A collapsible furniture assembly

Abstract

The present invention discloses a method of forming a joint between two adjacent panels (110, 120) within a collapsible furniture assembly, the method comprises the steps of: placing one panel (110, 120) on top of another in such a way that their joining edges are in alignment; cutting away at least one segment of the joining edges to create a continuous slanted surface (141) across the two panels (110, 120); and laying an adhesive (140) on the slanted surface (141) to form a hinge connection between the panels (110, 120).

Description

[0001] A COLLAPSIBLE FURNITURE ASSEMBLY

[0002] FIELD OF INVENTION

[0003] The invention relates to a furniture assembly. More particularly, the invention relates to a collapsible furniture module which is part of a furniture assembly.

[0004] BACKGROUND OF THE INVENTION

[0005] Conventionally ready-to-assemble furniture is furniture that is shipped and sold in separated pieces, requiring the consumers to put the different pieces together themselves before the assembled furniture can be used. Such furniture is usually cheaper and sold, unlike higher-end furniture that comes already assembled and costs more. While the ready-to-assemble furniture is affordable, putting the different pieces together requires some mechanical skill. The consumers have to read sometimes unclear instructions and use different tools, such as fasteners and glues, to assemble the parts. This renders the assembling process of such furniture time consuming. Even worse, the assembling process may be too complicated and the consumers might end up paying professionals to complete the assembling of furniture, especially if they don't have the skills or time. At the end of the process, such furniture can sometimes cost more than assembled furniture.

[0006] Over the years, there have been numerous attempts to create furniture that comes with components already connected to each other, but can still be folded into a compact shape for shipping and storage. For example, US Patent No. US3140133A describes a portable bar that has several back panels connected to each other and to side panels with hinges along vertical lines. Shelves are also attached to the side panels with hinges along horizontal lines. While this design makes assembling the bar easier for users and reduces the chance of errors, it requires the use of relatively expensive hardware hinges. These hinges are costly in terms of both materials and the labour needed for the preassembly.

[0007] Given the aforementioned drawbacks, there is a desire to develop an alternative solution for replacing the hardware hinges so that it can effectively address the challenges faced by the hardware hinges. This invention provides such a collapsible furniture module and method thereof.

[0008] SUMMARY OF INVENTION

[0009] In one aspect of the invention, there is provided a method of forming a joint between two adjacent panels within a collapsible furniture assembly, the method comprises the steps of placing one panel on top of another in such a way that their joining edges are in alignment; cutting away at least one segment of the joining edges to create a continuous slanted surface across the two panels; and laying an adhesive on the slanted surface to form a hinge connection between the panels.

[0010] In a second aspect of the invention, there is provided a furniture module comprises a rear panel having two opposing edges; and a pair of side panels, each pivotally connected to the edges of the rear panel using the method as described in the first aspect of the invention. Preferably, the side panels may be pivotable between a deployed configuration where the side panels are positioned perpendicularly to the rear panel and a stowed configuration where the side panels rest flush against the rear panel.

[0011] Preferably, each side panel may further comprise a door unit pivotable between an open state where the door unit lies flush with the side panel and a closed state where the door unit is arranged at a right angle to the side panel. Preferably, joining edges between the door unit and the side panel may have a triangular prism shape when in the open state.

[0012] Preferably, the joining edge of the side panel may comprise a stopper surface configured to engage with the joining edge of the door panel, thereby preventing the door unit from further rotation upon reaching the closed state.

[0013] Preferably, the door unit can be pivotally connected to the side panel via one or more hinge units.

[0014] Preferably, each side panel may further comprise a tongue profile configured to receive a groove of a top panel, thereby connecting the top panel to the side panels via a tongue and groove interlocking joint.

[0015] Preferably, each side panel may further comprise a groove configured to receive a tongue profile of an intermediate panel, thereby connected the intermediate panel to the side panels via a tongue and groove interlocking joint.

[0016] Preferably, each side panel may further comprise a plurality of pinholes for receiving pins that are configured to support one or more intermediate panels between the side panels of the furniture module in the deployed configuration.

[0017] Preferably, each intermediate panel may incorporate one or more furniture fittings for receiving the pins, each furniture fitting comprises an inclined slot configured to receive a protruded portion of the pin, and a bulge within the inclined slot to prevent the received pin from detaching.

