reasons, or for other reasons. In addition to varying the cross-section of the plurality of cones of the array, bending the array may also be considered to be within the definition of embossing the array. In this case, the mould may comprise two or more parts possibly separate from each other, and the mould itself may comprise a flexible material, but the flexible material has a high shore D hardness characteristic, preferably between 20 and 80, even more preferably 40 to 60. The flexible material may be made of silicone, synthetic or natural rubber, or the like. The advantage of being able to vary the shape of the conical assembly is that almost the same production system can be used for different aesthetic and functional requirements.

In fig. 7b, the bottom end has an elliptical shape 52. Figure 7c shows another form of the cone assembly. In this figure, the top end of the conical element 40 has a square cross-section 52, while the bottom end has a parallelogram, such as a diamond shape.

Manufacturing an array of cones is preferably performed by inserting a first cone into a master mold having the shape of a desired cone assembly, and then loading additional cones into the first cone. A male die may be used to further press the plurality of cones to a desired shape as needed. A female cone may be made up of two or more halves that can be opened. The mold may also be composed of two or more halves, which may be inserted and pulled out together or separately.

Reference is now made to a manufacturing method according to fig. 8. First, the plurality of sheets are constructed (step 110). The person skilled in the art knows that there are many ways to build sheets suitable for rolling into cones, which may not even have to be done as in the previously presented embodiment using waste as sheets. A substrate material is added to one or more of the sheets, either during or after the build (step 120). The backing material, which may be a number of different materials or a combination of materials, is important in improving the robustness of the cone once the foil is rolled into a cone and in ensuring that the foil is intact during cone formation. After the substrate material is added, the plurality of sheets may need to be cut (step 130). This may be done to better fit the cones together, or it may be possible to fit the sheets to a mould, however this is an optional step. The next step is to roll the plurality of laminae into a plurality of cones, respectively (step 140). This step may be accomplished in a number of different ways, and it may be preferable to attach the longitudinal ends of the sheet during this step. Once the plurality of cones are constructed, a cone is inserted into another cone (step 170). The single plate pyramid in this step will be the outermost pyramid in a completed array. After the first pyramid is inserted into the outermost pyramid, any number of other pyramids may be inserted into the array as desired by repeating step 180. It is considered indistinguishable herein between the insertion of cone a into cone B, and the accommodation of cone B into cone a. Those skilled in the art will appreciate that the various steps do not necessarily have to be performed in the order described, and that certain steps may be combined with other steps.

An alternative embodiment is shown in fig. 9. First, the plurality of sheets are constructed (step 110). Then, a plurality of the veneer sheets are heat-treated and softened (step 115). The term softening is to be understood as a process of controllably breaking or crushing the fibers of the veneer so that it is more flexible, which may be done, for example, by machines available from the company HOFER presstechnik gmbh. The heat treatment may be performed before, after or during softening. Most preferably, the heat treatment is performed together with inserting the wood veneer into the mould to soften the material. Suitable temperature ranges include 50-180 ℃, depending on the materials used. The heat treatment is a preferred choice for improving the results of a bending process. The benefit of bending the plurality of single sheet laminae is that they are more flexible so that a plurality of smaller cones can be rolled from them. After, before, or during the bending, a substrate material is added to the plurality of sheets (step 120), and the plurality of sheets are cut as needed (step 130). Next, the plurality of laminae are rolled into a plurality of cones (step 140). One embodiment of this method is to use a die to roll the plurality of sheets (step 140'). The benefits of using a mold are that the multiple cones are more easily made to conform in shape and size, the sheet 10 may be non-conforming in shape and size while still keeping the multiple cones identical in shape and size, the multiple ends are more easily attached to each other, and the mold can more easily apply multiple coatings. It will be appreciated that the sheet is preferably cut to fit precisely within the mould so that the longitudinal ends of the sheet are in contact but do not overlap. The step of adding a plurality of coatings (step 150) and a plurality of adhesives (step 160) may be performed before, after, or during the previous step. Applying an adhesive to the plurality of cones in the array has the advantage of maintaining the structural integrity of the array, ensuring that the array cannot be torn apart. This can also provide further advantages depending on the adhesive used. By using an adhesive that is malleable for the first application and rigid after drying, the adhesive can help maintain a shape of an array that is a new shape that has been pressed before the adhesive dries. Examples of such adhesives are glues, heat treated or melted plastics and various light curable resins. The advantage of applying a coating depends on the coating used. Certain oils or chemicals may be used to help the cone assembly withstand a variety of environmental conditions, further increasing the life of the product. Aesthetic advantages can also be achieved through the use of various coatings such as wood stains or paints. In this case, it may be beneficial for the coating to cover only the outermost cones. Next, a cone is inserted into a cone (step 170), forming the linear array of cones. Optionally, additional cones may be inserted (step 180). Finally, one embodiment compresses a finished linear array of multiple cones into a desired shape (step 190). The pressing may include manual or mechanical bending, manual or mechanical kneading, and manual or mechanical molding. The shape built up by the pressing may or may not be permanent, and in the case of permanent, a variety of pyramidal materials, a variety of substrates, a variety of coatings or a variety of adhesives may be used to maintain the shape after pressing.

Hereinafter, some embodiments of the multiple taper assembly will be described.