Method of Furniture Assembly
Patent Information
- Authority / Receiving Office
- GB · GB
- Patent Type
- Patents
- Current Assignee / Owner
- QUERNS TRADE SUPPLIES LTD
- Filing Date
- 2023-04-21
- Publication Date
- 2026-06-15
Smart Images
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Abstract
Description
07 04 25 The present invention relates to a method of assembling furniture. BACKGROUND TO THE INVENTION Furniture such as wardrobes can be heavy and have a large volume, so they cannot 5 be easily transported. For example, a wardrobe is often too large to fit through a door or up or down a flight of stairs. They are awkward to handle. A first solution is to dismantle the furniture into lighter, less bulky parts, which fit through doors and up stairs. To take furniture apart, joints are provided which allow them to be built and rebuilt. Once rebuilt, these joints can leave the furniture unstable, flimsy or 10 misaligned. The furniture may be rebuilt incorrectly. Furthermore, material reduction to reduce cost and weight, such as hardboard wardrobe backs, are flimsy. They can be easily pushed out, removing lateral stability and structural integrity and can lead to a piece of furniture feeling poorly made or physically breaking when it is shuffled, pushed, or heaved into its final position. 15 A second solution is to flat pack an entire product. This involves providing the furniture in a number of parts with a tool (e.g. hex keys and / or screwdrivers) and a bag of fixings (e.g. screws) so that the customer can transport the flat packed furniture more easily. It can then be carried more easily into a home or office and assembled in situ. However, this can be a time-consuming process and some customers find flatpack furniture 20 difficult and frustrating to construct. A large proportion of the customers that buy flat pack furniture move house on a more regular basis than ever before. Despite this, flat packed furniture can be difficult to dismantle and rebuild elsewhere. Furthermore, the tools provided with the flatpack are often lost over time. 25 It is an object of the present invention to reduce or substantially obviate the aforementioned problems. STATEMENT OF INVENTION According to the present invention there is provided a method of assembling furniture comprising a base, a back panel, a first side wall, a second side wall, and a top panel, 30 the method comprising the steps: engaging the back panel with the base; 07 04 25 resting the first side wall on the base and engaging the first side wall with the back panel by means of at least one sliding connector; and resting the second side wall on the base and engaging the second side 5 wall with the back panel by means of at least one sliding connector; in which the back panel, first side wall, and second side wall form a substantially U-shaped recess and in which the top panel is received in the U-shaped recess. The method may be used to quickly assemble furniture with a stable structure. The furniture may be assembled by one person with relative ease. The side walls and / or 10 back panel may be engaged by the sliding connector without requiring further fittings. The top panel may be held securely in the U-shaped recess without requiring further fittings. In other words, the furniture may be assembled by the method without requiring multiple fixings such as screws to be screwed into the furniture by the user, significantly reducing the time required to assemble the furniture. Where fittings are included, these 15 may be provided pre-fitted. The furniture assembled by the above method may be easy to dissemble by reversing the steps. It will be appreciated that the sliding connector may include any connector in which at least one member slides into a second member by movement of a first member in substantially one direction relative to the second member, in which the first member is 20 retained in a position relative to the second member. The sliding connector may be a keyhole fitting, for example. The top panel may be retained in the U-shaped recess by brackets extending along a top edge of the first and second side wall. The top panel may provide some degree of structural support when disposed in the U-shaped recess. 25 The back panel may comprise at least two panels. The two panels may be hinged together. The two panels may be movable between open and closed configurations. The back panel may be considered to be foldable along an axis of at least one hinge. Providing a hinged back panel allows the back panel to occupy less space during storage or transit. This is advantageous for flatpack furniture, for example. Providing 30 the hinged back panel is further advantageous as it is easy to open (i.e. unfold) during assembly. In other words, the back panel may occupy the space of two individual 07 04 25 panels, without requiring further fixings such as screws to be screwed into the back panel to connect the two panels together during assembly. The back panel may comprise at least one releasably attachable brace. The at least one releasably attachable brace may be connected to the panels of the back panel for 5 locking them in the open configuration. The at least one releasably attachable brace may include an upper back brace. The upper back brace may be disposed on an upper portion of the back panel. The at least one releasably attachable brace may include a lower back brace. The lower back brace may be disposed on a lower portion of the back panel. Having one or both of an upper 10 and lower back brace may provide further structural support. The base may provide a stable foundation. The back panel may be engaged with the base by means of the lower back brace. The lower back brace may include pegs for inserting into corresponding apertures in the base. The pegs may be chamfered for facilitating insertion into the apertures. The pegs may be substantially wedge-shaped. 15 The pegs may be considered self-centering. The pegs may limit the degrees of freedom of the back panel. The at least one brace may be engaged with at least one keyhole retainer on the back panel. The at least one brace may be fitted to the back panel without requiring further fittings such as screws to be screwed into the brace and / or back panel. 