[0018] Preferably, the rear panel can be formed by a pair of panels that are foldably interconnected via the adhesiveA Preferably, each hinge unit may comprise a first mounting plate attached to the side panel and a second mounting plate attached to the door unit, wherein one of the mounting plates may include an open ended channel for rotateably accommodating an extended portion of the other mounting plate in a detachable manner.

[0019] Preferably, the top panel and / or one or more intermediate panels may be attached to the furniture module in the deployed configuration via a plurality of first fastening members, wherein each first fastening member may comprise an elongate body having, in its longitudinal direction, a first section, a second section and a third section; wherein the first section may include external threads configured to be screwed into a threaded hole of the panels, the second section may include a plurality of serrated teeth configured to firmly engage with a hole of the side panels, and the third section may include a frictional surface configured to be gripped by a user to facilitate the screwing motion of the first section into the panels.

[0020] Preferably, a plurality of second fastening member can be provided for connection to a bottom of the furniture module and / or one or more intermediate panels to secure the connection between the furniture module and the one or more intermediate panels and to provide consistent levelling to the assembly, wherein each second fastening member comprises a plate body with a pair of projections extending from one side of the plate body for insertion into holes of the furniture module and / or one or more intermediate panels.

[0021] One skilled in the art will readily appreciate that the invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments described herein are not intended as limitations on the scope of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] For the purpose of facilitating an understanding of the invention, there is illustrated in the accompanying drawing the preferred embodiments from an inspection of which when considered in connection with the following description, the invention, its construction and operation and many of its advantages would be readily understood and appreciated.

[0023] Fig. la is a perspective view diagram illustrating a first embodiment of a furniture module in a stowed configuration.

[0024] Fig. lb is a top view diagram illustrating the first embodiment of the furniture module in the stowed configuration.

[0025] Fig. 2a is a perspective view diagram illustrating the first embodiment of the furniture module in a deploying configuration.

[0026] Fig. 2b is a top view diagram illustrating the first embodiment of the furniture module in the deploying configuration.

[0027] Fig. 3a is a perspective view diagram illustrating the first embodiment of the furniture module in a deployed configuration.

[0028] Fig. 3b is a top view diagram illustrating the first embodiment of the furniture module in the deployed configuration.

[0029] Figs. 4a-4b illustrates an attachment of a top panel to the furniture module in the deployed configuration. Figs. 5a-5b illustrates an insertion of one or more first pins to the furniture module in the deployed configuration.

[0030] Figs. 6a-6b illustrates an attachment of a first intermediate panel to the furniture module in the deployed configuration.

[0031] Figs. 7a-7b illustrates an exemplary of a furniture fitting for the intermediate panel.

[0032] Fig. 8a illustrates an insertion of one or more second pins to the furniture module in the deployed configuration.

[0033] Figs. 8b illustrates an attachment of one or more second intermediate panels to the furniture module in the deployed configuration.

[0034] Figs. 9a-9d illustrates a process of moving door units of the furniture module from an open position to a closed position.

[0035] Figs. 10a- lOd illustrates a hinge unit for connecting the door units to side panels of the furniture module.

[0036] Fig. 11 is a perspective view diagram illustrating the first embodiment of an assembled furniture.

[0037] Fig. 12a is a perspective view diagram illustrating a second embodiment of a furniture module in a stowed configuration.

[0038] Fig. 12b is a top view diagram illustrating the second embodiment of the furniture module in the stowed configuration. Fig. 13a is a perspective view diagram illustrating the second embodiment of the furniture module in a deploying configuration.

[0039] Fig. 13b is a top view diagram illustrating the second embodiment of the furniture module in the deploying configuration.

[0040] Fig. 14a is a perspective view diagram illustrating the second embodiment of the furniture module in a deployed configuration.

[0041] Fig. 14b is a top view diagram illustrating the second embodiment of the furniture module in the deployed configuration.

[0042] Figs. 15a-15b illustrates an attachment of a top panel to the furniture module in the deployed configuration.

[0043] Figs. 16a-16b illustrates an attachment of a third intermediate panel to the furniture module in the deployed configuration.

[0044] Figs. 17a- 17b illustrates an attachment of the second intermediate panel to the furniture module in the deployed configuration.

[0045] Fig. 18a is a perspective view diagram illustrating a third embodiment of a furniture module in a stowed configuration.

[0046] Fig. 18b is a top view diagram illustrating the third embodiment of the furniture module in the stowed configuration. Fig. 19a is a perspective view diagram illustrating the third embodiment of the furniture module in a deploying configuration.

