WO2023115121A1

WO2023115121A1 - Furniture assembly and tooless fastener

Info

Publication number: WO2023115121A1
Application number: PCT/AU2022/051544
Authority: WO
Inventors: Warren Asquith; Adam HARRIGAN; Francesco FELIZIANI; Kylie GRILO; Nat Geoffrey ALLEN
Original assignee: Koala Sleep Pty. Ltd
Priority date: 2021-12-21
Filing date: 2022-12-20
Publication date: 2023-06-29

Abstract

A toolless fastener comprises a threaded shaft having a central longitudinal axis and an enlarged head; and an inner cap for receiving the threaded shaft. An outer cap is connectable to the inner cap which is received in a cavity thereof. The outer cap is axially movable with respect to the inner cap between an engaged position wherein the inner and outer caps are radially fixed such that torque applied to the outer cap is translated to the inner cap and shaft; and a disengaged position wherein the outer cap is free to rotate with respect to the inner cap. There is further disclosed a furniture assembly kit comprising: two or more structural components requiring fastening together to form a piece of furniture; and one or more of the toolless fasteners as described above configured to fasten together at least two of the structural components.

Description

FURNITURE ASSEMBLY AND TOOLESS FASTENER

Field

[0001] The present invention relates to the design, manufacture, and assembly of furniture, particularly flat-pack furniture, which is both simple for the user to construct as well difficult to deconstruct or weaken by accident, particularly in the area of infant and toddler furniture such as cots. However, the invention is not limited to this field of use and may also be applied to other furniture products as well that require tamper-free functionality.

Background

[0002] Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of common general knowledge in the field.

[0003] It is well known for furniture products to be provided to users in flat-pack form. Flat-pack furniture has many benefits in comparison with pre-assembled furniture, such as reduced amounts of packing, reduced shipping, storage and delivery costs, ease of transport for the user, as well as in some cases the option for user customisation. Once the flat-pack furniture has arrived at its destination the user can then assemble the furniture according to the manufacturer’s instructions.

[0004] Some flat-pack furniture sets require a separate tool for the assembly process, typically for the tightening of threaded fasteners in particular, such as a hex key, screwdriver, or the like. Whilst these tools can facilitate for sturdy assembly by allowing for the tight fastening of the various components, the need for a tool also has its drawbacks. Providing a tool with the kit adds to the cost, whilst not including the tool requires the user to have made a second separate purchase, and can result in the user beginning the assembly process only to realise they do not have the necessary tools. Furthermore, requiring a tool that is separate from the final assembled product means that the tool then needs to be stored away, and can potentially be lost by the time the user might want to disassemble the furniture. [0005] Some flat-pack furniture is designed in a way that does not require a separate tool for the assembly process. Whilst this avoids some of the issues mentioned above, one or more other disadvantages may be present instead. Some flat-pack furniture may be assembled without the use of fasteners, such as designs where the components slot together, however these designs may not be as sturdy as those using fasteners. Alternatively, some flat-pack furniture may use permanent fasteners, however this does not allow for disassembly or correction of mistakes during the assembly process. Finally, some flat-pack furniture may use fasteners that can be tightened using only the user’s hands, such as wingnuts. Whilst this may allow for sturdy assembly and disassembly, the fasteners may be easily bumped during use, potentially loosening the fastening, and weakening the structural integrity of the furniture. This is a particular concern in infant and toddler furniture, where the infant or toddler may naturally want to play with parts of the furniture, and by accident loosen the fastening.

[0006] It is an object of the present invention to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative.

Summary of Invention

[0007] According to an aspect of the present invention, there is provided a toolless fastener for use in assembling furniture comprising: a threaded shaft having a central longitudinal axis and an enlarged head; and an inner cap comprising a through passage having sleeve portion for receiving the threaded shaft and a recess connected to the sleeve portion and configured to receive and radially fix the head of the shaft; and an outer cap connectable to the inner cap and axially movable with respect thereto between an engaged position wherein the inner and outer caps are radially fixed such that torque applied to the outer cap is translated to the inner cap and shaft; and a disengaged position wherein the outer cap is free to rotate with respect to the inner cap.

