US20100043679A1

US20100043679A1 - Slat tabletop with end caps

Info

Publication number: US20100043679A1
Application number: US12/197,606
Authority: US
Inventors: David J. Laws; Richard D. Smith; Brandon Ross
Original assignee: Individual
Current assignee: Mity Lite Inc
Priority date: 2008-08-25
Filing date: 2008-08-25
Publication date: 2010-02-25

Abstract

A tabletop formed from slats for use in rigid, light-weight tables, such as portable banquet tables. The tabletop includes a center section formed from a plurality of open-channel, rectangular tubular slats that are laterally coupled together. Each slat has a top wall that aligns with top walls to form the upper working surface of the tabletop. Each slat also has downwardly-projecting sidewalls and a bottom wall with a longitudinal slot running the length of the slat to form the rectangular, downwardly-orientated channel. The adjacent contacting sidewalls of adjacent slats coupled together to form substantially vertical support beams. The tabletop further includes a pair of elongate end caps disposed on opposite ends and spanning the plurality of slats of the center section, with each end cap having a plurality of finger pairs extending into the plurality of slats with a center slot the receives a support beam therein.

Description

FIELD OF THE INVENTION

The present invention relates generally to tables, and more particularly to tables with tabletops formed from a plurality of slats, such as picnic tables.

BACKGROUND OF THE INVENTION AND RELATED ART

Tables with tabletops and benches made from a plurality of slats, such as outdoor picnic tables, are well known. The tabletop assemblies are often made with multiple similarly-sized slats positioned adjacent and secured next to one another. In the past, the slats were often formed of wood and were substantially solid over the length of the slat.
Other materials have gained in popularity for use as slats for tabletops. For example, rectangular tubing or channels formed of aluminum have been used as a structural component for outdoor tabletops and furniture. Aluminum is ideal for tabletops because the metal is light-weight and weather-resistant. Additionally, because aluminum is relatively strong, the slats need not be solid.
Aluminum and similar metallic slat tables do have drawbacks, however. Because the metallic slats are hollow tubes or open-faced channels formed with an extrusion process, the ends of the slats are often left open and without the same smooth metal finish which defines the top or sides of the slat. In these circumstances, if the finished slats are not precisely dimensioned and finished before assembly into a table, the ends of the table can have an uneven, misaligned appearance with a number of protruding edges and points that can snag nearby objects and passersby. Likewise, if the slats are assembled together prior to being cut to length, the final cutting of the tabletop can also leave ends having sharp or jagged edges. In order to address these problems, some slat tables have the end portions of the slat cut and folded to form a closed end. Unfortunately, aluminum slats with integrally-formed closed ends can still have sharp corners which can be painful to bump or lean against, as well as a thin and relatively sharp bottom edge that can make the table difficult to pick up or move by hand.
Another challenge with slat tables is that the slats lend themselves to forming square or rectangular tables, but many users prefer round tables. Slats can be cut to form round tables, but as noted above, aluminum and other metal slats leave sharp edges where they are cut, and aluminum slats with smoothly-curved closed ends in the horizontal plane, for incorporation into a round table, have not been developed.
Yet another challenge with slat tables is that the slats making up the tabletop are typically formed with a thickness greater than the thickness of traditional one-piece composite/laminated banquet tables. For this reason, tables with slat tabletops have not been widely used for demonstration purposes, because the industry-standard skirt clips used to attach the skirts or drapes to the tables are typically sized to fit the ¾ inch thickness of traditional one-piece composite/laminated banquet tables, rather than the one and a ¾ thickness of the aluminum or wooden slat tables. Thus, many existing table skirt systems simply do not fit onto slat tabletops.