20 The at least one sliding connector may include at least one keyhole retainer on the back panel. The at least one sliding connector may comprise at least one pin with an enlarged head engaging with the least one keyhole retainer. At least one of the first and side panels may comprise a frame. The frame may provide 25 rigidity to the at least one side wall. The frame may extend around a periphery of the side wall. The top panel may sit above the frame of the at least one of the side walls. The frame may be mass produced and subsequently fitted to the rest of the side panel. At least one of the first and second side walls may be connected to the base. At least one of the first and second side walls may be connected to the base by a connector 30 comprising: a longitudinal body and an enlarged head disposed at one end of the body; a cavity disposed within the body; 07 04 25 a latch, the latch being pivotally mounted within the cavity and movable between a latched position in which part of the latch extends out of cavity and an unlatched position in which the latch is disposed substantially entirely within 5 the cavity; and a biasing means for biasing the latch to the latched position. The connector provides a means of quickly, securely and releasably connecting two or more elements together. The connector may be considered a peg for installing flatpack furniture. The connector may be used where a first element is disposed above or 10 against a second element. The first element may be a first piece of a flat pack furniture item. The second element may be a second piece of a flat pack furniture item. A bore may be provided through the first element. The connector may be inserted into the bore in the first element. A bore may be provided substantially through the second element. The connector may be inserted through at least a portion of the second 15 element. In the latched position, the latch can abut against the second element, preventing withdrawal of the connector, thereby connecting the first and second elements together. The biasing means provides a self-fixing or self-tightening connector. In other words, manually screwing, tightening and / or fixing the connector is not required. The 20 connector may be fitted without requiring a tool. This has advantages in flatpack furniture where quickly connecting the elements together without the use of tools minimises the time-consuming nature and difficulty of the installation. The elements may be straightforward to disassemble by releasing the latch. The connector may include a control rod. The control rod may be in communication 25 with the latch. The control rod may be operated to release the latch. Dissembling the elements is advantageous when relocating furniture, for example. The connector may be removed and reinserted multiple times without affecting the strength of the connection. The control rod may be operated by pulling the control rod in a direction away from the 30 latch. 07 04 25 A recess may be provided in the upper end of the connector. The biasing means may be disposed substantially within the recess. The biasing means may be a spring, for example, a coil spring. A bore may connect the recess to the cavity. The control rod may be disposed 5 substantially within the bore. The latch may be pivotally mounted to the body at a lower end of the latch. A link arm may be pivotally mounted to the latch proximate an upper end of the latch. The link arm may be pivotally mounted to the latch proximate a lower end of the link arm. The control rod may be pivotally connected to the link arm at one end. The control rod may 10 be connected to the biasing means at its other end. The biasing means may bias the control rod in a direction towards the cavity. The biasing means may bias the link arm further into the cavity. The biasing means may directly or indirectly pivot the latch. In the latched position, a portion of the latch may protrude from a lateral side. 15 The enlarged head may be exposed when the connector is fitted. The control rod may be accessible from the enlarged head, enabling operation of the control rod to release the connector. The control rod may be substantially disposed within the connector when the latch is in the latched position. The control rod may be substantially flush with the enlarged 20 head when the latch is in the latched position. Providing the control rod within the connector presents a substantially flat upper surface to the connector which does not snag on clothes or the like. A release tool may be provided to operate the control rod. The release tool may comprise an aperture for receiving the control rod. The release tool may provide a 25 connection means. The connection means may temporarily connect the release tool to the control rod. The connection means may be a press-fit fastener. The connection means may be a latch. The means may include male and female connectors. The connection means may include a threaded portion. At least a portion of the release tool aperture may be threaded for screwing the release tool onto the threaded portion of 30 the control rod. The control rod may ride up the threaded aperture of the release tool. The aperture of the release tool may be internally threaded, i.e., with a female thread. The end of the control rod may be externally threaded, i.e., with a mating male thread. 