[0008] According to another aspect of the present invention, there is provided a furniture assembly kit comprising: two or more structural components requiring fastening together to form a piece of furniture; and one or more of the toolless fasteners as described above configured to fasten together at least two of the structural components. [0009] According to a further aspect of the present invention, there is provided a cot comprising: two or more structural components fastened together by one or more of the fastening tools as described above; wherein the one or more toolless fasteners are located on the underside of the cot.

[0010] According to a further aspect of the present invention, there is provided a furniture assembly comprising: at least one pair of supporting members each member having at least one foot; at least one pair of supported side panels, each supported side panel to be connected between and supported by a pair of supporting members; wherein each of the supporting members and supported side panels comprise respective pairs of complementary supporting and supported connectors for connecting a supported side to a supporting member, each pair of complementary connectors configured for uniaxial connecting engagement in a first direction along a connection axis and disengagement along the connection axis in a second direction opposite of said first direction; a respective fastener for fastening each supporting member to a respective supported side panel for selectively restraining relative movement therebetween at least in the second direction of the respective complementary pair of supporting and supported connectors.

[0011] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a," "an," and "the" may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including," and "having," are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

[0012] When an element or layer is referred to as being "on," "engaged to," "connected to," or "coupled to" another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," or "directly coupled to" another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

[0013] Although the terms first, second, third, etc. may be used herein to describe various elements, compartments, components, regions, layers and/or sections, these elements, components, compartments, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

[0014] Spatially relative terms, such as "inner," "outer," "beneath," "below," "lower," "above," "upper," and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the example term "below" can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

Brief Description of Drawings

[0015] The invention will be more clearly understood from the following description of an embodiment thereof, given by way of example only, with reference to the accompanying drawings, in which: - [0016] Figure 1 is a side view of a furniture assembly with spacers in accordance with an embodiment of the invention;

[0017] Figure 2 is a top view of the furniture assembly shown in Figure 1

[0018] Figure 3 is a cross-sectional side view of the furniture assembly along section line A- A shown in Figure 2;

[0019] Figure 4 is a side view of the furniture assembly without spacers in accordance with an embodiment of the invention;

[0020] Figure 5 is a top view of the furniture assembly shown in Figure 4;

[0021] Figure 6 is a cross-sectional side view of the furniture assembly along section line B-B shown in Figure 7;

[0022] Figure 7 is a perspective view of the furniture assembly shown in Figure 4;

[0023] Figure 8 is an exploded perspective view of the furniture assembly shown in Figure 4;

[0024] Figure 9 is an exploded perspective view of the furniture assembly shown in Figure 1;

[0025] Figure 10 is a top view of the furniture assembly shown in Figure 4;

[0026] Figure 11 is a cross-sectional side view of the furniture assembly along section line C-C shown in Figure 10;

[0027] Figure 12 is a side view of the furniture assembly shown in Figure 4 with an end panel disconnected from the assembly;

[0028] Figure 13 is a top view of the furniture assembly shown in Figure 12;

[0029] Figure 14 is a cross-sectional side view of the furniture assembly along section line D-D shown in Figure 13; [0030] Figure 15 is an underside perspective view of the furniture assembly shown in Figure 4;

[0031] Figure 16 is a close-up view of detail D of the furniture assembly shown in Figure 15;

[0032] Figure 17 is a top view of a hook in accordance with an aspect of the invention;

[0033] Figure 18 is a side view of the hook shown in Figure 17

[0034] Figure 19 is a front view of the hook shown in Figure 17;

[0035] Figure 20 is a rear view of the hook shown in Figure 17;

[0036] Figure 21 is a bottom view of the hook shown in Figure 17;

[0037] Figures 22 to 24 are perspective views of the hook shown in Figure 17;

[0038] Figure 25 is a perspective view of the fastener comprising an outer cap, an inner cap, and a threaded shaft, in accordance with an aspect of the invention;

[0039] Figure 26 is an exploded perspective view of the toolless fastener shown in Figure 25;

[0040] Figure 27 is a side view of the toolless fastener shown in Figure 25;

[0041] Figure 28 is a cross-section side view of the toolless fastener along section line E-E shown in Figure 27;