SUMMARY OF THE INVENTION

In light of the problems and deficiencies inherent in the prior art, the present invention seeks to overcome these by providing a tabletop that includes a center section formed from a plurality of open rectangular tubular slats that are laterally coupled together, with each slat having a top wall with a substantially horizontal top surface, sidewalls, and a bottom wall having a longitudinal slot running the length thereof, and where adjacent slats having adjacent contacting sidewalls coupled together to form substantially vertical support beams. The tabletop further includes elongate end caps disposed on opposite ends and spanning the plurality of slats of the center section, with each end cap having a plurality of finger pairs that extend into the plurality of slats, and with a slot for receiving a support beam to align and couple the end cap to the center section.
The present invention can further comprise a rectangular-shaped tabletop that includes a center section formed from a plurality of open rectangular tubular slats laterally coupled together, with each slat having a top wall with a substantially horizontal top surface, sidewalls, and a bottom wall having a longitudinal slot running the length thereof, and adjacent slats having adjacent contacting sidewalls coupled together to form substantially vertical support beams. The tabletop also includes a pair of elongate end caps disposed on opposite ends and spanning the plurality of slats of the center section, with each end cap having a plurality of finger pairs extending into the plurality of slats, and each finger pair having a slot for receiving a support beam therein for aligning and coupling the end cap to the center section. The center section and the elongate end caps are further configured to couple together into a rectangular-shaped tabletop.
The present invention can also comprise a round-shaped tabletop that includes a round-shaped center section formed from a plurality of open rectangular tubular slats laterally coupled together, with each slat having a top wall with a substantially horizontal top surface, sidewalls, and a bottom wall having a longitudinal slot running the length thereof, and adjacent slats having adjacent contacting sidewalls coupled together to form substantially vertical support beams. The rounded tabletop also includes arcuate end caps disposed on opposite ends and spanning the plurality of slats of the center section, with each end cap having a plurality of finger pairs extending lengthwise into the plurality of slats and each finger pair having a slot for receiving a support beam therein for aligning and coupling the end cap to the center section, and arcuate side caps disposed on the center section between opposing end caps to complete the rounded perimeter of the tabletop, with each side cap having a plurality of attachment bars projecting crosswise into the slats. The arcuate end caps and side caps together form an edge ring that surrounds and encapsulates the edge of the round-shaped center section, and which can be configured to accommodate the differences in thermal expansion and contraction between the metallic center section and the molded plastic end ring to maintain a constant, secure fit between the end ring and the center section.

BRIEF DESCRIPTION OF THE DRAWINGS

Features and advantages of the invention will be apparent from the detailed description that follows, and which taken in conjunction with the accompanying drawings, together illustrate features of the invention. It is understood that these drawings merely depict exemplary embodiments of the present invention and are not, therefore, to be considered limiting of its scope. And furthermore, it will be readily appreciated that the components of the present invention, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Nonetheless, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:

FIG. 1 illustrates a perspective top view of a rectangular slat table with end caps, according to an exemplary embodiment of the present invention;

FIG. 2 illustrates a top, perspective view of the center section of the embodiment of FIG. 1;

FIG. 3 illustrates a bottom, perspective view of the center section of the embodiment of FIG. 1;

FIG. 4 illustrates a perspective view of the end cap of the embodiment illustrated in FIG. 1;

FIG. 5 illustrates an exploded perspective view of the bottom of the embodiment of FIG. 1;

FIG. 6 illustrates a side view of the embodiment of FIG. 1;

FIG. 7 illustrates a perspective top view of a round slat table with end caps and side caps, according to another exemplary embodiment of the present invention;

FIG. 8 illustrates an exploded perspective view of the bottom of the embodiment of FIG. 7;

FIG. 9 illustrates a close-up, exploded perspective view of the bottom of the embodiment of FIG. 7;