07 04 25 The body may be substantially cylindrical for inserting into cylindrical bores. The enlarged head may be substantially circular. An end of the aperture distal from the enlarged head may be substantially rounded. The substantially rounded distal end may facilitate insertion of the connector into a 5 bore. The control rod may be disposed through and attached to a star lock washer. The star lock washer may be connected to the biasing means. The cavity may include an abutment means for abutting the link arm. The abutment means may restrict the movement of the link arm. The abutment means may ensure 10 the link arm (and latch) pivots in the correct direction, for example, in one direction only. The restriction of movement of the link arm may prevent the latch from jamming. The abutment means guides the movement of the link arm to some degree. At least a portion of the release tool may be sized to fit into the recess. During use, a portion of the release tool may be inserted into the recess. Alternatively, the control 15 rod may protrude from the connector body. The release tool may connect to a protruding portion of the control rod. During insertion of the connector into the apertures in the first and second element, the latch may be compressed inwards, that is, into the cavity. Once inserted, a portion of the latch may extend out of the cavity. The latch may not be repositioned into the cavity 20 without operating the control rod. The connector may be provided as a fixing for flat packed furniture. The release tool may be provided as part of the flat packed furniture. The release tool may be provided as a magnetic door stop. The release tool may include a spirit level. The spirit level may be used to ensure the 25 base of the product is level. A level base may facilitate alignment of the features disposed on the base. The spirit level may be hidden from view when the release tool is fitted to the furniture. The first element may be a portion of the first or second side wall. The first element may be a portion of the frame of the first or second side wall. The second element may 30 be the base. 07 04 25 The method may include attaching a rail to the first side wall and / or second sidewall. The method may include further biasing apart the first side wall and second side wall to enable space for the subsequent attachment of a first end of a rail to the first side wall and / or a second end of the rail to the second side wall. 5 The rail may include a first aperture on the first end and a second aperture on the second end. The first aperture may receive a first protrusion on the first side wall. The second aperture may receive a second protrusion on the second side wall. The rail may be mounted onto the first and / or second side wall without requiring further fittings such as screws to be screwed into the rail and / or side walls. 10 The rail may be mounted in a U-shaped protrusion in at least one of the first and second side walls. A releasably attachable front brace may be connected to at least one of the first side wall and second side wall. The front brace may be connected to a portion of the frame of the at least one side wall. The front brace may provide further support for the first 15 side wall and / or second side wall. The front brace may comprise an attachment means for attaching to at least one of the first side wall and second side wall. The attachment means may be at least one double keyhole retainer The front brace may be mounted onto the first and / or second side wall without requiring further fittings such as screws to be screwed into the rail and / or side 20 walls. In other words, pre-assembled fittings may be provided on the front brace and / or at least one of the first and second side walls without requiring further user assembled fittings. The front brace may be releasably connected to the top panel. The front brace may provide further support for the top panel. 25 The front brace may be connected to the top panel by an attachment means. The attachment means may be a ball and socket latch. The front brace may be connected to the top panel without requiring further fittings such as screws to be screwed into the front brace and / or top panel. The ball and socket latch may comprise an elongate member and an enlarged head 30 disposed at a distal end of the elongate member. During use, the elongate member may be disposed through the front brace and the enlarged head may be received in a recess in the top panel. 07 04 25 The elongate portion may include a threaded portion. The ball and socket latch may include a recess. The release tool may be used to disengage the ball and socket latch in a similar manner as discussed for the connector. The method may comprise the step of attaching at least one door to the furniture. The 5 furniture may include a first hinge portion. The at least one door may include a second hinge portion. One of the first hinge portion and second hinge portion may include a pin and the other of the first and second hinge portion may include a barrel, in which the at least one door may be fitted by sliding the pin into the barrel. The at least one door may be connected to the furniture without requiring further fittings 10 such as screws to be screwed into the at least one door and / or furniture. The method may include releasably connecting at least one door catch to the base. The furniture may be a wardrobe. According to a second aspect of the present invention, there is provided a kit for assembling furniture, the kit comprising: 15 a base, a back panel for engaging with the base, a first side wall for engaging with the back panel by means of at least one sliding connector, a second side wall for engaging with the back panel by means of at least one sliding connector, and a top panel, in which the back panel, first side wall, and second side wall form a substantially U-shaped recess for receiving the top panel. 20 The advantages are similar to those discussed for the first aspect of the invention. The back panel may comprise at least two panels, hinged together, and movable between open and closed configurations. the back panel comprises at least one releasably attachable brace, in which the at least one releasably attachable brace is connected to the panels of the back panel, for 25 locking them in the open configuration. At least one of the base, back panel, first side wall, second side wall, and top wall may include a first hinge portion. The kit may further include at least one door having a second hinge portion, in which one of the first hinge portion and second hinge portion includes a pin and the other of the first and second hinge portion includes a barrel for 30 receiving the pin. The kit may comprise a connector comprising: 07 04 25 a longitudinal body and an enlarged head disposed at one end of the body; a cavity disposed within the body; a latch, the latch being pivotally mounted within the cavity and movable 5 between a latched position in which part of the latch extends out of cavity and an unlatched position in which the latch is disposed substantially entirely within the cavity; and a biasing means for biasing the latch to the latched position. The