GB2411707A

GB2411707A - Panel connection system

Info

Publication number: GB2411707A
Application number: GB0405058A
Authority: GB
Inventors: Paul Shenton
Original assignee: Individual
Current assignee: Individual
Priority date: 2004-03-05
Filing date: 2004-03-05
Publication date: 2005-09-07
Anticipated expiration: 2024-03-05
Also published as: GB2411707B; GB0405058D0; WO2005085656A1

Abstract

A panel connection system includes two panels (10, 40). One of the panels (10) has a slot (12) in an edge to receive the edge (40c) of another of the panels (40). The slotted panel (10) has panel engagement means (14) associated with the slot (12). The panel engagement means (14) are resiliently deformable when the other panel (40) is inserted in the slot, and engages the other panel (40).

Description

241 1 707 - 1 - Panel Connection System

Description

s The present invention relates to a system for joining two panels together, and in particular, a system to allow two panels to be slotted together and be held rigidly secure without the need for the thickness of each panel and the slot in each panel to be of a precise dimension.

A popular type of furniture is that known as 'flat-pack' furniture, which comprises a packaged set of components which the user buys in a disassembled state and has to assemble themselves at home. Many of these components are planar, for example panels, and various means are used to Join such components together, such as screws, nails and glue. However, for complex furmture, these construction methods I: can be time consuming and/or messy.

One known way of quickly and cleanly 1omlng panels together is by means of a reciprocating slot in each panel (shown in Figures 1 and 2 of the accompanying drawings hereafter). In this way, the ends of each panel are aligned, with the slot in each panel facing one another, usually with the planes of the panels at right angles, and the panels are pushed together so that the each slot slides through the other until the ends of the slots abut each other.

One problem with this panel connection means is that the rigidity and strength of the connection depends greatly on the dimensions of both the slot width and the panel thickness being precise. If either the slots are slightly too wide, or the panel thickness' are too small, then the fit will be too loose to hold the panels firmly in place, so they will be able to move relative to each other and the Joint would lack strength. Conversely, if either the slots are too narrow, or the panels are too thick, the two panels will not fit together at all. Thus, to achieve a satisfactory fit using this sort of connection between two panels, the acceptable range of tolerances within which the panels and the slots may be manufactured, is very small and difficult to consistently achieve in practice. - 2

These variations in slot size or panel thickness can come about for a number of reasons. Manufacturing inconsistencies, for example machine tolerances, can vary from Item to item and from batch to batch. Also, the suppliers of the raw materials for the panels can only pronde the materials within a certain tolerance of the requested dimensions. Treatment of the panels also affects their dimensions. For example, paint, varnish, and lacquer will increase the thickness, each treatment by a different amount, whereas sanding or polishing a panel may reduce the thickness.

Variations are also caused by ambient or atmospheric changes, either in site, or 0 between the panel manufacturing site and the final assembly site. For example, porous materials may expand in environments where the air Is damp by absorbing moisture, or conversely, may contract If placed in a dryer environment than it had been m previously. Wooden panels or those made from wood derivatives are particularly prone to this sort of dimensional variation.

Therefore, the object of the invention is to provide a quick, clean and industrially practical means to connect two panels together that substantially alleviates or overcomes the problems mentioned above.

According to the present Invention, therefore, there Is provided a system for releasably connecting together first and second panels substantially at right angles to each other, at least one panel having a slot m the edge thereof to receive the edge of another panel, the or each slotted panel including panel engagement means associated with the slot so that when another panel is inserted Into the slot, the panel engagement means are resiliently deformable by said Inserted panel to releasably connect said panels together.

In a preferred embodimcut, the panel engagement means composes at least one arm extending from a boss that protrudes from a first side of the slot, said at least one arm bemg resiliently deformable in response to mscrtion of said other panel. - 3

Preferably, the at least one arm has a panel engaging surface spaced from the other side of the slot to define a first gap between said panel engaging surface and said other side to receive said other panel.