[0042] Figure 29 is a close-up view of detail E of the toolless fastener shown in Figure 28;

[0043] Figure 30 is a side view of the outer cap shown in Figure 25;

[0044] Figure 31 is an underside view of the outer cap shown in Figure 25;

[0045] Figure 32 is a cross-sectional side view of the toolless fastener along section line F-F shown in Figure 31; [0046] Figure 33 is a side view of the toolless fastener shown in Figure 25 with the outer cap in a disengaged position;

[0047] Figure 34 is a side view of the toolless fastener shown in Figure 25 with the outer cap in an engaged position;

[0048] Figure 35 is a cross-sectional side view of the toolless fastener along section line G-G shown in Figure 33;

[0049] Figure 36 is a cross-sectional side view of the toolless fastener along section line H-H shown in Figure 34;

[0050] Figure 37 is a cross-sectional side view of the toolless fastener along section line G-G shown in Figure 33;

[0051] Figure 38 is a cross-sectional side view of the toolless fastener along section line J-J shown in Figure 34;

[0052] Figure 39 is an exploded perspective view of a toolless fastener comprising in accordance with another aspect of the invention;

[0053] Figure 40 is a side view of the toolless fastener shown in Figure 39; and

[0054] Figure 41 is a cross-sectional side view of the toolless fastener along section line K-K shown in Figure 40.

Description of Embodiments

[0055] Referring to the Figures 1 to 16, the invention provides a furniture assembly 1 comprising at least one pair of supporting members 2 having at least one foot and at least one pair of supported side panels 3. Each supported side panel 3 configured to be connected between and supported by a pair of supporting members 2. Each of the supporting members and supported side panels comprise respective pairs of complementary supporting and supported connectors, each pair of connectors configured for uniaxial engagement in a first direction along a connection axis and disengagement along the connection axis in a second direction opposite of said first direction.

[0056] A plurality of fasteners, each fastener configured to extend between a supporting member and a respective supported side panel for selectively restraining relative movement therebetween at least in the second direction of the respective complementary pair of supporting and supported connectors. Preferably the connection axis is substantially vertical when the furniture assembly in an upright, in use configuration and the first direction is a downward direction.

[0057] With particular reference to Figure 8, a furniture assembly 1 is shown wherein the at least one pair of supporting members comprises two end panels 2, and the at least one pair of supported side panels comprises two side panels 3. The assembly further includes a base panel 4. The furniture assembly 1 herein is depicted as a cot for an infant or toddler, however the features may be applicable to other types of furniture assemblies.

[0058] One or more of the end panels 2 and/or one or more of the side panels 3 may comprise a substantially continuous sheet 10. Additionally, or alternatively, one or more of the end panels 2 and/or one or more of the side panels 3 may comprise a pair of spaced rails, and a series of slats extending between the rails. Preferably, as can be seen the rails are disposed horizontally and comprise a lower rail 7 and upper rail 8 with slats 9 extending vertically therebetween. One or more of the end panels 2 and/or one or more of the side panels 3 may comprise one or more feet 6 to provide a gap between the floor and the remainder of the furniture assembly 1.

[0059] Each of the end panels 2 may be connected and disconnected from each of the side panels 3 as a part of the assembly and disassembly process. To secure the panels 2, 3 together during the assembly process, each of the panels 2, 3 may be provided with at least one supported connector in this embodiment in the form of hook 100 and/or at least one complementary supporting connector in this embodiment in the form of recess 12 complementary to said hook 100. In the illustrated configuration, each end panel 2 is provided with four supporting connectors or hooks 100, and each side panel 3 is provided with four supported connectors or recesses 12. However, it will be understood that any number of hooks and recesses may be implemented, as well as alternative configurations in which the hooks 100 are located on the side panels 3 and the recesses 12 are located on the end panels 2, or a combination thereof. [0060] With reference to Figures 11, 14, and 17 to 24, each hook 100 comprises a horizontal member 102 and a vertical member 101. The horizontal member 102 comprises one or more apertures 103 for receipt of a fastener, such as a screw 104. The aperture 103 extends through the majority of the horizontal member 102 with a diameter wide enough to accommodate the head of the screw 104, before narrowing at a flange 105, where the diameter of the aperture is wide enough for the threaded shaft of the screw 104 but not the head.

