Multi-Layer Board Coupling for Tool-Free Furniture Panel Assembly
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Solution Overview
Problem
Existing furniture assembly methods, particularly for flat-pack furniture, are cumbersome due to the complexity of connection accessories and the difficulty for DIY users to assemble panels correctly, leading to increased costs and packaging challenges for manufacturers.
Innovation Solution
A composed element design featuring panel-shaped elements with integrated profiled parts that allow interlocking coupling, where the profiled parts are hidden from view, enabling easy assembly and minimizing 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
1Reliability
If traditional connection accessories (pins, screws, clamping pins) are used to couple furniture panels, then the panels can be securely connected, but the assembly process becomes complex and difficult for DIY users
Solution Approach 1:
The patent integrates the coupling function directly into the panel edges by forming profiled parts (tongues and grooves) as integral components of the panel structure itself, eliminating the need for separate connection accessories. This merging of the coupling function into the panel structure simplifies assembly while maintaining secure connections.
Solution Approach 2:
The profiled parts are designed to enable self-aligning and self-locking during assembly. The tongue automatically engages with the groove and the locking elements secure the connection without requiring external tools or complex manipulation, making the assembly process intuitive and easy for DIY users.
2Reliability
If multiple connection accessories are supplied with furniture, then secure coupling is achieved, but packaging costs and complexity increase
Solution Approach 1:
The coupling functionality is merged into the panel structure itself through integrally formed profiled parts. This eliminates the need to package and supply multiple separate connection accessories, reducing packaging complexity and costs while maintaining secure coupling capability.
3Strength
If profiled parts extend to the end face of panels, then coupling strength is maximized, but aesthetic appearance is compromised
Solution Approach 1:
The patent extracts the profiled parts (tongues and grooves) so that they do not extend to the visible end faces of the panels. The coupling mechanism is positioned within the panel thickness, leaving the end faces clean and aesthetically pleasing while maintaining sufficient coupling strength through the integrated locking elements.
4Reliability
If classical dowel and glue connection is used, then panels are securely connected, but the method is not suitable for DIY assembly
Solution Approach 1:
The patent replaces the classical mechanical connection method (dowels requiring drilling and glue application) with an integrated profiled part system where the tongue and groove with locking elements provide secure mechanical coupling. This substitution eliminates the need for additional tools and materials, making the process suitable for DIY assembly while maintaining connection strength.
Data Source
Figure 1~13
Figure 2~3
Figure 4~7
AI summary
Composed element, wherein this composed element comprises at least two panel- shaped elements (2-3), which substantially are formed from a board material; wherein said panel-shaped elements (2-3) are interconnected at an angle by means of coupling means comprising a tongue (13) and a groove (14), which coupling means substantially are made as profiled parts in the board material; and wherein said coupling means also comprise locking elements (15-16), which, in coupled condition, prevent the moving apart of the tongue and groove, characterized in that the panel-shaped elements (2-3) are formed on the basis of board material in the form of particle board consisting of two or more layers, which layers, in respect to the average fineness of the particles, show a different degree of fineness, respectively a basic layer (138, 139) with coarser particles, more particularly chips, and at least one outer layer (136, 137), or at least a more outward-situated layer, which is of a finer composition than the composition of the basic layer (138, 139), in other words, with particles, chips, respectively, which on average are finer.