Panel-Shaped Furniture Assembly Using Integrated Profiled 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 involving numerous accessories, which complicates user assembly and increases manufacturing costs.
Innovation Solution
A composed element design featuring panel-shaped elements with profiled parts along their edges that interlock seamlessly, using a tongue and groove mechanism with hidden profiled parts, allowing for easy assembly without visible connectors, and utilizing multi-layered boards for enhanced strength and cost-effectiveness.
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 sufficient, but the assembly complexity increases and manufacturing costs rise due to packaging and managing numerous accessories
Solution Approach 1:
The coupling means integrate multiple connection functions into a single integrated structure. The profiled parts with interlocking geometries combine positioning, locking, and load-bearing functions that previously required separate accessories like pins, screws, and clamping elements, thereby reducing assembly complexity while maintaining connection strength
Solution Approach 2:
The coupling means are designed to be self-aligning and self-locking through their profiled geometries. The interlocking profiled parts automatically guide and secure the connection without requiring external tools or multiple accessories, enabling DIY assembly while maintaining robust connections
2Ease of operation
If profiled parts are used for coupling panel-shaped elements, then the connection is strong and assembly is simplified, but the aesthetic appearance is compromised due to visible connectors
Solution Approach 1:
The visible connector elements are extracted and replaced by integrating the coupling function directly into the panel edges through profiled parts. The coupling means become part of the panel structure itself rather than separate visible accessories, maintaining aesthetic appearance while preserving assembly simplicity
Solution Approach 2:
The coupling means are nested within the panel structure, with profiled parts integrated into the edges of panel-shaped elements. The interlocking profiles are housed within the panel thickness, allowing strong connections to form within the panel volume rather than extending outward as visible connectors
3Reliability
If multiple connection accessories are supplied with furniture, then adequate connection options are provided, but packaging space and manufacturing costs increase
Solution Approach 1:
Multiple connection functions that previously required separate accessories are merged into integrated profiled parts. The coupling means incorporate positioning features, locking mechanisms, and load-bearing structures within unified profiled elements, reducing the quantity of separate components needed while maintaining connection reliability
Solution Approach 2:
The profiled coupling means are designed with universal applicability, where single integrated structures can accommodate various connection requirements through their geometric profiles. This multi-functionality eliminates the need for multiple specialized accessories, reducing packaging volume while ensuring reliable connections
Data Source
Figure 1~13
Figure 2~3
Figure 4~7
AI summary
The composed element, in the form of a wall portion or a furniture element, comprises at least two panel-shaped elements (2-3). The two panel-shaped elements (2-3) are connected by means of coupling means (6-7) which make use of a locking element (16), which is performed as an insertion piece in an edge of one of the panel-shaped elements (2-3).