[0047] Fig. 19b is a top view diagram illustrating the third embodiment of the furniture module in the deploying configuration.

[0048] Fig. 20a is a perspective view diagram illustrating the third embodiment of the furniture module in a deployed configuration.

[0049] Fig. 20b is a top view diagram illustrating the third embodiment of the furniture module in the deployed configuration.

[0050] Fig. 21 illustrates an insertion of one or more first and second pins to the furniture module in the deployed configuration.

[0051] Figs. 22a-22b illustrates an attachment of the first intermediate panel to the furniture module in the deployed configuration.

[0052] Figs. 23a-23h illustrates an attachment of the top panel and a plurality of intermediate panels to the furniture module in the deployed configuration.

[0053] Figs. 24a-24g illustrates an assembling process of a fourth embodiment of the furniture module.

[0054] Figs. 25a-25c illustrates a first method of forming a joint between two adjacent panels. Figs. 26a-26b illustrates a second method of forming the joint between two adjacent panels.

[0055] Figs. 27a-27i illustrates a third method of forming the joint between two adjacent panels.

[0056] DETAILED DESCRIPTION OF THE INVENTION

[0057] The invention generally provides a furniture module comprising a rear panel with two opposing edges and a pair of side panels pivotally connected to the rear panel. The side panels can pivot between a deployed configuration, where they are perpendicular to the rear panel, and a stowed configuration, where they lie flat against the rear panel, facilitating collapsibility and efficient storage. The method for joining the side panels to the rear panel involves the steps of placing one panel on top of another in such a way that their joining edges are in alignment, cutting away at least one segment of the joining edges to create a continuous slanted surface across the two panels, and laying adhesive on the slanted surface to form a hinge connection between the panels.

[0058] The invention will now be described in greater detail, by way of example, with reference to the drawings.

[0059] Referring to Figs. la-3b, a first embodiment of a furniture module 100 for use as part of a furniture assembly is illustrated. Preferably, the furniture module 100 comprises a rear panel 110 with two opposing edges and a pair of side panels 120 pivotally connected to the edges of the rear panel 110. The side panels 120 can pivot between a deployed configuration, where the side panels 120 are positioned perpendicularly to the rear panel 110, and a stowed configuration, where the side panels 120 rest flush against the rear panel 110. Preferably, the side panels 120 are connected to the opposing edges of the rear panel 110 via an adhesive 140. The adhesive 140 may include but is not limited to adhesive tape, plastic sheet lamination, furniture edging, adhesive sprays, glues, epoxies, or other bonding agents suitable for facilitating a robust connection while also allowing the side panels 120 to rotate in relation to the rear panel 110. The adhesive 140 may partially or entirely extend along longitudinal edges between the side panels 120 and the rear panel 110.

[0060] Alternatively, the rear panel 110 can be formed by a pair of panels that are foldably interconnected via the adhesive 140. Such arrangement allows the rear panel 110 to be folded into stack where one of the panels rest flush against the other. In this embodiment, each side panel 120 can comprise a door unit 130 that is pivotable between an open state where the door unit 130 lies flush with the side panel 120 and a closed state where the door unit 130 is arranged at a right angle to the side panel 120. The rear panel 110, the side panels 120 and the door units 130 can be folded in an accordion manner, as shown in Figs, la & lb, for storage or expanded to a generally U-shape configuration for the assembly process to take place, as shown in Figs. 3a & 3b.

[0061] Figs. 4a & 4b illustrate an attachment of a top panel 150 to a top section of the furniture module 100 in its deployed configuration. Preferably, the top section of each side panels 120 comprises a tongue profile 121 and the top panel 150 includes a pair of grooves 151 to receive the respective tongue profiles 121 of the side panels 120. This effectively connects the top panel 150 to the respective side panels 120 via tongue and groove interlocking joint. Nevertheless, it should be noted that the tongue and groove interlocking joint can be conveniently replaced by other types of existing interlocking joints. Alternatively, the groove and the tongue profiles 121, 151 could adopt a half-dovetail shape where one longitudinal side is upright while the other side is slanted.

[0062] Figs. 5a & 5b illustrate an insertion of a plurality of first pins 123 to the side panels 120. Preferably, the side panels 120 include a plurality of holes 122 for receiving the first pins 123. Each first pin 123 may comprise an elongate body with a threaded end and a screw head portion. The threaded end can be firmly screwed into the holes 122 of the side panels 120, leaving the screw head portion exposed.