[0061] During construction of the end panel 2, the screw 104 is inserted through aperture 103 and then screwed into the end panel 2. In the preferred configuration, the horizontal member 102 comprises at least two apertures 103 to accommodate at least two screws 104, thereby preventing rotation of the hook 100 relative to the end panel 2.

[0062] With reference to Figures 11 and 14, the side panels 3 comprise one or more recesses 12 to accommodate the one or more hooks 100. In the preferred configuration, the recesses 12 form a tight fit or an interference fit with the hooks 100, such that the end panels 2 and the side panels 3 cannot be disassembled without a minimum amount of force.

[0063] To assemble the furniture assembly 1, a user must position each of the hooks 100 below the corresponding recess 12. The user must then lower the side panels 3 and/or raise the end panels 2 until the hooks 100 have engaged with the recesses 12. To disassemble the furniture assembly 1 this process must be reversed, with the side panels 3 being raised and/or the end panels being lowered before horizontal separation of the panels 2, 3 is possible.

[0064] One or more of the recesses 12 may be located on the underside of one or more of the rails 7, 8, such that the recess is structured as a slot. Additionally, the horizontal member 102 may have a flat base that aligns with the portions of the rail 7, 8 that are adjacent to the recess 12, such that when assembled the hook 100 forms a smooth surface with the rail 7, 8.

[0065] With reference to Figures 8, 9, 15, and 16, the end panels 2 and the side panels 3 may further comprise one or more plates 11. The plates 11 may extend horizontally from the panels 2, 3. The plates 11 may have one or more apertures. The plates 11 may be positioned such that when the furniture assembly 1 is assembled, the plates 11 on the end panels 2 overlap with the plates 11 on the side panels 3. [0066] The plates 11 may provide a support structure to support the base panel 4. Additionally, or alternatively, the base panel 4 may be supported by one or more brackets 17. The brackets 17 may have dowels that insert into holes 16 in the base panel 4 to aid in positioning the base panel 4.

[0067] The plates 11 may have one or more apertures 13. The apertures 13 on the plates 11 of the ends panels 2 may align with the apertures 13 on the plates 11 of the side panels 3 when the furniture assembly 1 is assembled. The apertures 13 may be configured to receive a fastener 201 that fastens the plates 11 together. The fastener 201 in particular prevents vertical separation of the plates 11, which in turn prevents the relative vertical movement of the panels 2, 3 that is required for disassembly.

[0068] The furniture assembly 1 may be configured such that once assembled the fastener 201 is located on the underside of the furniture assembly 1. This is particularly beneficial when the furniture assembly l is a cot, as it inhibits the infant/toddler from being able to reach the fastener 201, further reducing the risk of them loosening it.

[0069] The base panel 4 may further comprise one or more apertures 14. The apertures 14 may be positioned to align with the apertures 13 of the plates 11, such that the fastener 201 will also retain the base panel 4 to the rest of the furniture assembly 1.

[0070] The base panel 4 in configured to support a mattress (not shown). The base panel may be provided with one or more slots 15 to allow for aeration of said mattress.

[0071] In at least one configuration, the end panels 2 comprise the feet 6 and the hooks 100, and the side panels 3 comprise the recesses 12. Additionally, in said configuration, the plates 11 of the side panels 3 are located above the plates 11 of the end panels 2 when the furniture assembly 1 is assembled. In this configuration, the weight of the base panel 4 and the side panels 3 bias the recesses 12 and the hooks into engagement whilst the furniture assembly 1 is upright. Any items placed in the furniture assembly 1, such as a mattress, further add to this weight.

[0072] In at least one alternative configuration, the side panels 3 comprise the feet 6 and the hooks 100, and the end panels 2 comprise the recesses 12. Additionally, in said configuration, the plates 11 of the end panels 2 are located above the plates 11 of the side panels 3 when the furniture assembly 1 is assembled. In this configuration, the weight of the base panel 4 and the end panels 2 bias the recesses 12 and the hooks into engagement whilst the furniture assembly 1 is upright. Any items placed in the furniture assembly 1, such as a mattress, further add to this weight.