The arm preferably has a raised portion that extends toward the other side of the slot, a portion of the panel engaging surface bemg formed on said raised portion.

Conveniently, the panel engaging surface IS flat.

In a preferred embodiment, the arm is spaced from the first side of the slot such that the arm is deflectable into said space when the other panel is inserted mto the slot.

The panel engagement means may comprises one arm, or alternatively it may comprise two arms extending from the boss in opposite directions.

The boss preferably extends from a mld-pomt of the first side of the slot, and the or each arm preferably extends substantially parallel to the sides of the slot.

The slot has an end, and conveniently, a rebate Is formed m a corner of the slot where said other side of the slot meets the end of the slot.

Both first and second panels preferably have a slot in the edge thereof to rccctve the edge of the other panel, each slotted panel including panel engagement means associated with the slot.

In a prefctred embodiment, the or each panel engaging means is integrally formed with the or each panel. Alternatively, the or each panel cogagmg means can be a separate body attached to the slot of the or each panel.

The or each panel may be made from wood, a wood derivative, plastic, acrylic, metal or a resin. - 4

Conveniently, the or each panel and panel engagement means are moulded as one unitary body.

Another preferred embodiment Includes an item of furmture comprising a number of interlocked panels Incorporating the connection system of the invention, and the item can be a chair.

The present Invention will now be described, with reference to the accompanying drawings, in which: Figure I show a prior art means for connecting two panels together; Figure 2 shows the prior art connection means of In Figure I with the panels slotted together; Figure 3 shows a panel Incorporating the connection system of the present mventlon; Figure 4 shows the panel of Figure 3 with the connection system receiving another panel; Figure 5 shows the panel of Figure 3 with the connection system receiving a panel of larger thickness than that shown In Figure 4; Figure 6 shows the panel of Figure 3 with the connection system receiving a panel of smaller thickness than that shown in Figures 3 and 4; Figure 7 shows a perspective view of the panels shown In Figure 6; Figure 8 shows a perspective view of two panels, each incorporating the connection system of the present Invention bemg fitted together; Figure 9 shows a panel incorporating an alteratlve embodiment of the connection system of the present Invention; Figure 10 shows a number of panels Incorporating the connection system of the present Invention In a disassembled state; and Figure I I shows the panels of Figure 10 assembled to form a chair.

Referring now to Fgurc 1, a known means for connecting a first and a second panel 1, 2 together is shown, and comprises a straight slot 3, 4 cut Into each panel 1, 2 from an edge la, 2a towards the middle of the panel 1, 2, respectively. The two - 5 panels 1, 2 are connected together by aligning them, with the plane of one panel perpendicular to that of the other, as shown in Figure 1, and pushing together in the directions shown by arrows A and B until a rear wall 5, 6 of each slot 3, 4 abut each other, as shown In Figure 2. s

However, the problems mentioned above with respect to this known means for conuccting panels are illustrated In Figures 1 and 2. Referring to Figure 1, if, due to manufacturing Inconsistencies or otherwise, width W1 of the slot 3 in the first panel 1 IS smaller than thickness T2 of the second panel 2, then the second panel 2 will /0 not fit into the slot 3 in the first panel 1, so the bottom edge la of the first panel 1 will not be able to pass beyond the rear wall 6 of the slot 4 in the second panel 2 and the two panels 1, 2 will not be able to be connected together.

Conversely, If the width W1 of the slot 3 is significantly larger than the thickness T2 /5 of the second panel 2, then a gap G1 will be left between a face of the second panel 2 and an inside wall of the slot 3 In the first panel 1. This gap G1 will result m a loose fit between the two panels 1, 2 so they will be able to move relative to each other, as shown by arrows C and D In Figure 2.

Either of the above manufacturing inconsistencies In, for example, flatpack furniture, would result In the Item of furniture being either impossible to assemble or of a weak and poor quality finish. However, It is not easy to produce the required exact and consistent quality of panels In practice, especially with market pressure of low cost and high volume production. Therefore, there exists the need to provide a means to connect two panels together which will allow for a certain degree of manufacturing Inconsistency, as well as for other factors that can affect panel dimensions as mentioned above, yet still hold the panels together rigidly, and which avoids the need to use fixing devices such as screws, nails, or glue, or the use of hand-tools.