[0063] Figs 6a & 6b illustrate an attachment of a first intermediate panel 160 to a bottom section of the side panels 120. Preferably, the first intermediate panel 160 comprises a plurality of furniture fittings 170, each configured to accommodate the exposed screw head portion of the first pin 123. As shown in Figs. 7a & 7b, each furniture fitting 170 comprises a housing body 171 with an inclined slot 172 configured to receive the screw head portion of the first pin 123. The inclined slot 172 includes an open end 173 for the insertion of the first pin 123, a closed end 174 to secure the first pin 123, and a bulge 175 to firmly hold the first pin 123 at the closed end 174 and prevent it from detaching. Preferably, the first intermediate panel 160 includes one or more recesses for receiving the furniture fittings 170. The inclined slot 172 not only accommodates the screw head portion of the first pin 123 but also serves as a mechanism to prevent the first intermediate panel 160 from detaching when subjected to an uplifting force. Detachment of the first intermediate panel 160 would require a force that is in line with orientation of the inclined slot 172. The bulge 175 firstly provides an additional layer of security to prevent the first intermediate panel 160 from detaching by firmly holding the first pin 123 at the closed end 174 of the inclined slot 172. Secondly, by securely gripping the first pin 123, the bulge 175 helps to minimize wobbling within the furniture assembly, thereby enhancing its structural stability and integrity.

[0064] Referring to Fig. 8a, the side panels 120 can include additional holes configured to receive a plurality of second pins 124. Preferably, the second pins 124 are shelf pins. These shelf pins serve the purpose of supporting one or more second intermediate panels 161 as shown in Fig. 8b. The second intermediate panels 161 partition the space surrounded by the top panel 150, the first intermediate panel 160 and the side panels 120 into multiple compartments.

[0065] Figs. 9a-9d illustrate the transition of the door units 130 from the open state to the closed state. Preferably, each door unit 130 is connected to its corresponding side panel 120 via one or more hinge units 180. The hinge units 180 are capable of allowing the door units 130 to pivot about 270°, ensuring that the door units 130 can lie flush with the side panels 120 when fully opened, as shown in Fig. 9a. When in the closed state, the door units 130 align at a right angle to the side panels 120, as shown in Fig. 9d. The joining edges between the door unit 130 and the side panel 120 have a slanted surface, forming a triangular prism shape when fully opened. The slanted surface also serves as a stopper surface to prevent the door unit 130 from further rotation upon reaching the closed state.

[0066] Figs. lOa-lOd illustrate an exemplary of the hinge unit 180. Preferably, the hinge unit 180 comprises a pair of mounting plates 181, 182 and one or more hinge knuckles 185 for facilitating the rotation of the mounting plates 181, 182. Each mounting plate 181, 182 further includes a free end that is angled in a direction to match the slanted surface of either the door unit 130 or the side panel 120. At the free end of each mounting plate 181, 182 can be provided with one or more through holes 183, 184 for firm attachment of the mounting plates 181, 182 to the door unit 130 and the side panel 120 using screws.

[0067] Referring to Fig. 11, an assembled furniture is illustrated. Preferably, the assembled furniture is cupboard or cabinet. Attaching door handles 190 to the door units 130 can serves as the final step in the furniture assembly process.

[0068] Referring to Figs. 12a-14b, a second embodiment of a furniture module 100 for use as part of a furniture assembly is illustrated. In this embodiment, the furniture module 100 comprises a rear panel 110 with two opposing edges and a pair of side panels 120 pivotally connected to the edges of the rear panel 110. The side panels 120 can pivot between a deployed configuration, where the side panels 120 are positioned perpendicularly to the rear panel 110, and a stowed configuration, where the side panels 120 rest flush against the rear panel 110. Preferably, the side panels 120 are connected to the opposing edges of the rear panel 110 via the adhesive 140 as described in the first embodiment. Alternatively, the rear panel 110 can be formed by a pair of panels that are foldably interconnected via the adhesive 140. Such arrangement allows the rear panel to be folded into stack where one of the panels rest flush against the other. The rear panel 110 and the side panels 120 can be folded in an accordion manner, as shown in Figs. 12a & 12b, for storage or expanded to a generally U-shape configuration for the assembly process to take place, as shown in Figs. 14a & 14b.

[0069] Figs. 15a & 15b illustrate an attachment of a top panel 150 to a top section of the furniture module 100 in its deployed configuration. Similar to the first embodiment, the top section of each side panels 120 comprises a tongue profile 121 and the top panel 150 includes a pair of grooves 151 to receive the respective tongue profiles 121 of the side panels 120. This effectively connects the top panel 150 to the respective side panels 120 via tongue and groove interlocking joint.