kit may have any feature or combination of features of the second aspect of the 10 present invention. BRIEF DESCRIPTION OF THE DRAWINGS For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made by way of example only to the accompanying drawings, in which: 15 Figure 1 shows a perspective view of a wardrobe constructed by a method according to the present invention; Figure 2 shows a perspective view of a back panel of the wardrobe; Figure 3 shows a perspective view of a lower back brace being mounted to the back panel; 20 Figure 4 shows a perspective view and cross section of the back panel being fitted to a base of the wardrobe; Figure 5 shows a perspective view of an upper back brace being mounted to the back panel; Figure 6 shows a perspective view of a first side wall being fitted to the back panel; 25 Figure 7 shows a perspective view of the first side wall and a second side wall fitted to the back panel; 07 04 25 Figure 8 shows a perspective view of a top panel being fitted to the back panel, and side walls; Figure 9 shows a cross-section of a protrusion fitted to the side walls; Figure 10 shows a perspective view of a rail being fitted to the protrusions; 5 Figure 11 shows front and perspective views of a front brace; Figure 12 shows a perspective view of the front brace being fitted to the first and second side walls, the front brace including a ball and socket latch; Figure 13 shows a cross section of the ball and socket latch fitted to the top panel; Figure 14 shows a cross-section, side view and front view of a connector; 10 Figure 15 shows a perspective view of the connector being inserted into the side walls and base; Figure 16 shows a cross-section of the connector inside the side walls and the base; Figure 17 shows a perspective view of a door being fitted to the first side wall and a pair of release tools; 15 Figure 18 shows a release tool attached to the connector; Figure 19 shows a perspective view of the connector being removed from the first side wall and base using the release tool; Figure 20 shows a perspective view of the ball and socket latch being removed from the top panel and upper front brace using the release tool; and 20 Figure 21 shows a perspective view of a second embodiment of the release tool. DESCRIPTION OF PREFERRED EMBODIMENTS Referring firstly to Figure 1, a wardrobe assembled by a method according to the present invention is generally shown at 800. The method of assembly is described in more detail below. The wardrobe 800 includes a base 300, a back panel 500, a first 25 side wall 200, and a second side wall 400. The wardrobe 800 includes a top panel 600. The wardrobe also includes a pair of doors 700. The wardrobe 800 is constructed by sliding and / or inserting elements into each other without requiring additional fixings 07 04 25 such as screws to be screwed into the furniture during assembly. The wardrobe 800 can be constructed without the use of tools. The wardrobe 800 may be assembled quickly and easily. It will be appreciated that in other embodiments, the wardrobe 800 may be a different 5 piece of furniture. For example, the furniture may be a carcass for a chest of drawers, shelving or a cabinet. Referring now to Figure 2, the back panel 500 is shown. The back panel 500 includes a first back panel portion 502 and a second back panel portion 504. The first back panel portion 502 and second back panel portion 504 are connected by hinges 506. In 10 this embodiment, three hinges 506 are provided. During assembly, the back panel 500 is opened from a closed configuration to an open configuration. In the open configuration, the back panel 500 is substantially planar. In Figure 3, the back panel 500 is locked in the open configuration by a lower back brace 512. The lower back brace 512 is mounted to the back panel 500. The lower 15 back brace 512 includes pins (not shown). The back panel 500 includes a first set of keyhole retainers 508. Each keyhole retainer in the first set of keyhole retainers 508 receives one of the pins. The keyhole retainers have a keyhole-shaped aperture 516. The keyhole-shaped aperture 516 includes a wide portion 518 for inserting the pin. The keyhole-shaped 20 aperture 516 includes a narrow portion 520 for retaining the pin once the pin slides from the wide portion 518 to the narrow portion 520. In this embodiment, the wide portion 518 and narrow portion 520 are disposed laterally adjacent to each other. In other words, when mounting the lower back brace 512, the pins must be inserted into the wide portion 518 and then slid in a direction along a width of the back panel 500. 25 The lower back brace 512 includes pegs 514. The pegs 514 protrude from the lower back brace 512 in a direction towards the base 300 during use. As can be seen in Figure 4, the back panel 500 is engaged with the base 300 during assembly. The base 300 includes a slot 528. The slot 528 extends along the width of the base 300. The slot further includes apertures 522. The apertures 522 correspond 30 to the pegs 514. During assembly, the back panel 500 is inserted into the slot 528. The pegs 514 are received in the apertures 522. In this embodiment, the pegs 514 are chamfered for facilitating insertion of the pegs 514 into the apertures 522. 07 04 25 Referring now to Figure 5, an upper back brace 526 is mounted to a second set of keyhole retainers 524. The upper back brace 526 mounts in a substantially similar way to the lower back brace 512. The upper back brace 526 provides further structural support. 