Referring now to Figure 3, a panel 10 is shown featuring the connection system 11 of the present Invention. The connection system 11 comprises a slot 12 cut In the panel 10 extending from one edge 1Oa thereof towards the middle of the panel 10. - 6

The slot 12 has inside walls 12a, 12b and an end wall 12c. A panel engagement means is associated with the slot and comprises a trunk portion or boss 13 extending from the one inside wall 12b of the slot 12 with resilient arms 14 extending perpendicular to the trunk 13 and parallel to the inside walls 12a,12b of s the slot 12. One corner of the slot 12 has a small rebate 18 where the inside wall 12a meets the end wall 12c.

Each resilient arm has an enlarged end 15 having a contact surface 15a. Said contact surface 15a extcods further towards the inside wall 12a of the slot 12 that it faces 0 than does a corresponding contact surface 14a of the arm 14. The difference in distance by which each contact surface 14a, 15a extends towards the facing inside wall 12a is distance d. The distance from the contact surface 15a of the end 15 to the inside wall 12a of the slot 12 is shown as Dm,n. The distance from the surface 14a of the arm 14 to the edge 12a of the slot 12 is shown as DmaX. Thus, the distance d equates to [Dm3X - Don]. As will be explained in more detail below, the difference d between DmaX and Dm,n is important as it represents the range of panel thickness that the connection system can securely accommodate i.e. Dm,n IS the thinnest thickness of panel that can be slotted into and rigidly held in position by the connection system of the invention, and DmaX is the thickest thickness of panel that can be slotted into and rigidly held in position by the connection system of the Invention.

Each arm 14 defines a first gap 16 between the arm contact surface 14a/end contact surface 15a and one inside wall 12a of the slot 12, and a second gap 17 between the arm 14 and the other side 12b of the slot 12.

Referring now to Figures 4 - 7, the panel of Figure 3 can be seen with further panels 20/30/40 fitted into the slot 12. Figure 4 shows a second panel 20 having a thickness DaVc which is between the values of DmaX and Dm,n. One side 20a of the second panel 20 lies flush against the inside wall 12a of the slot 12, and an opposite side 20b of the second panel 20 presses against the contact surfaces 15a of the ends of the arms 14. An end 20c of the panel 20 abuts the end wall 12c of the slot 12, and the rebate 18 ensures that the panel 20 can be inserted all of the way into this - 7 position in the slot 12 by accommodating a corner of the panel 20. This avoids the possibility that said corner of the panel 20 and a corresponding corner of the slot 12 do not fit together exactly. As the thickness of the second panel 20 is less than DmaX, side 20b does not contact the surface 14a of the arm 14. However, as Dave IS greater than Don, the ends 15 are forced to deflect slightly into the gap 17 towards mside wall 12b of the slot 12. However, part of the contact surfaces 15a of the ends 15 still lie flush agamst the side 20b of the second panel 20, which means that there IS no play between the two panels 10, 20 so they cannot move relative to one another.

Additionally, a resistance force F that the arm 14 exerts on the side 20b of the 0 second panel 20 helps grip the panel 20 and hold it rigidly secure in place in the slot 12.

Figure 5 shows a third panel 30 having a thickness equal to DmaX fitted into the slot 12 in the first panel 10, the largest thickness panel 30 that the connection system can accommodate. As with the situation shown in Figure 4 described above, one side 30a of the third panel 30 lies flush against the mslde wall 12a of the slot 12.