FIG. 10 illustrates a bottom view of the embodiment of FIG. 7; and

FIG. 11 illustrates sectional a side view of the embodiment of FIG. 7.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The following detailed description of the invention makes reference to the accompanying drawings, which form a part thereof and in which are shown, by way of illustration, exemplary embodiments in which the invention may be practiced. While these exemplary embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, it should be understood that other embodiments may be realized and that various changes to the invention may be made without departing from the spirit and scope of the present invention. As such, the following more detailed description of the exemplary embodiments of the present invention is not intended to limit the scope of the invention as it is claimed, but is presented for purposes of illustration only: to describe the features and characteristics of the present invention, and to sufficiently enable one skilled in the art to practice the invention. Accordingly, the scope of the present invention is to be defined solely by the appended claims.
The present invention describes a slat tabletop with end caps for providing a strong, light-weight and multi-function tabletop that is easy to manufacture and assemble. The tabletop can include a center section comprising of a number of open-ended channel slats made from metal, such as aluminum, that are laterally coupled together to form a tabletop structure. The shape of the center section, as viewed from above, can be rectangular, square, oblong or round, or any other shape for a tabletop appreciated by one of skill in the art. The individual channel slats can have a solid top wall with a smooth upper face, two solid sidewalls, and an open bottom wall, meaning “open” in the sense that a longitudinal slot is formed along the length of the bottom wall to divide the bottom wall into two ledges extending inwardly from the bottom corners of the sidewalls.
The slats can be orientated with the upper faces of the channel slats aligned together to form the top working of the tabletop. The open side of the slats can be at the bottom. The sidewalls of adjacent slats can be coupled together to form vertical, downwardly-projecting support beams that can serve to both stiffen and strengthen the tabletop, and to provide attachment points for end caps, legs, table supports, handles, etc.
The channel slats comprising the center section of the tabletop can be further separated into interior slats and perimeter slats. The interior slats can have matching, squared sidewalls on both sides of the slat for providing uniform contact surfaces for abutting and coupling adjacent slats together. The perimeter slats, on the other hand, can have one sidewall squared for coupling to the interior slats, and the other sidewall curved to provide an outer edge of the tabletop.
The slat tabletop can also include elongate end caps installed at the ends of the center section. The end caps can be made from the same metallic material as the center section. The end caps can also be made from a different material such as plastic, etc., that lends itself to manufacturing techniques, such as injection molding, that can be used to make complex parts. The end caps can be provided with projecting finger pairs that are inserted into the open ends of the channel slats to align and attach the end caps to the center section.
Both the end caps and the perimeter slats can be provided with the same uniform and rounded outer edge or edge profile, so that the outer rim of the tabletop has a uniformly smooth shape around its entire perimeter, to facilitate lifting and handling and to avoid the narrow or sharp edges or corners found in the prior art that could be hazardous to passersby or those working around the table.
The present invention provides several significant advantages over prior related tabletops made from wooden or metallic slats, some of which are recited here and throughout the following more detailed description. For instance, manufacturing a tabletop from aluminum slats provides a light-weight yet durable and weather-resistant tabletop surface that is reinforced from below with the downwardly-projecting support beams formed by the joined sidewalls of adjacent slats. This configuration provides the greatest strength for a given amount of material, as an aluminum tabletop with spaced support beams is much stronger than a tabletop formed from a single span of aluminum sheet or plate. At the same time, the aluminum tabletop is much lighter than a tabletop made from solid wooden slats that can support an equivalent load.
The tabletop of the present invention also resolves the sharp or hazardous edge issues present in other aluminum slat tabletops by covering the roughened edges with the elongate end caps. Covering the acute or sharp edges and corners found in prior existing aluminum slat tables with specifically-formed end caps results in a tabletop that is safe to work around, bump against, lean on, etc.
The tabletop of the present invention can be simple to manufacture and assemble. For instance, the end caps can be made from plastic using an injection molding or similar manufacturing process, which lends itself to the low-cost production of the complex part. The open-ended aluminum channel slats forming the center section can also be made with low-cost metal working processes, such as extrusion, folding, welding and cutting. Directing the metal working processes towards simple steps and organizing the complex components into the end caps can result in improved manufacturing efficiency and lower material and production costs.
Manufacturing an aluminum channel slat having a closed end with a rounded surface or large-radius corners can be very difficult and expensive. By fabricating the center section and end caps separately and assembling them together afterwards, the tabletop can be configured with an outer edge that is uniformly curved and smooth around its entire perimeter. This facilitates lifting, handling and other human contact. Moreover, the shape of the outer edge can be adjusted to allow for an overhang or projecting flat with a defined thickness less than the thickness of the channel slat, such as the ¾ inch thickness of traditional one-piece composite/laminated banquet tables. This allows the slat tabletop of the present invention to be used with skirt clamping systems that are designed to attach skirts or drapes to demonstration tables having more industry-standard dimensions.