5 Figure 6 shows the assembly of the first side wall 200 with the base 300 and the back panel 500. The first side wall 200 is slidably connected to the back panel 500. The back panel 500 includes a third set of keyhole retainers 510. The first side wall 200 includes a second plurality of pins 206. The pins 206 are received in a third set of keyhole retainers 510. The first side wall 200 includes a frame 201 extending around 10 an edge of the side wall. The second plurality of pins 206 protrude from the frame 201. The third set of keyhole retainers 510 are disposed along the length of the back panel 500. Each keyhole retainer in the third set of keyhole retainers 510 includes a keyholeshaped aperture 530. The keyhole-shaped aperture 530 is substantially similar to the keyhole-shaped apertures 516 of the first set of keyhole retainers 508. Providing 15 keyhole retainers 510 along the length of the back panel 500 limits the degrees of freedom of the side walls 200, 400. The keyhole-shaped aperture 530 of the third set of keyhole retainers 510 differs from the keyhole-shaped apertures 516 of the first set of keyhole retainers 508 in that the wide portion 532 is disposed vertically adjacent to the narrow portion 534. In other 20 words, when mounting the first side wall 200, the pins 206 must be inserted into the wide portion 518 and then slid downwards in a direction towards the base 300. Referring now to Figure 7, the back panel 500 is shown connected to the base 300. The side walls 200, 400 are shown connected to the back panel 500. The back panel 500 and side walls 500, 200, 400 form a substantially U-shaped recess. The first side 25 wall 200 includes an abutment surface 208. The abutment surface 208 is disposed above the frame 201. The abutment surface 208 extends along the width of the frame 201 The first side wall 200 includes an L-shaped bracket 210. The second side wall 400 is substantially similar to the first side wall 200. As can be seen in Figure 8, the abutment surface 208 and L-shaped bracket 210 30 provide a slot for receiving the top panel 600. When fitted, the top panel 600 sits above the abutment surface 208 of each side wall 200, 400 and the upper back brace 526. The installation of a rail 230 is shown in Figures 9 and 10. The rail 230 is substantially hollow at either end. Each side wall 200, 400 includes a protrusion 212. The rail 230 is 07 04 25 mounted on each protrusion 212 at either end. To mount the rail 230 to each side wall 200, 400, the side walls 200, 400 are biased, or gently eased apart to provide space to accommodate the rail 230. The rail 230 is fitted onto each protrusion 212 by means of a friction-fit connection. 5 Referring now to Figures 11 and 12, an upper front brace is shown at 240. The upper front brace 240 comprises keyhole retainers 242 at both ends. In this embodiment, the keyhole retainers 242 are double keyhole retainers. In other words, each keyhole retainer 242 comprises two keyhole-shaped apertures 244. The keyhole-shaped apertures 244 are substantially similar to the keyhole-shaped apertures 516, 530 10 described above. Each end of the upper front brace 240 is fitted to one of the first side wall 200 and second side wall 400. The frame 201 of the first and second side walls 200, 400 include pins 250. The keyhole retainers 242 of the upper front brace 240 are mounted to the pins 250 in substantially the same way as the keyhole retainers 508, 510 described 15 above. The upper front brace 240 is moved upwards in a direction towards the top panel 600 to engage the pins 250 with the keyhole-shaped apertures 244. A portion of the upper front brace 240 at either end overlaps the frame 201. The overlap limits the degree to which the upper front brace 240 can flex. The upper front brace 240 includes a pair of press-fit latches. The press-fit latches lock 20 the upper front brace 240 in abutment with the top panel 600. In this embodiment, the press-fit latches are ball and socket latches 246. The ball and socket latches 246 are disposed at either end of the upper front brace 240. Each ball and socket latch 246 is disposed adjacent to one of the keyholes retainers 242 The ball and socket latches 246 are best shown in Figure 13. 25 The ball and socket latch 246 includes an elongate member 252 with a rounded “ball” end 260. The upper front brace 240 includes a recess 248 for receiving the elongate member 252 and ball end 260. The elongate member 252 is disposed through the upper front brace 240. The top panel 600 includes a socket 602 for receiving the ball end 260 of the elongate member 252. The socket 602 and ball end 260 form a ball and 30 socket connection. The connection between the top panel 600 and the upper front brace 240 limits the degrees of freedom of the front brace 240 and the first and second side walls 200, 400. 07 04 25 An end of the elongate member distal to the ball and socket connection is partially disposed within an enlarged head portion 255. The enlarged head portion 255 includes a recess 256. The recess 256 is disposed at an end of the enlarged head portion 255 distal to the ball and socket connection. The elongate member 252 includes a threaded 5 portion 254. The threaded portion 254 is disposed within the recess 256. The threaded portion 254 and recess 256 facilitate attachment of a release tool 100, described in more detail below with reference to Figures 17 to 20. The first and second side walls 200, 400 are connected to the base 300 by means of a connector 10, shown in Figure 14. 10 The connector 10 is a fitting for connecting two or more elements (200, 300, see Figure 2) together. In this embodiment, the first element is the first side wall 200 and the second element is the base 300. The connector 10 limits the degrees of freedom of the side walls 200, 400 and the base 300. The connector has a connector body 12. The connector body 12 is substantially 15 cylindrical. The connector body 12 may be considered a longitudinal connector body 12. The connector body 12 is received in an aperture when in use. In other embodiments, the connector body 12 may be shaped to prevent rotation in the aperture. For example, the connector body 12 may have a substantially hexagonal, rectangular, or square cross section. The connector 10 has a connector head 13. The 20 connector head 13 has an area larger than a cross section of the connector body 12. The connector head 13 may be considered an enlarged head 13. The connector head 13 sits above a surface of an element when in use. In other embodiments, the connector head 13 may sit substantially within the element. A cavity 14 is provided in the connector body 12. The connector 10 includes a latch 25 16. The latch 16 is disposed within the cavity 14. The latch 16 is connected to the connector body 12 by a first pivot 17. The latch 16 has a latched position. In the latched position, the latch 16 protrudes from the cavity 14. The latch 16 has an unlatched position, shown in Figure 18 and described in more detail below. In the unlatched position, the latch 16 is substantially disposed within the cavity 14. 