However, as the thickness of the third panel 30 is equal to DmaX, the opposite side 30b of the third panel 30 1les flush against the arm surface 14a. The ends 15 of the arms 14 are therefore forced to deflect fully backwards mto the gap 17 to accommodate this third panel 30. In this situation, each side 30a, 30b of the third panel 30 lies flush against the slot Inside wall 12a/ arm surface 14a, respectively, so, as with the situation shown m Figure 4, there is no play between the two panels 10, so they cannot move relative to one another. As the ends 15 are deflected further than in the situation shown In Figure 4, the equal and opposite force F' that they will be exerting on the side 30b of the third panel will be even greater than in this previous situation. Again, this helps to securely grip the panel 30 and thereby hold the two panels 10, 30 rigidly together.

Referring now to Figures 6 and 7, a situation is shown in which a fourth panel 40 hanng a thickness equal to Dm,n is fitted mto the slot 12 m the first panel 10. Again, one side 40a of the tilled panel 40 lies flush against the inside wall 12a of the slot 12.

However, as the thickness of the fourth panel 40 Is equal to Dm,n, the arms 14 are not forced to be deflected backwards into the gap 17 and the opposite side 40b of - 8 the fourth panel 40 does not contact the surface 14a of the arms 14. Despite this, the contact surfaces 15a of the ends 15 still he flush against the opposite side 40b of the fourth panel 40, and thereby prevent any play between the two panels 10, 40 so they are still unable to move relative to one another and held rigidly secure.

Figure 8 shows two panels 10, 10' incorporating the connection system 11/11' of the Invention, before and after being fitted together. Lower panel 10' is moved in the drcction of arrow F. to Interconnect with the upper panel 10 as shown. The system 11 works exactly as described above, but as both panels 10, 10' feature the system 11, there is greater allowance for dimensional variations of the panels 10, 10' than if a simple known slot-slot connection means was used.

From the situations described above, it will be appreciated that variations in the thckocss of panels 20/30/40, or In the size of the gap 16 between Dm,n and DmaX, for what ever of the reasons given earlier, do not affect the ability of the connection system to hold two panels rigidly secure to one another.

All of the above embodiments illustrate the connection system of the present mventon in the form of a boss or trunk portion 13 having two arms 14 extending therefrom in opposite directions pcrpendcular thereto. However, the invention can also comprise a trunk portion 13 with only a single arm 14 extending therefrom, as shown m Figure 9. In this embodiment, the connection system performs as described above, and so the slot 12 of the connection system 11 can still accommodate panels of a thickness varying from Dm,n to DmaX without adversely affecting the rigidity of the lows.

It will be appreciated that the present invention can be applied to many more complicated 3-dlmenslonal assemblies than the exemplary rectangular panels shown m Figures 3 - 8. An example of a more complex application of the invention is shown in Figures 10 and 11, which shows five separate panels 50, 60, 70, 80, 90 which form the back, front, left and right sides and seat of a chair respectively, the back, front, and side portions 50, 60, 70, 80 each having a connection system 51, 61, 71, 81 of the Invention respectively. The separate panels can be seen in their - 9 assembled form m Figure 11. It will be noted that connection system 61 of the front portion 60 are of the single-arm variant described above with reference to Figure 9.

This chair can be assembled from the five panel parts by setting the side pieces 70, side by side, fitting slots 52 of the back piece 50 into rear slots 72a, 82a of the s side pieces 70, 80, and fitting slots 62 of the front piece 60 into front slots 72b, 82b, of the side pieces 70, 80, and finally placing the seat portion 90 on top surface 60a of the front portion 60 so that tongue portions 93 are received in apertures 53 in the back portion. The seat portion 90 is laterally secured by arms 75, 85 on the side portions 70, 80 being received m apertures 95 m the seat portion 90. The assembly of this chair requires no supplementary fixing devices such as screws, nails, glue or staples, and does not require the use of any hand tools, yet because of the features of the connection system of the invention described above, the chair is held together firmly and securely, yet the panels may be manufactured within a generous tolerance range without affecting the integrity of the furniture.