[0073] The two configurations above result in the furniture assembly 1 having inherent structural stability such that provided that the furniture assembly 1 remains in an upright position, the mass of the supported components maintains connected engagement of the connections of the assembly. Thus the furniture may remain “assembled” without the use of the fasteners to lock the connections together.

[0074] The furniture assembly 1 may further comprise one or more spacers 5. The user may then decide whether to utilise the spacers when assembling the furniture assembly 1. The purpose of the spacers is to alter the height of the base panel 4, and in turn the mattress.

[0075] As shown in Figures 4 to 8, and 10 to 16, the user may decide to forgo using the spacers 5. As described above, in this scenario the user places the base panel 4 directly on the plates 11, and then fastens the base panel 4 and the plates 11 directly together using the fastener 201. This lowers the base panel 4 resulting in the maximum possible distance between the top of the mattress and the top of the panels 2, 3. This is beneficial for accommodating a toddler, where higher relative walls of the cot are required to inhibit the toddler from climbing out.

[0076] Alternatively, for younger and/or less mobile infants, as shown in Figures 1 to 3 and 9, the furniture assembly 1 may be assembled with the spacers 5 to raise the height of the mattress. To do so, the user aligns each spacer 5 with apertures 13 on the plates 11, and then fastens them together with the fastener 201. The user then positions the base panel 4 on top of the spaces 5, and fastens them together using a separate fastener. This configuration results in a shorter distance between the top of the mattress and the top of the panels 2, 3 when compared with the previous configuration. This is beneficial in the case of a cot for use with an infant, where there is less risk of the infant climbing out. Additionally, the raised mattress means the user does not have to reach in as far to place and remove the infant. [0077] With reference to Figures 25 to 38, aspects of a toolless fastener 300 in accordance with the invention will now be described. The toolless fastener 300 comprises a threaded fastener 301, an inner cap 400 and an outer cap 500 and a threaded shaft 302 having a central longitudinal axis 303 and a head portion 304 to be received and axially fixed within a recess within the inner cap. The head portion 304 includes an axial engagement shoulder 305, in this case surfaces of an enlarged head304. The shaft 302 may be threaded along its length or include threaded portions such as a threaded end extremity portion.

[0078] The outer cap 500 is connectable to the inner cap 400 and axially movable with respect thereto between an engaged position wherein the inner and outer caps are radially fixed such that torque applied to the outer cap is translated to the inner cap and shaft; and a disengaged position wherein the outer cap is free to rotate with respect to the inner cap.

[0079] Referring to Figure 26, the inner cap 400 comprises a cylindrical body 401 having internal and external end surfaces (402 & 403 respectively), a circumferential sidewall 404 and a centrally disposed through passage 405 comprising sleeve portion 406 to accommodate the shaft 302 of the fastener and the recess 407 for receipt of the enlarged head 304 as best seen in Figure 35. A seat 408 disposed within the through passage may define the boundary between the sleeve portion 406 and the recess portion 407 and provides a stop against which the axial engagement shoulder 305 in this case the underside of the head 304 rests thereby to retain the head 304 within the recess 407 and prevent the shaft passing entirely through the through passage 405. The recess 407 of the through passage has a non-circular cross-section to accommodate a noncircular head 304 of shaft 302, in this case a standard hexagonal head, to radially fix the shaft to the inner cap such that rotation of the fastener 301 relative to the inner cap 400 is prevented. The recess portion 407 may form a tight fit or an interference fit with the head 304.

[0080] The outer cap 500 comprises base wall 501 and a skirt 502 extending downwards from the base wall 501 to provide a cavity 504 for receiving the inner cap 400. Preferably outer cap 500 and base wall 501 are circular and the skirt 503 is annular in cross-section providing the cavity as generally cylindrical. Preferably the outer cap 500, base wall 501, a skirt 502, and cavity 504 are coaligned on a central axis 505. [0081] The inner and outer caps comprise inter-engageable drive formations (410 and 510 respectively) for transmitting torque between the inner and outer caps when in the engaged position. In this embodiment the drive formations include one or more complementary indents and/or protrusions located on an inner floor 506 of the base wall 501 of the outer cap and the internal end surface 402 of the inner cap 400 cylindrical body 401. In this way compression of the inner cap 400 into the cavity 504 of the outer cap 500 may bring the respective drive formations (410 and 510) on the inner and outer caps into torque transmitting engagement.