Each of the above-recited advantages will be apparent in light of the detailed description set forth below and best understood with reference to the accompanying drawings, wherein the elements and features of the invention are designated by numerals throughout. These advantages are not meant to be limiting in any way. Indeed, one skilled in the art will appreciate that other advantages may be realized, other than those specifically recited herein, upon practicing the present invention.
With reference to FIGS. 1-6, illustrated is a rectangular slat tabletop with end caps according to an exemplary embodiment 10 of the present invention. As shown generally in FIG. 1, the tabletop 10 comprises a center section 20 made from a plurality of interior slats 22 and perimeter slats 24, and with elongate, substantially-straight end caps 60 attached at both ends of the center section. The upper faces of slats and the elongate end caps can be aligned flush to form the tabletop working surface 26. The tabletop 10 can be supported on a table base 90 having legs 92, or with any other similar support system including a tubular frame, a pedestal, etc. Furthermore, the rectangular tabletop 10 of the present invention is not limited for use as a portable banquet table, as illustrated, but can also be incorporated into a wide variety of table types and configurations, such as the top piece of an outdoor picnic table, a cafeteria table, a patio dining or end table, a work bench, etc.
The topside and underside of the center section 20 are shown with more detail in FIGS. 2 and 3, respectively. As stated above, the center section can be made with a plurality of interior slats 22 and perimeter slats 24. Each slat, both interior and perimeter, can have a solid top wall 40, the upper faces of which form the working surface 26 of the tabletop. Extending downward from each side of the top wall 40 are the sidewalls 42, which can turn inward at the base to form the bottom wall of the channel slat. When the tabletop 10 is made with channel slats, as shown in the exemplary embodiment 10, the bottom wall can be divided by a longitudinal slot 44 into two short ledges 46 extending inwardly from both sidewalls. The longitudinal slot 44 can run the length of the slat. Holes 48 for fasteners can be formed at the either end of the ledges 46 for providing enhanced connection of the slats to the end caps after assembly.
The top wall 40 of each interior slat 22 and perimeter 24 can be aligned flush with the adjacent slats, and the slats coupled together to form the tabletop working surface 26. In one aspect of the invention, the slats can be coupled together using any manufacturing method known in the art, such as welding, adhesives, fasteners, etc. In another aspect, the slats can be positioned adjacent and secured next to one another using an underlying crossbar or similar structural member (not shown) that spans the width of the tabletop.
The interior slats 22 forming the interior portion of the center section 20 can have squared sidewalls 42 on both sides for providing uniform contact surfaces when abutting and coupling the slats together to form the center section. When the sidewalls 42 of two adjacent channel slats are laterally coupled together, the two sidewalls and associated ledges 46 can combine to form an underlying support beam 56. The support beam can have a shape substantially similar to the shape of an I-beam, which is to be appreciated by one having skill in the art as a support structure capable of providing substantial stiffness, rigidity and strength to the tabletop. When the tabletop is formed from a plurality of channel slats, multiple support beams 56 can run the length of the tabletop.
The perimeter slats 24 can have one sidewall distinct from the other, with one squared sidewall 42 to provide attachment to an interior slat 22, and the other sidewall shaped and curved to provide an outer edge 30 of the center section. The outer edge 30 of the perimeter slat 24 can be configured with a protruding flat 32 having a top surface that is part of the working surface 26, and an outer side surface 34 that defines the lateral boundary of the center section. The protruding flat can also be configured with an overhanging bottom surface 36 that folds directly downward into vertical apron surface 38. Because the slats can be made from a malleable aluminum or similar metal, the curved profile of the outer edge 30 can be integrally formed into the slat by bending the perimeter edge of the slat into the desired shape.
In one embodiment of the present invention, vertical apron surface 38 can be the outside face of a rectangular member 50 which has an underlying stepped configuration with respect to the protruding flat 32. The bottom surface 52 of the rectangular member can be co-planar with the bottom ledges 46 extending from each of the squared sidewalls 42, and can also have a hole 48 formed at the tip for the post-assembly insertion of a fastener. Furthermore, the back surface 54 of the rectangular member 50 can be curved to provide a comfortable gripping surface for a person lifting or handling the tabletop. This configuration eliminates the sharp or narrow bottom edge of the metallic slat that is common with the prior art, and which can dig into the hands of users handling the tabletop.
In an alternative embodiment, the perimeter slats 24 can have the same sidewall configuration as the interior slats 22, so that the outside edge 30 of the center section 20 is a squared sidewall similar to the squared sidewalls 42 coupled or abutted together within the interior of the center section.
Illustrated in FIG. 4 is a perspective view of the elongate end cap 60, according to an embodiment of the present invention. The end cap 60 can have a substantially-straight elongate body 62 with multiple internal finger pairs 64 that interconnect with the support beams in the center section. The end cap 60 can further include two outer finger pairs 70 that interconnect with the protruding flats and rectangular members formed into the outer edges of the center section. Both finger pairs can comprise a projecting bar 66, 72 and a screw tab 68, 74. Furthermore, the exposed outer side of the end caps 60 can be configured with substantially the same configuration as the outer edges of the perimeter slats, including a protruding flat 82, outer side edge 84, overhang surface and vertical apron surface.