[0070] Figs. 16a & 16b illustrate an attachment of a third intermediate panel 162 to a bottom section of the side panels 120. Preferably, the third intermediate panel 162 includes a pair of tongue profiles 163 and each side panel 120 include a groove 125 at the bottom section to accommodate one of the tongue profiles 163 of the third intermediate panel 162. Not only does the third intermediate panel 162 conceals the bottom section of the furniture assembly, but it also enhance the structural integrity of the furniture assembly. Alternatively, such groove and the tongue profiles 125, 163 could adopt a dovetail shape. Fig. 17a illustrates the insertion of a plurality of second pins 124 to the side panels 120. Preferably, the second pins 124 are shelf pins. These shelf pins serve the purpose of supporting one or more second intermediate panels 161. A shelf furniture is assembled as shown in Fig. 17b.

[0071] Referring to Figs. 18a-20b, a third embodiment of a furniture module 100 for use as part of a furniture assembly is illustrated. In this embodiment, the furniture module 100 comprises a rear panel 110 with two opposing edges and a pair of side panels 120 pivotally connected to the edges of the rear panel 110. The side panels 120 can pivot between a deployed configuration, where the side panels 120 are positioned perpendicularly to the rear panel 110, and a stowed configuration, where the side panels 120 rest flush against the rear panel 110. Preferably, the side panels 120 are connected to the opposing edges of the rear panel 110 via the adhesive as described in the first embodiment. Alternatively, the rear panel 110 can be formed by a pair of panels that are foldably interconnected via the adhesive 140. Such arrangement allows the rear panel 110 to be folded into stack where one of the panels rest flush against the other. The rear panel 110 and the side panels 120 can be folded in an accordion manner, as shown in Figs. 18a & 18b, for storage or expanded to a generally U-shape configuration for the assembly process to take place, as shown in Figs. 20a & 20b.

[0072] Fig. 21 illustrates an insertion of a plurality of first and second pins 123, 124. It is preferably to insert pins of the same type into holes at the same level of height of the side panels 120, while intermittently changing pin type at different level of height. Figs. 22a & 22b illustrate an attachment of the first intermediate panel 160 to a bottom section of the side panels 120. Preferably, the first intermediate panel 160 comprises the plurality of furniture fittings 170, each configured to accommodate the exposed screw head portion of the first pin 123. Fig. 23a illustrates an attachment of a fourth intermediate panel 164 to a middle portion of the first intermediate panel 160. The fourth intermediate panel 164 is provided with dowel pins for insertion into pinholes at the first intermediate panel 160. Fig. 23b illustrates an attachment of the second intermediate panel 161 to the side panel 120. Preferably, the second intermediate panel 161 are supported by the second pins 124 and it has a plurality of pinholes for receiving the dowel pins of the fourth intermediate panel 164 to also facilitate an attachment to the fourth intermediate panel 164. The process in Figs. 22a-23b is repeated in Figs. 23c-23h until the top panel 150 is attached. In this embodiment, the top panel 150 has the same configuration as per the first intermediate panel 160. A multiple compartment shelf is then formed in Fig. 23h.

[0073] Referring to Figs. 24a-24f, a fourth embodiment of the furniture module 100 for use as part of a furniture assembly is illustrated. In this embodiment, the furniture module 100 comprises a rear panel 110 with two opposing edges and a pair of side panels 120 pivotally connected to the edges of the rear panel 110. The side panels 120 can pivot between a deployed configuration, where the side panels 120 are positioned perpendicularly to the rear panel 110, and a stowed configuration, where the side panels 120 rest flush against the rear panel 110. Preferably, the side panels 120 are connected to the opposing edges of the rear panel 110 via the adhesive 140 as described in the first embodiment. Alternatively, the rear panel 110 can be formed by a pair of panels that are foldably interconnected via the adhesive 140. Such arrangement allows the rear panel to be folded into stack where one of the panels rest flush against the other. The rear panel 110 and the side panels 120 can be folded in an accordion manner for storage or expanded to a generally U- shape configuration for the assembly process to take place, as shown in Fig. 24a. Alternatively, each side panel 120 may comprise a door unit 130 that is pivotable between an open state where the door unit 130 lies flush with the side panel 120 and a closed state where the door unit 130 is arranged at a right angle to the side panel 120. The rear panel 110, the side panels 120 and the door units 130 can be folded in the accordion manner.

