Interlocking Multi-Layer Furniture Panels for Hidden Snap Assembly
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Solution Overview
Problem
Existing furniture assembly methods, particularly for flat-pack furniture, are cumbersome for DIY assembly due to the complexity of connections and the need for numerous accessories, which increases manufacturing costs and confuses users.
Innovation Solution
A composed element design featuring panel-shaped elements with profiled parts that allow interlocking coupling, where the profiled parts are hidden from view, enabling easy assembly with minimal aesthetic impact, using materials like laminate strips or ABS for durability and a snap-action mechanism for secure joining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If furniture panels are connected using classical techniques with dowels and gluing, then connection strength is improved, but ease of operation deteriorates due to complexity and suitability for DIY assembly
Solution Approach 1:
The patent combines multiple connection functions into a single integrated profiled coupling means that incorporates both mechanical interlocking (tongue and groove) and locking elements (cam mechanisms, spring-loaded components) in one piece, eliminating the need for separate dowels, screws, and glue applications
Solution Approach 2:
The coupling means incorporates self-aligning and self-locking features where the cam mechanism automatically engages with the tongue-groove interface, and spring-loaded elements automatically adjust to secure the connection without requiring precise manual alignment or additional fastening steps
2Reliability
If connection accessories are supplied in large numbers, then reliability of connection is improved, but device complexity deteriorates due to number of parts and packaging requirements
Solution Approach 1:
Multiple previously separate connection accessories (dowels, screws, clamping pins, locking mechanisms) are merged into a single integrated profiled coupling means that is built directly into the furniture panel edges, reducing the total part count to essentially one component per joint
Solution Approach 2:
The profiled coupling means serves multiple functions simultaneously: it provides mechanical interlocking through tongue and groove, automatic locking via cam mechanisms, alignment guidance, and structural reinforcement, replacing what previously required several different specialized accessories
3Strength
If profiled parts are made visible for structural integrity, then strength is improved, but esthetical appearance deteriorates
Solution Approach 1:
The patent extracts the functional coupling elements (tongue and groove, locking mechanisms) into a separate profiled coupling means that is built into the panel edges, allowing the visible surface of the furniture panel to remain smooth and uninterrupted while the connection structure exists in a separate, hidden configuration
Solution Approach 2:
The coupling means is nested within the profile of the furniture panel edge, with the tongue and groove mechanisms and locking elements contained within the cross-sectional geometry of the panel, so that when panels are joined, the connection structure is hidden within the joint rather than protruding on the visible surface
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.