30 The connector 10 includes a control rod 18. The control rod 18 is disposed in a top end of the connector 18. The control rod 18 is indirectly connected to the latch 16. The control rod 18 is accessible from the connector head 13. 07 04 25 A recess 22 is disposed in the top end of the connector 10. A biasing means 20 is provided in the connector 10. In this embodiment, the biasing means 20 is a spring, for example a coil spring. The biasing means 20 is disposed in the recess 22. The biasing means 20 is connected to the control rod 18. The biasing means 20 is connected at an 5 upper end of the control rod 18. The biasing means 20 biases the control rod 18 in a direction towards the cavity 14. In this embodiment, a star lock washer 36 is disposed on the control rod 18. The star lock washer 36 is connected to the biasing means 20. A spring cap 36 is provided above the biasing means 20 for retaining the spring within the recess 22 and resisting the upward force (as viewed) applied by the spring. 10 A bore 24 is provided through the connector 10. The bore 24 is disposed between the cavity 14 and the recess 22. An end of the control rod 18 is disposed inside the bore 22. The control rod 18 can move axially inside the bore 24. A link arm 26 is provided. The link arm 26 is pivotally connected to the control rod 18. The link arm 26 is pivotally connected to the control rod 18 at a second pivot 28. An 15 upper end of the link arm 26 is pivotally connected to the control rod 18 at a lower end of the control rod 18. The link arm 26 is pivotally connected to the latch 16 at a third pivot 30. A lower end of the link arm 26 is pivotally connected to the latch 16 at an upper end of the latch 16. An abutment means 32 is provided in the connector body 12. In this embodiment, the 20 abutment means 32 is provided within the latch 16. The abutment means 32 is disposed adjacent to the link arm 26. The abutment means 32 prevents the latch 16 from jamming when fully retracted. During engagement, the biasing means 20 biases the control rod 18 towards the cavity 14. The control rod 18 pushes the link arm 26 against the abutment means 32. The 25 link arm 26 pivots on the second pivot 28 in a direction towards an opening in the cavity 14. The latch 16 pivots with the link arm 26 on the first pivot 17 in a direction towards the opening in the cavity 14. A portion of the latch 16 protrudes from the cavity 14. The latch 16 provides a secure connection between the first and second element (200, 300, see Figure 2) as described below with reference to Figures 15 and 16. 30 Referring now to Figure 15, the connector 10 is shown being inserted into the first element (i.e. the first side wall 200) and the second element (i.e. the base 300). The first element 200 has a first aperture or bore 202. The first aperture 202 extends substantially through the first element 200. The second element 300 has a second 07 04 25 aperture 302. The first aperture 202 and second aperture 302 are axially aligned. The connector 10 is inserted through the first aperture 202. The connector 10 is inserted into the second aperture 302. The connector 10 has a rounded bottom 38 to facilitate insertion into the first aperture 202 and second aperture 302. During insertion, the latch 5 16 abuts against interior walls of the first aperture 202 and second aperture 302. The latch 16 is compressed inwards. In other words, during insertion the latch 16 is disposed substantially inside the cavity 14. Referring to Figure 16, when the connector 10 is fully inserted into the apertures 202, 302, a portion of the latch 16 protrudes from the cavity 14 in the manner described 10 above. It effectively springs out facilitating automatic latching. The portion of the latch 16 protrudes into a cavity 304 in the second member 300. In other words, once the latch 16 is no longer abutting the interior wall of the apertures 202, 302, the biasing means 20 pushes the latch 16 into an engagement position with the second member 300. 15 When engaged in the apertures 202, 302, the latch 16 abuts underneath a lower surface 306 of the second member cavity 304. The abutment between the latch 16 and surface 306 provides a latch point. The abutment prevents the connector 10 from being removed from the apertures 202, 302. The latch 16 is shaped to prevent the abutment with the top surface 306 pushing the latch 16 into the cavity 14. The connector 10 20 connects the first element 200 and second element 300 without the use of tools. The connector 10 is held snug in one or preferably both apertures 202, 302. The snug fit prevents wobbling and instability of the connector 10. The connector also holds the elements 200,300 in tight face to face engagement. The connector 10 abuts the first element 200 along the entire length of the connector 25 10, preventing the connector 10 from wobbling left or right. The same is true at the second side wall 400. The resulting connection between the third element 300 and side walls 200, 400 is extremely stable. Referring to Figure 17, each door 700 in the pair of doors 700 are mounted to one of the first and second side walls 200, 400. Each side wall 200, 400 includes first hinge 30 portions 270. The first hinge portions 270 can be considered a first half of a door hinge. The first hinge portions 270 are screwed onto the first and second side walls 200, 400. Each door 700 includes second hinge portions 702. The second hinge portions 702 can be considered a second half of a door hinge. The second hinge portions 702 are 07 04 25 screwed onto the doors 700. In this embodiment, each door 700 and side wall 200, 400 provide three corresponding pairs of first and second hinge portions 270, 702. Each first hinge portion 270 includes a pin 272. Each pin 272 extends in a direction upwards towards the top panel 700. Each second hinge portion 702 includes a barrel 5 704 corresponding to a pin 272. During assembly, each barrel 704 vertically slides onto the corresponding pin 272. The barrel 704 is free to rotate on the corresponding pin 272. The doors 700 and side walls 200, 400 can be provided with their respective hinge portions 270, 702 already fitted. In other words, the doors 700 can be fitted onto the 10 first and second side walls 200, 400 without installing requiring further fixings to be installed. A pair of the release tools 100 form part of the furniture 800. It will be appreciated that in other embodiments, just one release tool 100 may be provided. The release tools 100 can be used as magnetic door stops. The release tool 100 includes a magnet 110. 