As can be seen in FIG. 5, the projecting bars 66, 72 can be configured to align with and extend into the open-ended slots formed by the sidewalls of the slats. For instance, the projecting bars 66 of the internal finger pairs 64 can be configured to slide into the vertically-exaggerated C-shaped slots formed by the top walls 40, sidewalls 42, and ledges 46 comprising one side of the underlying support beams 56. Likewise, the projecting bars 72 of the outer finger pair 70 can be configured to extend into the horizontally-exaggerated C-shaped slots created by the internal surfaces of the protruding flats 32 formed into the outer edges 30 of the perimeter slats.
As the entire end cap 60 can be made from a deformable plastic material, the projecting bars 66, 72 can be configured with a height that spans the distance from the top wall to the bottom wall of the open-ended slots, so as to interconnect with the open-ended slots with a snug or slight compression fit. Moreover, the length of the projecting bars 66, 72 extending into the slats can be greater than the height of the bars to provide rigidity and stiffness to the joint and help secure the end caps 60 to the center section 20.
The screw tabs 68 of each internal finger pair 64 can be configured to fit into the vertically-exaggerated slots formed in the opposite side of the support beam 56, and to align with the screw holes 48 formed into the ledges 46. The screw tabs 74 of each outer finger pair 70 can be configured to fit into the open space created by the internal surfaces of the rectangular members 50, and to align with the screw holes 48 formed in the bottom surfaces 52 of the rectangular members. Fasteners can be installed through the screw holes after assembly to further secure the end caps 60 to the center section 20.
The interior support beams 56, formed by laterally coupling two channel slats together as described above, can fit into gaps or slots 58 formed between the projecting bars 66 and the screw tabs 68 of the internal finger pairs. In one aspect of the invention the slots 58 can be used to align the end caps to the center section. In another aspect, the width of the slots 58 and the thicknesses of the combined sidewalls 42 can be configured so that the support beams 56 are grasped and held within the slots, to provide additional gripping and coupling between the end caps 60 and the center section 20.
Depicted in FIG. 6 is a side view of the outside edge 30 and corner of the assembled tabletop 10, defined by the outer edge of the perimeter slats 24 of the center section 20 and the elongate end cap 60. The interface between the center section 20 and the elongate end cap 60 can be a butt-joint, so that the two pieces join together to form a continuously smooth tabletop surface 26. Furthermore, both the outer edge of the perimeter slats and the end caps can be provided with the same cross-sectional profile on their outer boundary, so that when assembled together they form a tabletop 10 having an outside edge 30 that is uniformly smooth and round around its entire perimeter, and with large-radius corners.
As described above, the outside edge 30 of the assembled tabletop 10 can include protruding flats 32, 82 having a flush top surface 26, an outer vertical side surface 34, 84, and an underside overhanging surface 36, 86 that folds downwardly into a vertical apron 38, 88. As the perimeter slats 24 can be made from folded metal, and the end caps 60 from molded plastic, it can be a simple process to manufacture the outer side surfaces 34, 84 overhanging surfaces 36, 86 and vertical apron surfaces 38, 88 with smooth flat faces and large-radius edges and corners to facilitate handling and lifting the table, as well as providing safe surfaces to bump against, lean on, work around, etc. Moreover, unlike the prior art where the tabletop is a flat, plate-like structure and the vertical apron is a separate and distinct underlying support, with the present invention the protruding flats 32, 82 and the vertical apron surfaces 38, 88 that form the outer edge 30 can be integrated into the same component, either an end cap or a perimeter slat.
Besides providing for enhanced safety and comfort, the outside edge of the 30 of the tabletop 10 of the present invention can be configured for improved utility over other prior-related aluminum tables. For instance, the thickness of the protruding flats 32, 82 as exemplified by the height of the side surfaces 34, 84 can be configured with the ¾ inch thickness of traditional one-piece composite/laminated banquet tables, which allows the slat tabletop of the present invention to be used with skirt clamping systems sized to industry-standard dimensions.
A slat table having a round center section 120 and arcuate end caps 140 and side caps 160, according to another exemplary embodiment of the present invention, is illustrated in FIGS. 7-11. Similar to the rectangular slat table with elongate end caps described above, the rounded embodiment 110 can also comprise a plurality of individual slats that are laterally coupled together to form the center section of the tabletop. As shown generally in FIG. 7, the plurality of joined slats 122 can be cut into a circle having a smooth top working surface 126 and a cut edge 128. Arcuate end caps 140 can be attached at both ends of the center section 120, which ends can be defined as the sections of the cut edge 128 that are more perpendicular to the long axis of the slats 122.
The rounded tabletop 110 may differ from the rectangular embodiment in that specially-formed perimeter slats may not be used, and instead all of the slats 122 forming the center section 120 can have the same configuration, with squared sidewalls on both sides for providing uniform contact surfaces when abutting and coupling the slats together. Instead of the perimeter slats defining the outer side edges of the tabletop, arcuate side caps 160 can be coupled to the sides of the center section, which sides can be defined as the sections of the cut edge 128 that are more parallel to the long axis of the slats 122. The arcuate side caps 160 and end caps 140 can couple with both the center section 120 and with each other to form a uniform edge ring 180 that completely surrounds and covers the cut edge 128 of the center section.