[0074] Fig. 24b illustrate the furniture module 100 being attached with a top panel 150, a plurality of second intermediate panels 161, and a third intermediate panels 162. The top panel 150 is attached to the top section of the furniture module 100 in its deployed configuration via a plurality of first fastening members 152. Each first fastening members 152 may comprise an elongated body, which is longitudinally divided into a first section 153, a second section 154, and a third section 155. The elongated body is generally cylindrical, but it should be understood that it can also have a polygonal cross-section. The sections 153, 154, 155 can be arranged sequentially, with the second section 154 positioned between the first and third sections 153, 155. The first section 153 extends from one end of the second section 154 and includes external threads configured to be screwed into a threaded hole 156 on the top panel 150. The second section 154 comprises a plurality of serrated teeth configured to firmly engage with a hole 126 on top edges of the side panels 120. The third section 155 extends from an opposite end of the second section 154 and includes a frictional surface that can be gripped by a user to facilitate the screwing motion of the first section 153 into the top panel 150.

[0075] The second intermediate panels 161 may be attached to the side panels 120 via a plurality of dowel pins. The lowermost second intermediate panel 161 may be attached with the third intermediate panel 162 at a right angle via the dowel pins. After the attachment to the lowermost second intermediate panel 161, the third intermediate panel 162 can be further attached to the side panels 120 via the dowel pins. Not only does the third intermediate panel 162 conceals the bottom section of the furniture assembly, but it also enhance the structural integrity of the furniture assembly. It should be understood that the dowel pins can be readily substituted with the first fastening members 152 or other any other type of fasteners conventionally available in the art.

[0076] A plurality of second fastening member 127 may be provided to secure the joints between the side panels 120 and the third intermediate panel 162. In general, each second fastening member 127 preferably includes a plate body 127a with a pair of projections 127b extending from one side, configured for insertion into corresponding holes 128 on the bottom edge of the side panels 120 and the third intermediate panel 162. Further second fastening member 127 can be purely attached to the side panels 120 such that the second fastening members 127 can further act as leg supports to provide consistent levelling for the furniture assembly.

[0077] Referring to Fig. 24c, a specific embodiment of the second fastening member 127 is illustrated. The second fastening member 127 comprises a plate body 127a and a pair of projections 127b, which extend from one side of the plate body 127a. Each projection 127b includes a corrugated surface that provides a frictional grip for securing the insertion, at least one tooth flange 127d along a length of the projection 127b to firmly engage the inner surface of the hole, and a slot 127c, adjacent to the tooth flange 127d, that allows a resilient deformation in the area where the tooth flange 127d is located, thereby creating a return force that presses the tooth flange 127d against the inner surface of the hole. The size of the slot 127c determines the spring constant of the deformation during insertion. Specifically, a larger slot 127c size may result in lower spring constant, making the projection 127b more flexible and easier to insert, while a smaller slot 127c size increases the spring constant, providing a stiffer resistance. Additional resilient material can be inserted into the slot 127c to adjust the spring constant for different applications.

[0078] Figs. 24d & 24e illustrate a door installation method. Preferably, the door unit 130 is connected to its corresponding side panel 120 via one or more hinge units 180 in its second embodiment, which function similarly or identically to those in the first embodiment. Referring to Fig. 24f, the second embodiment of each hinge unit comprises a first mounting plate 188 and a second mounting plate 186, which respectively attached to the side panel 120 and the door unit 130 in a detachable manner. The first mounting plate 188 includes an open ended channel 189, while the second mounting plate 186 includes an extended portion 187. The open ended channel 189 is configured to rotatably accommodate the extended portion 187. Upon insertion, a complete hinge unit 180 is formed for pivoting the door unit 130 relative to the side panel 120. In an embodiment incorporating an upper hinge unit and a lower hinge unit, the extended portion 187 of the upper hinge unit may be configured with a length shorter than that of the lower hinge unit to facilitate alignment. Alternatively, this configuration may be reversed, such that the lower hinge unit includes the shorter extended portion 187. Furthermore, the positional relationship between the extended portion 187 and the open-ended channel 189 may be interchanged relative to one another in alternative embodiments, as needed. In an exemplary configuration, the open-ended channel 189 may be disposed on the second mounting plate 186 in lieu of the first mounting plate 188, with the extended portion 187 correspondingly positioned on the first mounting plate 188 rather than the second mounting plate 186.

