Tool-Free Panel Assembly Using Flexible Tongue and Groove Locking
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Solution Overview
Problem
Existing furniture assembly methods require tools and are not easily adaptable for creating products like flat-pack furniture that need strong, tool-free assembly solutions with flexible locking systems.
Innovation Solution
A set of panels with flexible tongue and groove locking devices that allow for tool-free assembly, featuring panels that can be connected by hand, with the flexible tongue cooperating with a tongue groove for locking in one direction and an edge section with a groove for locking in a perpendicular direction, facilitating the creation of frames and additional panels like back or bottom panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical locking system with flexible tongue and groove is used, then the strength and reliability of the connection is improved, but the complexity of the device increases
Solution Approach 1:
The locking device is segmented into distinct functional components: a flexible tongue element, a tongue groove, and an edge section with edge groove. This segmentation allows each component to perform its specific locking function independently, achieving reliable connections while keeping individual components simple and manageable.
Solution Approach 2:
The tongue is designed as a flexible element that can dynamically adapt during assembly. The flexibility allows the tongue to bend and engage with the groove during the connection process, providing reliable locking without requiring complex adjustment mechanisms or precise alignment tools.
2Strength
If traditional mechanical locking systems are used, then the connection strength is improved, but the ease of operation deteriorates due to tool requirements
Solution Approach 1:
The locking device is designed to be self-servicing during assembly. The flexible tongue automatically engages with the groove when panels are brought together, and the edge section with its groove provides self-aligning features. This eliminates the need for external tools or complex manipulation, allowing strong connections to be made easily by hand.
Solution Approach 2:
The design changes the operational parameters by eliminating tool requirements. The flexible tongue's material properties and geometric configuration are optimized to engage with the groove under manual assembly conditions, transforming a traditionally tool-dependent process into a tool-free operation while maintaining connection strength.
3Ease of manufacture
If the insertion groove extends along the entire length of the edge, then the ease of manufacture is improved, but the device complexity increases
Solution Approach 1:
The edge groove and tongue groove are designed as universal features that can be produced using standard woodworking or panel processing equipment. The grooves serve multiple functions: they guide the tongue during assembly, provide the locking mechanism, and allow for easy manufacturing through common routing or grooving operations, making the design both simple to produce and functionally complete.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the assembly of furniture components like drawers, cupboards, and bookshelves without tools, providing strength and ease of disassembly, while allowing for the production of complex shapes like perpendicular corners and slideable panels.
Implementation Method 1
a flexible tongue arranged in an insertion groove at an edge of a panel, said flexible tongue cooperates with a tongue groove, at an adjacent edge of an adjacent panel, for locking the panel and the adjacent panel together
Implementation Method 2
The locking devices comprise an edge section groove at the panel or at the adjacent panel. An edge section of the other of the panel or the adjacent panel cooperate with said edge groove for locking the panel and the adjacent panel together
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3A~3B
AI summary
An assembled product, such as an assembled product, such as a furniture component or a furniture, such as a drawer, a cupboard, bookshelves, a wardrobe, a kitchen fixture, or a box for storing or transporting including at least three panels arranged in three different planes. Also, a set of panels for an assembled product and a method of assembling the product.