It can be particularly problematic to cut a rounded center section 120 from a plurality of aluminum slats 122 having a uniform or smooth border, as the blades of the saw can often bend and twist during the cutting process. The resulting cut edge 128 can be sharp and jagged, and likely to damage or snag nearby objects and passersby. The arcuate end caps 140 and side caps 160 can provide protection and safety by combining together to form the edge ring 180, which can completely surround and encapsulate the hazardous edge and provided a rounded border surface that is suitable to bump or lean against or pick up and move by hand. Furthermore, the edge ring 180 can also be configured to accommodate the differences in thermal expansion between the round center section 120 and the edge ring formed from the end caps 140 and side caps 160.
As will be discussed in more detail below, differential thermal expansion between the edge ring 180 and the round center section 120 can act to loosen the connection between the two components, or even open a gap at the joint line. The arcuate end caps 140 and side caps 160 can be configured with a stepped boss joint that can maintain a constant and secure fit between the end ring and the center section regardless of differences in material composition or uneven thermal expansion between the center section and the edge rings.
Like the rectangular embodiment described above, the rounded tabletop 110 can be supported on a table base 190 having legs 192, or with any other similar support system including a tubular frame, a pedestal, etc. Likewise, the rounded tabletop 110 of the present invention is not limited for use as a portable banquet table, as illustrated, but can also be incorporated into a wide variety of table types and configurations, such as the top piece of an outdoor picnic table, a cafeteria table, a patio dining or end table, a work bench, etc. Moreover, the shape of the rounded tabletop, as viewed from above, can be round, ellipsoid, oblong, or any another rounded shape for a tabletop appreciated by one of skill in the art.
The construction of the rounded embodiment is shown in more detail in FIGS. 8-10. Like the rectangular center section described above, the rounded center section 120 can be made with a plurality of channel slats 122, each slat having a solid top wall 130, the upper face of which forms the top working surface of the tabletop. Squared sidewalls 132 can extending downward from each side of the top wall 130 to provide uniform contact surfaces for laterally abutting and coupling the slats together to form the center section. The sidewalls can turn inward at the base to form a bottom wall, which can be divided by a longitudinal slot into two short ledges 134 extending inwardly from both sidewalls 132. The longitudinal slot can run the length of the slat. Holes 138 for fasteners can be formed at the either end of the ledges 134 for providing enhanced connection of the slats to the end caps after assembly.
When the sidewalls 132 of two adjacent channel slats 122 are laterally coupled together, the two sidewalls and associated ledges 134 can combine to form an underlying support beam 136. The support beam 136 can have a shape substantially similar to the shape of an I-beam, which is to be appreciated by one having skill in the art as a support structure capable of providing substantial stiffness, rigidity and strength to the tabletop. As the tabletop can be formed from a plurality of channel slats 122, multiple support beams 136 can run the length of the tabletop.
Arcuate end caps 140 can be attached at either end of the rounded tabletop. The end caps 140 can have curved elongate bodies 142 with multiple finger pairs 144 that interconnect with the support beams 136. The finger pairs can comprise a projecting bar 146 and a screw tab 148. The projecting bars 146 can be configured to align with and extend into the open-ended slots formed by the downwardly extending sidewalls of the slats 122. For instance, the projecting bars 146 can be configured to slide into the vertically-exaggerated C-shaped slots defined by a top wall 130, a sidewall 132, and a ledge 134 forming one side of a support beam.
As the entire end cap 140 can be made from a deformable plastic material, the projecting bars 144 can be configured with a height that spans the distance from the top wall to the bottom wall of the open-ended slots, so as to interconnect with the open-ended slots with a snug or slight compression fit. Moreover, the length of the projecting bars 144 extending into the slats can be greater than the height of the bars to provide rigidity and stiffness to the joint and help secure the end caps 140 to the center section 120.
The screw tabs 148 of each internal finger pair 144 can be configured to fit into the vertically-exaggerated slots formed in the side of the support beam 136 opposite the projecting bar 146, and to align with the screw holes 138 formed into the ledges 134. Fasteners can be installed through the screw holes after assembly to further secure the end caps 140 to the center section 120.
The support beams 136, formed by laterally coupling two channel slats together as described above, can fit into gaps or slots 150 formed between the projecting bars 146 and the screw tabs 148 of the finger pairs 144. In one aspect of the invention the slots 150 can be used to align the end caps to the center section. In another aspect, the width of the slots 150 and the thicknesses of the combined sidewalls 132 can be configured so that the support beams 136 are grasped and held within the slots, to provide additional gripping and coupling between the end caps 140 and the center section 120.
Arcuate side caps 160 can be coupled to the sides of the center section 120, which sides can be defined as the sections of the cut edge 128 that are more parallel to the long axis of the slats 122. Like the end caps 140, the side caps 160 can also have curved elongate bodies 162 with multiple attachment bars 166, 168 that project into the center section 120. Instead of the attachment bars sliding lengthwise into the vertically-exaggerated C-shaped slots defining one side of a support beam, however, the attachment bars 166, 168 can be configured so that only the tips of the attachment bars enter the vertically-exaggerated C-shaped slots from the side, or crosswise.
Curved attachment bars 164 can be formed at both ends of the side caps 160 for interconnection into tip slots 152, which can be formed into both tips of the end caps 140. The attachments bars 164 can slide into and couple with the end slots with a tongue-in-groove type connection, to couple the side caps and end caps together and form an edge ring 180 that completely surrounds and covers the perimeter edge 128 of the center section 120. The side caps 160 and end caps 140 can be further configured so that the side caps can be first assembled to the center section, followed by the end caps coupling to both the side caps and the center section. Securing the end caps to the center section with fasteners can, in effect, lock the side caps into position with the tip slots 152.