The panel engagement means of the system of the invention described above can all be formed integrally with the panel. For example, the panel may be made from plastic, acrylic or resm and mouldcd as one unitary body. Alternatively, the panel may be made from one of the above materials, or wood or a wood derivative such as Medium Density Fibre Board (MDF), plywood, chip-board, particle board, a combination thctcof, or any other suitable material, and the panel engagement means can be then formed in the panel by cutting out an appropriate shape therefrom to leave the panel engagement means that is shown in the Figures.

2s As a further alternative, mstead of the panel engagement means being integrally formed with the panel as one unitary body, the panel engagement means may be made as a separate unit that Is subsequently fiend to an internal side wall of a rectangular slot in the panel. In this unillustrated embodiment, the panel engagement means could comprise a flat base portion having a boss or trunk portion extending therefrom, with one or two arms extending from the trunk portion as described above with reference to the integral embodiments. Once such a separate panel engagement means had been fixed to the internal slot wall, the system of the panel and the engagement means would be operable to simply and securely connect two panels together as described above. Such a system could still be used 1n the context of flat-pack furmture, for example, if the panel engagement means was fixed to the internal side wall of the slot in a panel directly after the panel was manufactured, and the panel was then packaged and sold as part of the s item of furniture. The system of the invention would still allow a purchaser to quickly and cleanly assemble the item of furniture without using any tools or supplementary fixing devices, and still provide a rigid and secure joint between the Individual panels.

The description of the invention given above is Intended as an example only, and not limiting to the scope of the invention which Is set out in the claims hereafter. - 11

Claims

Claims 1. A system for releasably connecting together first and second

panels substantially at right angles to each other, at least one panel having a slot in the edge thereof to receive the edge of another panel, the or each slotted panel including panel engagement means associated with the slot so that when another panel is inserted into the slot, the panel engagement means are resiliently deformable by said inserted panel to releasably connect said panels together.

0 2. A system according to claim 1 wherein the panel engagement means comprises at least one arm extending from a boss that protrudes from a first side of the slot, said at least one arm being resiliently deformable in response to 1nscrtion of said other panel.

3. A system according to claim 1 or claim 2 whercn the at least one arm has a panel engaging surface spaced from the other side of the slot to define a first gap between said panel engaging surface and said other side to receive said other panel.

4. A system according to claim 3 wherem the arm has a raised portion that extends toward the other side of the slot, a portion of the panel engaging surface being formed on said raised portion.

5. A system according to claim 3 or claim 4 wherein the panel engaging surface IS flat.

G. A system according to any of claims 2 - 5 whercm the arm is spaced from the first side of the slot such that the arm IS deflectable mto said space when the other panel IS inserted mto the slot.

7. A system according to any of claims 2 - 6 wherein the panel engagement means comprises one arm. - 12

8. A system according to any of claims 2 - 6 wherein the panel engagement means comprises two arms extending from the boss in opposite directions.

9. A system according to any of claims 2 - wherein the boss extends from a s md-pomt of the first side of the slot.

10. A system according to any of claims 2 - 9 wherein the or each arm extends substantially parallel to the sides of the slot.

JO 1 l. A system according to any preceding claim wherein the slot has an end, and a rebate IS formed in a corner of the slot where said other side of the slot meets the end of the slot.

12. A system according to any preceding claim wherein both first and second panels have a slot in the edge thereof to receive the edge of the other panel, each slotted panel including panel engagement means associated with the slot.

13. A system according to any preceding claim wherein the or each panel engaging means is integrally formed with the or each panel.

14. A system according to any of claims 1 -12 wherem the or each panel engaging means is a separate body attached to the slot of the or each panel.

15. A system according to any preceding claim wherem the or each panel IS made from wood, a wood derivative, plastic, acrylic, metal or a resin 1G. A system according to any of claims 1 - 13 wherein the or each panel and panel engagement means are moulded as one unitary body.

17. A system according to claim 16 wherein the unitary body IS made from plastic, acrylic or a resin. - 13

18. An item of furniture comprising a number of interlocked panels incorporating the connection system according to any preceding claim.

19. An item of furniture according to claim 18 wherein the item IS a chair. s