Interlocking Furniture Panels With Hidden Edge Coupling
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Solution Overview
Problem
Existing furniture assembly methods, particularly for flat-pack furniture, are cumbersome for DIY assembly due to complex connection systems and high accessory counts, which increase manufacturing costs and complexity, while also affecting the aesthetic appearance and ease of assembly.
Innovation Solution
A composed element design featuring panel-shaped elements with profiled parts that allow interlocking coupling, where the coupling means are integrated into the edges and can be hidden from view, using materials like laminate or ABS strips, and locking elements that prevent drifting apart, enabling easy assembly without visible fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional connection accessories (pins, screws, clamping pins) are used to connect furniture panels, then the connection strength is improved, but the device complexity and ease of operation deteriorate due to the large number of accessories required
Solution Approach 1:
The patent merges the coupling means directly into the panel-shaped elements themselves, integrating the connection function into the panels rather than using separate accessories. The profiled parts are formed as integral features of the panels, eliminating the need for separate pins, screws, or clamping elements, thus reducing device complexity while maintaining connection strength
Solution Approach 2:
The panels are designed with self-coupling capabilities through their profiled edges. The complementary profiled parts automatically guide and secure the panels together during assembly without requiring additional fastening accessories, allowing the panels to serve their own connection needs
2Reliability
If multiple connection accessories are provided for furniture assembly, then the reliability of connection is improved, but the ease of operation deteriorates due to user confusion about assembly instructions
Solution Approach 1:
The profiled parts are designed to be self-explanatory and self-assembling. The complementary shapes of the profiled edges naturally guide the assembly process, making it intuitive for users to understand how to connect the panels without complex instructions or multiple accessory types
Solution Approach 2:
The connection function is segmented into the basic panel design rather than being added through multiple separate accessories. This segmentation simplifies the assembly process to basic panel-to-panel coupling actions, reducing user confusion while maintaining reliable connections
3Strength
If profiled parts extend to the end face of panels for interlocking coupling, then the connection strength is improved, but the aesthetic appearance deteriorates due to visible fasteners
Solution Approach 1:
The patent extracts the visible portion of the profiled parts from the end face area while maintaining their functional coupling capability. The profiled parts are positioned and dimensioned to provide sufficient interlocking strength while being hidden from external view, separating the functional requirement from the aesthetic requirement
Solution Approach 2:
The profiled parts are designed with different characteristics in different locations: they have sufficient extension and complexity in the edge zone to provide strong interlocking coupling, but are concealed or minimized at the end face where they would be visible, creating local variations in the profiled part design to satisfy both functional and aesthetic requirements
4Device complexity
If complex coupling means are integrated into panel edges, then the ease of manufacture deteriorates, but the device complexity improves by reducing the number of separate accessories
Solution Approach 1:
The coupling means are merged into the panel manufacturing process itself. The profiled parts are formed as integral features of the panels during panel production, combining what would traditionally be separate manufacturing steps into a unified process, thereby reducing overall device complexity without significantly increasing panel manufacturing complexity
Data Source
AI summary
Composed element, wherein this composed element comprises at least two panel-shaped elements, which substantially are formed from a board material; wherein said panel-shaped elements are interconnected at an angle by means of coupling devices including a tongue and a groove, which coupling devices substantially are made as profiled parts in the board material; and wherein said coupling devices also include locking elements, which, in coupled condition, prevent the moving apart of the tongue and groove. The panel-shaped elements are formed on the basis of board material in the form of particle board consisting of two or more layers, which in respect to the average fineness of the particles, show a different degree of fineness, namely a basic layer with coarser particles, more particularly chips, and at least one outer layer, or at least a more outward-situated layer, which is of a finer composition than the composition of the basic layer, in other words, with particles, chips, respectively, which on average are finer.