[0079] Referring to Fig. 24g, an assembled furniture is illustrated. Preferably, the assembled furniture is a cupboard or cabinet. Attaching door handles 190 to the door units 130 can serves as the final step in the furniture assembly process.

[0080] Referring to Figs. 25a-25c, a method of forming a joint between two adjacent panels 110, 120 is illustrated. Preferably, the method comprises three steps. Initially, one panel 110 is placed on top of another in such a way that their joining edges are in alignment. Next, at least one segment of the joining edges is cut away to create a continuous slanted surface 141 across the two panels 110, 120 using a trim router. Lastly, the adhesive 140 is laid on the slanted surface 141 to form a hinge connection between the panels 110, 120. Preferably, the adhesive 140 is a plastic sheet with glue being pressed onto the slanted surface 141 via roller press machine to create a hingelike connection between the panels 110, 120. The slanted surface 141 has a surface area greater than the initial surface of the joining edges (before cutting), therefore the area of coverage, at the joining edges of both the panels 110, 120, for the adhesive 140 is substantially increased to ensure a stronger bond. The coverage of the adhesive 140 can be extended to cover adjacent surfaces of the joining edges. Preferably, this method is used to connect the side panels 120 to the rear panel 110.

[0081] Figs. 26a & 26b illustrates an alternative method of forming a joint between two adjacent panels 110, 120. Preferably, the method comprises two steps. First, one panel 110 is placed on top of another in such a way that their joining edges are in alignment. Second, the adhesive 140 is laid on a flat surface between the joining edges to form a hinge connection between the panels 110, 120. Unlike the previous method, the flat surface here has a smaller area. Alternatively, this method may also be used to connect the side panels 120 to the rear panel 110.

[0082] Figs. 27a-27i illustrate a further embodiment of the method for forming a joint between two adjacent panels 110, 120. Initially, the rear panel 110 is stacked on top of the side panel 120 in such a way that their joining edges are in alignment. The stacked panels 110, 120 are then convey by a conveyor system 220 in a compressed manner to undergo subsequent processing steps such that lateral displacement or vibration of the panels can be prevented to facilitate a smoother cut edges with reduced microfractures or splintering.

[0083] Next, the at least one segment of the joining edges is removed to create a continuous slanted surface 141 across the two panels 110, 120. This removal may be performed using either an industrial grade cutter 201 or a trim router 200. Adhesive 140 is then applied to the slanted surface to form a hinge connection between the panels 110, 120. The adhesive 140 may be in the form of a plastic sheet 142 with glue 143, which is pressed onto the slanted surface 141 via one or more roller press machines 210 to create a hinge-like connection between the panels 110, 120. Alternatively, the glue 143 may be applied directly to the slanted surface 141 before pressing the plastic sheet 142 on top of the glue 143 via the one or more roller press machines 210. The adhesive 140 may extend to other surfaces of the panels 110, 120. A trimming process may be performed, using one or more trimmers 220, to remove excessive adhesive portions from the edges of the panels 110, 120. The trimming process may be repeated multiple times to ensure complete removal of any excess adhesive 140. Additionally, a cleaning process may be carried out to remove dust using a brush 230 or to eliminate any residual or leaked glue using scraper or sponge 240.

[0084] The present disclosure includes as contained in the appended claims, as well as that of the foregoing description. Although this invention has been described in its preferred form with a degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and the combination and arrangements of parts may be resorted to without departing from the scope of the invention.

Claims

CLAIMS1. A method of forming a joint between two adjacent panels (110, 120) within a collapsible furniture assembly, the method comprising the steps of: placing one panel (110, 120) on top of another in such a way that their joining edges are in alignment; cutting away at least one segment of the joining edges to create a continuous slanted surface (141) across the two panels (110, 120); and laying an adhesive (140) on the slanted surface (141) to form a hinge connection between the panels (110, 120).

2. The method according to claim 1, wherein the adhesive is in the form of a plastic sheet (142) pre-applied with glue (143).

3. The method according to claim 1, wherein the laying of the adhesive comprises the steps of: applying glue (143) to the slanted surface (141); and pressing a plastic sheet (142) on top of the glue via one or more roller press machines (210).

4. The method according any one of claims 1 to 3, further comprising the step of trimming excessive portions of the adhesive (140) from edges of the panels (110, 120) using one or more trimmers (220).