[0082] The toolless fastener may utilise a snap fit mechanism for assembly so as to prevent inadvertent disassembly. A distal edge portion 520 of the skirt 502 comprises a series of slots 521 dividing the distal edge portion of the skirt into a series of circumferentially spaced locking fingers 522. The outer cap 500 comprises a resilient material that allows for elasticity in the locking fingers 522. The outer cap 500 may comprise a plastics material such as nylon. The inner cap 400 may also comprise a plastics material such nylon.

[0083] The locking fingers 522 comprise inwardly facing radial projections 523 as seen in Figure 29. The lower corners 524 of the projections 523 are angled and/or rounded to assist with assembly of the outer cap onto the inner cap.

[0084] During assembly of the toolless fastener 300, the user initially positions the shaft 302 within the through passage 405 of the inner cap 400, with the head 304 of the shaft 302 located within the recess 407 and sitting on the seat 408, as shown in Figure 28.

[0085] Following this, the user positions the outer cap 500 on top of the inner cap 400, with the lower corners 524 of the projections 523 resting on an upper peripheral edge 419 of the inner cap 400. The upper peripheral edge 419 is chamfered or rounded to assist with deflection of the locking fingers 522 and assembly of the outer cap onto the inner cap.

[0086] The outer cap 500 may then be pressed over the inner cap 400 so that the inner cap 400 is received and located within the inner cavity 254 of the outer cap 500. The resulting contact between the lower corners 524 of the projections 523 against the upper peripheral edge 419 of the inner cap 400 forces the locking fingers 522 outward, allowing the skirt 502 to pass over the circumferential sidewall 404 of the inner cap 400. [0087] Once the projections 523 pass over the cylindrical body 401, the locking fingers 522 snap inward and locate in a circumferential groove 420 located in the circumferential sidewall 404 of inner cap 400. Subsequent upwards movement of the outer cap 500 is restricted by contact between the projections 523 and an axial facing annular surface 421 of the groove 420, whilst downward movement is restricted by contact of the internal end surface 402 of the inner cap against the base wall 501. However, the groove 420 is configured to allow some axial movement between the inner and outer caps in order to allow for engagement and disengagement of the drive formations (410 and 510).

[0088] One or both of the upper corners of the projections 523 and/or the outer peripheral edge of surface 421 may be angled and/or rounded such that removal of the upper cap is possible given a sufficient force.

[0089] Once the fastening assembly 1 is assembled according to the above listed steps, the outer cap 500 remains movable relative to the inner cap 400 and the shaft 302 in an axial direction defined as parallel to the central axis 505.

[0090] As described above, upwards movement of the outer cap 500 relative to the rest of the fastening assembly 300 is limited by contact between the projections 523 and the annular surface 421 of the groove 420. This position may be referred to herein as a disengaged position.

[0091] Downwards movement of the outer cap 500 relative to the rest of the fastening assembly 300 is restricted by contact of the internal end surface 402 of the inner cap against the base wall 501. In this position, known as the engaged position, the drive formations 510 located on the internal floor of the base wall 501 of the outer cap are engageable with the drive formations 410 located on the internal end surface 402 of the inner cap 400 cylindrical body 401. Furthermore, as can be seen in Figure 28 and 34, in the engaged position external end surface 403 protrudes beyond the lower extremity of the skirt.

[0092] A comparison of the disengaged position and engage position can be made with reference to Figures 33 and 34 respectively and corresponding cross-section views in Figures 35 and 36 and Figures 37 and 38. [0093] Whilst in the disengaged position, the outer cap 500 can rotate freely relative to the rest of the fastening assembly 300. That is to say, rotation of the outer cap 500 will not result in rotation of the shaft 302 so long as the outer cap 500 remains in the disengaged position.

[0094] However as described above, the user can move the outer cap 500 to the engaged position by shifting the outer cap 500 downwards relative to the rest of the fastening assembly 300.