15 The magnet 110 connects to a corresponding magnet on the door 700. The magnets 110 keep the wardrobe doors 700 closed when the wardrobe 800 is shut. The release tools 100 can be inserted into a further aperture 304 in the second element 300 of the flat pack wardrobe. The release tools 100 are screwed into this aperture 304. The method of disassembly is described below with reference to Figures 18 to 20. To 20 disassemble the wardrobe the release tools 100 may be removed from the apertures 304. Referring to Figures 18 and 19, the latch 16 of the connector 10 can be disengaged using the release tool 100. The release tool 100 can be used to operate the control rod 18. The release tool 100 can be connected to the control rod 18 to operate the control 25 rod 18. The release tool 100 has a handle portion 102. The release tool 100 has an engagement portion 104. The engagement portion 104 is inserted inside the recess 22 to engage the control rod 18. The engagement portion 104 is substantially tubular. In other embodiments, the engagement portion 104 may have a substantially hexagonal, 30 rectangular, or square cross section. The engagement portion 104 includes an aperture 106. The size and shape of the aperture 106 corresponds to the size and shape of the control rod 18. In this embodiment, an upper portion of the control rod 18 includes a male threaded portion 40. The release tool aperture 106 includes a female 07 04 25 threaded portion 108. The release tool 100 is screwed onto the control rod 18 to provide engagement between the tool 100 and the connector 10. Screwing the release tool 100 onto the connector 10 facilitates operation of the control rod 18. During engagement, the handle 102 abuts a top of the connector 10. The 5 control rod 18 is screwed into the aperture 106 and is pulled against the biasing means 20. The control rod 18 is pulled towards the handle 102, out of the cavity 14. The link arm 26 is pulled towards the biasing means 20. The link arm 26 pivots the latch 16, bringing the latch 16 into the cavity 14. In other words, operation of the control rod 18 with the release tool 100 brings the latch 16 into the unlatched position. Once the latch 10 16 is in the unlatched position, the connector 10 can be removed from the apertures 202, 302, thereby allowing the first element 200 and second element 300 to be disconnected. Referring now to Figure 20, the release tool 100 may be used to disengage the ball and socket latch 246. The engagement portion 104 is inserted inside the recess 256 15 to engage the elongate rod 252. The size and shape of the aperture 106 corresponds to the size and shape of the elongate rod 252. In this embodiment, the threaded portion 254 of the elongate rod 252 includes a male thread. The release tool 100 is screwed onto the elongate rod 252 to provide engagement between the tool 100 and the ball and socket 246 latch. The release tool 100 can be used to pull the ball 260 out of the 20 socket 602, thereby disengaging the ball and socket connection. Once the connector 10 and ball and socket latch 246 are disengaged, the wardrobe 800 can be quickly disassembled by reversing the above steps. Referring to Figure 21, a further embodiment of the release tool 100 is shown. In this embodiment, the engagement portion 104 has a substantially hexagonal cross section. 25 The substantially hexagonal cross section prevents movement of the engagement portion 104 in the handle portion 102. In this embodiment, the handle portion 102 comprises a cavity 112. A spirit level 114 is provided. The spirit level 114 is disposed within the cavity 112. The spirit level 114 is hidden from view when fitted into the base 300. The spirit level 114 can be used to ensure the base 300 is level. 30 The significant advantages of the method describe above is that the furniture 800 can be assembled quickly and easily. Where fittings such as the keyhole retainers 508, 510, 524, 242, connectors 10, hinge portions 270, 702, or hinges 506 are provided, these can be pre-fitted to individual elements as part of a flatpack furniture kit. The 07 04 25 method provides flatpack furniture that is secure without requiring multiple fittings to be screwed during assembly. In other words, no tools are required to assemble the furniture 800. The significant advantages of the connector 10 described above is that the connector 5 10 can be used to connect the first element 200 and second element 300 quickly and securely. The connector 10 provides an automatic self-tightening connection. The first element 200 and second element 300 can be connected without the use of tools. The connection can be easily disengaged by use of the release tool 100 to facilitate disassembly of the flat pack furniture with the connection remaining secure after the 10 elements are disassembled and reassembled multiple times. In other words, the method allows an unskilled person with no expertise or special tools to quickly construct a piece of furniture which is structurally sound. The embodiments described above are provided by way of example only, and various changes and modifications will be apparent to persons skilled in the art without 15 departing from the scope of the present invention as defined by the appended claims.
Claims
07 04 251. A method of assembling furniture comprising a base, a back panel, a first side panel, a second side wall, and a top panel, the method comprising the steps:engaging the back panel with the base;5 resting the first side wall on the base and engaging the first side wallwith the back panel by means of at least one sliding connector; andresting the second side wall on the base and engaging the second side wall with the back panel by means of at least one sliding connector;in which the back panel, first side wall, and second side wall form a substantially 10 U-shaped recess and in which the top panel is received in the U-shaped recess.