Like the rectangular embodiment described above, the center section 120 of the rounded tabletop 110 can be made from aluminum slats 122 providing a light-weight yet durable and weather-resistant tabletop surface 126 that is reinforced from below with the downwardly-projecting support beams 136 formed by the joined sidewalls of adjacent slats. This configuration can provide the greatest strength for a given amount of material, and can be much lighter than a rounded tabletop made from solid wooden slats that can support an equivalent load. It is further anticipated that both the arcuate end caps 140 and side caps 160 can be made from a moldable material such as plastic, etc., that lends itself to injection molding or similar manufacturing processes that can be used to make low-cost complex parts, such as the smoothly curving elongate bodies 142, 162 with projecting bars 146, 166, 168 and screw tabs 148 that can provided for coupling the end caps and side caps to the center section 120 and to each other.
A sectional view of the edge ring 180 of the rounded tabletop 110 is illustrated in FIG. 11, as taken through a finger pair of an end cap 140. As shown, the projecting bar 146 of the finger pair can fit lengthwise into the vertically-exaggerated C-shaped slot defined by the top wall 130, sidewall 132, and ledge 134 forming one side of a support beam. The upper surface of the top wall can provide the tabletop working surface 126. The end cap 140 (and side caps) can have a top surface 196 that is raised above the working surface 126 of the center section to form an assembled tabletop 110 with a raised lip or end ring 180, as shown.
The top surface 196 of the edge ring 180 can make with contact the center section 120 by way of a stepped boss joint 198 or registered fit that can receive and encapsulate the cut edge 128. Combined with the finger pairs, the boss joint 198 can contribute to a snug, secure fit between the cut edge 128 of the center section and the top of the edge ring 180, while allowing for small gaps or clearances underneath the top surface of the edge ring and between the lip of the cut edge and the inside surface of the boss joint. These gaps can accommodate the differences in differential thermal expansion and contraction between the center section 120 and the edge ring 180 resulting from uneven heating and cooling of the table, differences in the coefficients of thermal expansion between the materials comprising the two components, or other thermal affects, etc., which may otherwise loosen the connection between the two components or open a large gap at the joint line. In essence, the boss joint 198 can allow the edge ring 180 to float around the center section 120 while still anchored to the center section with the finger pairs 146, and while completely surrounding and covering the sharp and jagged cut edge 128.
Similar to the outside edge of the rectangular embodiment described above, the end ring 180 can further comprise a protruding flat 182 with an outer vertical side surface 184, and an underside overhanging surface 186 that folds downwardly into a vertical apron 188. This configuration eliminates the sharp or narrow bottom edge of the metallic slat that is common with the prior art, and which can dig into the hands of users handling the tabletop. Receiving and encapsulating the sharp or jagged cut edge 128 of the center section 120 with the specifically-formed end caps 140 and side caps 160 further results in a tabletop 110 that is safe to work around, bump against, lean on, etc.
Besides providing for enhanced safety and comfort, the edge ring 180 of the rounded tabletop 110 of the present invention can also be configured for improved utility over other prior-related aluminum tables. For example, the thickness of the protruding flat 182 as exemplified by the height of the side surfaces 184 can be configured with the ¾ thickness of traditional one-piece composite/laminated banquet tables, which allows for the round, aluminum slat tabletop of the present invention to be used with skirt clamping systems sized to industry-standard dimensions.
The foregoing detailed description describes the invention with reference to specific exemplary embodiments. However, it will be appreciated that various modifications and changes can be made without departing from the scope of the present invention as set forth in the appended claims. The detailed description and accompanying drawings are to be regarded as merely illustrative, rather than as restrictive, and all such modifications or changes, if any, are intended to fall within the scope of the present invention as described and set forth herein.
More specifically, while illustrative exemplary embodiments of the invention have been described herein, the present invention is not limited to these embodiments, but includes any and all embodiments having modifications, omissions, combinations (e.g., of aspects across various embodiments), adaptations and/or alterations as would be appreciated by those in the art based on the foregoing detailed description. The limitations in the claims are to be interpreted broadly based on the language employed in the claims and not limited to examples described in the foregoing detailed description or during the prosecution of the application, which examples are to be construed as non-exclusive. For example, in the present disclosure, the term “preferably” is non-exclusive where it is intended to mean “preferably, but not limited to.” Any steps recited in any method or process claims may be executed in any order and are not limited to the order presented in the claims. Means-plus-function or step-plus-function limitations will only be employed where for a specific claim limitation all of the following conditions are present in that limitation: a) “means for” or “step for” is expressly recited; and b) a corresponding function is expressly recited. The structure, material or acts that support the means-plus function are expressly recited in the description herein. Accordingly, the scope of the invention should be determined solely by the appended claims and their legal equivalents, rather than by the descriptions and examples given above.