5. The method according to claim 4, wherein the step of trimming can be repeated until complete removal of the excessive portions of the adhesive (140).

6. The method according to any one of claims 1 to 5, further comprising the step of removing dust from the panels (110, 120) using a brush (230).

7. The method according to any one of claims 1 to 6, further comprising the step of removing residual or leaked glue using scraper or sponge (240).

8. The method according to any one of claims 1 to 7, wherein the panels (110, 120) are conveyed in a compressed manner to each subsequent processing steps using a conveyor system (220).

9. A furniture module (100) comprising: a rear panel (110) having two opposing edges; and a pair of side panels (120), each pivotally connected to the edges of the rear panel (110) using the method according to any one of claims 1 to 7; wherein the side panels (120) are pivotable between a deployed configuration where the side panels (120) are positioned perpendicularly to the rear panel (110) and a stowed configuration where the side panels (120) rest flush against the rear panel (HO).

10. The furniture module (100) according to claim 9, wherein each side panel (120) further comprises a door unit (130) pivotable between an open state where the door unit (130) lies flush with the side panel (120) and a closed state where the door unit (130) is arranged at a right angle to the side panel (120).

11. The furniture module (100) according to claim 10, wherein joining edges between the door unit (130) and the side panel (120) have a triangular prism shape when in the open state.

12. The furniture module (100) according to claim 11, wherein the joining edge of the side panel (120) comprises a stopper surface configured to engage with the joining edge of the door panel (130), thereby preventing the door unit (130) from furtherrotation upon reaching the closed state.

13. The furniture module (100) according to claim 11 or claim 12, wherein the door unit (130) is pivotally connected to the side panel (120) via one or more hinge units (180).

14. The furniture module (100) according to claim 13, wherein each hinge units comprises a first mounting plate (188) attached to the side panel (120) and a second mounting plate (186) attached to the door unit (130), wherein one of the mounting plates (186, 188) includes an open ended channel (189) for rotateably accommodating an extended portion (187) of the other mounting plate (186, 188) in a detachable manner.

15. The furniture module (100) according to any one of claims 9 to 14, wherein each side panel (120) further comprises a tongue profile (121) configured to receive a groove (151) of a top panel (150), thereby connecting the top panel (150) to the side panels (120) via a tongue and groove interlocking joint.

16. The furniture module (100) according to any one of claims 9 to 15, wherein each side panel (120) further comprises a groove (125) configured to receive a tongue profile (163) of an intermediate panel (162), thereby connected the intermediate panel (162) to the side panels (120) via a tongue and groove interlocking joint.

17. The furniture module (100) according to any one of claims 9 to 16, wherein each side panel (120) further comprises a plurality of pinholes (122) for receiving pins (124) that are configured to support one or more intermediate panels (160, 161) between the side panels (120) of the furniture module (100) in the deployed configuration.

18. The furniture module (100) according to claim 17, wherein each intermediatepanel (161) incorporates one or more furniture fittings (170) for receiving the pins (123), each furniture fitting (170) comprises an inclined slot (172) configured to receive a protruded portion of the pin (123), and a bulge (175) within the inclined slot (172) to prevent the received pin (123) from detaching.

19. The furniture module (100) according to any one of claims 9 to 18, wherein the rear panel (110) is formed by a pair of panels that are foldably interconnected via the adhesive (140).

20. The furniture module (100) according to any one of claims 9 to 19, wherein the top panel (150) and / or one or more intermediate panels (161, 162) are attached to the furniture module (100) in the deployed configuration via a plurality of first fastening members (152), wherein each first fastening member (152) comprises an elongate body having, in its longitudinal direction, a first section (153), a second section (154) and a third section (155); wherein the first section (153) includes external threads configured to be screwed into a threaded hole (156) of the panels (150, 161, 162), the second section (154) includes a plurality of serrated teeth configured to firmly engage with a hole (126) of the side panels (120), and the third section (155) includes a frictional surface configured to be gripped by a user to facilitate the screwing motion of the first section (153) into the panels (150, 161, 162).

21. The furniture module (100) according to any one of claims 9 to 20, further comprising a plurality of second fastening member (127) connected to a bottom of the furniture module (100) and / or one or more intermediate panels (162) to secure the connection between the furniture module (100) and the one or more intermediate panels (162) and to provide consistent levelling to the assembly, wherein each second fastening member (127) comprises a plate body with a pair of projections extending from one side of the plate body for insertion into holes (128) of the furniture module (100) and / or one or more intermediate panels (162).

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