2. A method of assembling furniture as claimed in claim 1, in which the back panel comprises at least two panels, hinged together, and movable between open and closed configurations.
3. A method of assembling furniture as claimed in claim 2, in which the back panel 15 comprises at least one releasably attachable brace, in which the at least onereleasably attachable brace is connected to the panels of the back panel for locking them in the open configuration.
4. A method of assembling furniture as claimed in claim 3, in which the at least one releasably attachable brace includes an upper back brace disposed on an 20 upper portion of the back panel.
5. A method of assembling furniture as claimed in claim 3 or claim 4, in which the at least one releasably attachable brace includes a lower back brace disposed on a lower portion of the back panel.
6. A method of assembling furniture as claimed in claim 5, in which the back panel 25 is engaged with the base by means of the lower back brace.
7. A method of assembling furniture as claimed in any one of claims 3 to 6, in which the at least one brace is engaged with at least one keyhole retainer on the back panel.07 04 258. A method of assembling furniture as claimed in any preceding claim, in which the at least one sliding connector includes at least one keyhole retainer on the back panel.
9. A method of assembling furniture as claimed in claim 8, in which the at least 5 one sliding connector comprises at least one pin with enlarged head engagingwith the least one keyhole retainer.
10. A method of assembling furniture as claimed in any preceding claim, in which at least one of the first and second side walls are connected to the base by a connector comprising:10 a longitudinal body and an enlarged head disposed at one end of the body;a cavity disposed within the body;a latch, the latch being pivotally mounted within the cavity and movable between a latched position in which part of the latch extends out of cavity and an unlatched position in which the latch is disposed substantially entirely within 15 the cavity; anda biasing means for biasing the latch to the latched position.
11. A method of assembling furniture as claimed in any preceding claim, in which the method includes further biasing apart the first side wall and second side wall to enable space for the subsequent attachment of a first end of a rail to the 20 first side wall and a second end of the rail to the second side wall.
12. A method of assembling furniture as claimed in claim 11, in which the rail includes a first aperture on the first end and a second aperture on the second end, in which the first aperture receives a first protrusion on the first side wall and the second aperture receives a second protrusion on the second side wall.25 13. A method of assembling furniture as claimed in any preceding claim in which areleasably attachable front brace is connected to at least one of the first side wall and second side wall.
14. A method of assembling furniture as claimed in claim 13 in which the front brace comprises at least one double keyhole retainer for attaching to at least one of 30 the first side wall and second side wall.07 04 2515. A method of assembling furniture as claimed in claim 13 or claim 14 in which the front brace is releasably connected to the top panel.
16. A method of assembling furniture as claimed in claim 15 in which the front brace is connected to the top panel by a ball and socket latch.5 17. A method of assembling furniture as claimed in claim 16, in which the ball andsocket latch comprises:an elongate member; andan enlarged head disposed at a distal end of the elongate member;in which the elongate member is disposed through the front brace and the 10 enlarged head is received in a recess in the top panel.
18. A method of assembling furniture as claimed in any preceding claim, in which the method comprises the step of attaching at least one door to the furniture, the furniture including a first hinge portion and the at least one door including a second hinge portion, in which one of the first hinge portion and second hinge 15 portion includes a pin and the other of the first and second hinge portionincludes a barrel, in which the at least one door is fitted by sliding the pin into the barrel.
19. A method of assembling furniture as claimed in any preceding claim, in which method includes the step of releasably connecting at least one door catch to 20 the base.
20. A method of assembling furniture as claimed in any preceding claim, in which the furniture is a wardrobe.
21. A kit for assembling furniture, the kit comprising:a base, a back panel for engaging with the base, a first side wall for engaging 25 with the back wall by means of at least one sliding connector, a second sidewall for engaging with the back wall by means of at least one sliding connector, and a top panel, in which the back panel, first side wall, and second side wall form a substantially U-shaped recess for receiving the top panel.07 04 2522. A kit as claimed in claim 21, in which the back panel comprises at least two panels, hinged together, and movable between open and closed configurations.
23. A kit as claimed in claim 21 or claim 22, in which the back panel comprises at 5 least one releasably attachable brace, in which the at least one releasablyattachable brace is connected to the panels of the back panel, for locking them in the open configuration.
24. A kit as claimed in any of claims 21 to 23, in which at least one of the base, back panel, first side wall, second side wall, and top panel includes a first hinge 10 portion and the kit further includes at least one door having a second hingeportion, in which one of the first hinge portion and second hinge portion includes a pin and the other of the first and second hinge portion includes a barrel for receiving the pin.
25. A kit as claimed in any of claimed 21 to 24, in which the kit comprises a 15 connector comprising:a longitudinal body and an enlarged head disposed at one end of the body;a cavity disposed within the body;a latch, the latch being pivotally mounted within the cavity and movable between a latched position in which part of the latch extends out of cavity and 20 an unlatched position in which the latch is disposed substantially entirely withinthe cavity; anda biasing means for biasing the latch to the latched position.25