Claims

1. A tabletop comprising:

a center section formed from a plurality of open rectangular tubular slats laterally coupled together, each slat having a top wall with a substantially horizontal top surface, sidewalls, and a bottom wall having a longitudinal slot running the length thereof, and adjacent slats having adjacent contacting sidewalls coupled together to form substantially vertical support beams, the slats having open opposite ends; and

a pair of elongate end caps each disposed on a different one of the open opposite ends and spanning the plurality of slats of the center section, each end cap having a plurality of finger pairs extending into the plurality of slats, each finger pair having a slot for receiving a support beam therein for aligning and coupling the end cap to the center section.

2. The tabletop of claim 1, wherein each finger pair further comprises a projecting bar and a screw tab.

3. The tabletop of claim 2, wherein the height of the projecting bar substantially spans the distance from the top wall to the bottom wall of the slat.

4. The tabletop of claim 3, wherein the length of the projecting bar extending into the slats is greater than the height of the projecting bar.

5. The tabletop of claim 3, wherein the screw tab is configured for securing the end cap to the bottom wall of the slat with a fastener.

6. The tabletop of claim 1, wherein a top surface of the elongate end cap is flush with a top surface of the plurality of slats.

7. The tabletop of claim 1, further comprising the center section and the elongate end caps having an outer edge having a constant profile around the perimeter of the tabletop.

8. The tabletop of claim 7, wherein the outer edge further comprises an outwardly-projecting overhang above a vertical apron surface, the overhang and apron surface being formed from the same component.

9. A rectangular-shaped tabletop comprising:

a center section formed from a plurality of open rectangular tubular slats laterally coupled together, each slat having a top wall with a substantially horizontal top surface, sidewalls, and a bottom wall having a longitudinal slot running the length thereof, and adjacent slats having adjacent contacting sidewalls coupled together to form substantially vertical support beams, the slats having open opposite ends;

a pair of elongate end caps each disposed on a different one of the open opposite ends and spanning the plurality of slats of the center section, each end cap having a plurality of finger pairs extending into the plurality of slats, each finger pair having a slot for receiving a support beam therein for aligning and coupling the end cap to the center section; and

the center section and the elongate end caps being configured to couple together into a rectangular-shaped tabletop.

10. A round-shaped tabletop comprising:

a round-shaped center section formed from a plurality of open rectangular tubular slats laterally coupled together, each slat having a top wall with a substantially horizontal top surface, sidewalls, and a bottom wall having a longitudinal slot running the length thereof, and adjacent slats having adjacent contacting sidewalls coupled together to form substantially vertical support beams, the slats having open opposite ends;

a pair of arcuate end caps each disposed on a different one of the opposite ends and spanning the plurality of slats of the center section, each end cap having a plurality of finger pairs extending lengthwise into the plurality of slats, each finger pair having a slot for receiving a support beam therein for aligning and coupling the end cap to the center section;

a pair of arcuate side caps, each disposed on the center section between opposing end caps to complete the rounded perimeter of the tabletop, each side cap having a plurality of attachment bars projecting crosswise into the slats; and

the center section, the arcuate end caps and arcuate side caps being configured to couple together into a round-shaped tabletop.

11. The tabletop of claim 10, wherein the arcuate end caps and the arcuate side caps couple together to form an edge ring having a boss fit on an interior edge for receiving and encapsulating a cut edge of the center section.

12. The tabletop of claim 11, wherein the boss fit accommodates a differential thermal expansion between the edge ring and the center section to maintain a secure fit between the end ring and the center section.

13. The tabletop of claim 10, wherein each finger pair further comprises a projecting bar and a screw tab.

14. The tabletop of claim 13, wherein the height of the projecting bar substantially spans the distance from the top wall to the bottom wall of the slat.

15. The tabletop of claim 14, wherein the length of the projecting bar extending into the slats is greater than the height of the projecting bar.

16. The tabletop of claim 15, wherein the screw tab is configured for securing the end cap to the bottom wall of the slat with a fastener.

17. The tabletop of claim 10, further comprising the center section, the end caps and the side caps having an outer edge having a constant profile around the perimeter of the tabletop.

18. The tabletop of claim 17, wherein the outer edge further comprises an outwardly-projecting overhang above a vertical apron surface, the overhang and apron surface being formed from the same component.