[0095] As noted above the drive formations (410 and 510) include one or more complementary indents and/or protrusions located on the internal end surface 402 of the inner cap 400 cylindrical body 401 and the inner floor of the base wall 501 of the outer cap 500. In some embodiments the drive formations may be disposed in other locations for instance on opposing side walls of the inner and outer caps.

[0096] As can be seen in Figure 26 and Figure 31 (and Figure 32) in this embodiment the drive formations are in the form of arrays of complementary axially extending circumferentially spaced protrusions (411 and 511 respectively) arranged on the inner and outer caps.

[0097] Rotation of the outer cap 500 whilst in the engaged position causes the drive formations 510 to engage the drive formations 410 such that torque applied to the outer cap 500 will be translated to the inner cap 400 and the shaft 302, thereby resulting in tightening or loosening of the shaft 302 depending on the direction of rotation. Preferably the skirt 502 comprises a textured outer surface 525 to aid the user in gripping the outer cap 500.

[0098] Each drive formation on the inner cap includes oppositely directed drive surfaces (412 and 413) for engaging complementary oppositely directed drive surfaces on drive surfaces (512 and 513) on the outer cap. With reference to Figure 37 and particularly Figure 38 drive surface 512 on the outer cap 500 are configured to complement and engage drive surfaces 412 on the inner cap 400. Rotation of the outer cap 500 in a clockwise direction as shown by arrow A, will translate clockwise torque to the inner cap and shaft 302 via drive surface 512 and 412, which corresponds to a tightening of the fastener where the thread shaft has a right-hand thread.

[0099] In contrast drive surface 513 on the outer cap 500 are configured to complement and engage drive surfaces 413 on the inner cap 400. Rotation of the outer cap in an anti-clockwise direction as shown by arrow B, will translate clockwise torque to the inner cap and shaft 302 via drive surfaces 513 and 413, which corresponds to a loosening of the shaft 302 where the thread shaft is a right-hand thread.

[0100] Furthermore, the angle of the drive surfaces 412 & 512, and 413 & 513 may be used to influence the user interaction required to tighten and loosen the fastener 300. For instance, in this embodiment, complementary drive surfaces 413 and 513 are angled with respect to the axis of rotation 303 such that application of an anti-clockwise torque (arrow B in Figure 38) across the drive surfaces 413 and 513 generates an axial force (represented by arrow C) separating the inner and outer caps and deflecting them toward the disengaged position. In this embodiment, assuming a typical right-hand thread of the threaded shaft, anti-clockwise rotation of outer cap in order to loosen the fastener thus requires application of an axial compressive force to the outer cap 500 simultaneously with the torque to overcome the induced deflection of the tool into the disengaged position. This “push-and-twisf ’ requirement provides a safety feature to reduces the chance of accidental loosening of the fastener 300. Furthermore, once in position, generally the outer cap 500 is the only outwardly exposed portion of each fastening assembly 300. This is particularly beneficial when the furniture assembly comprises a cot, as it reduces the chance of an infant and/or toddler from tampering with the fastener.

[0101] The angle of complementary drive surfaces may be select to regulate the degree of deflection generated when tightening and loosening the bolt. In this embodiment the complementary drive surfaces 420 and 270 are set at an angle of around 45° to the rotation axis however angles of between a 30° and 60° with respect to the rotation axis are contemplated. It will be appreciated that the smaller the angle the less axial force will be generated while the larger the angle to greater compressive force will need to be applied relative to the torque applied.

[0102] In alternative embodiments the inner and outer caps may also or alternatively include a bias means, such as a resilient member to hold the inner and outer caps in the disengaged position. In such cases, the resilient member can be formed into the inner and/or outer caps or be a separate component. [0103] Figure 39 show an exploded view of another toolless fastener 300' in accordance with the invention. Side and cross-sectional side views of toolless fastener 300' are shown in Figs. 40 and 41 respectively. The toolless fastener 300' comprises a threaded fastener 301', an inner cap 400' and an outer cap 500'. As seen in the cross-sectional side view Fig 41, the threaded fastener 301' comprises a threaded shaft 302' having a central longitudinal axis 303' and a head portion 304' to be received and axially fixed within a recess within the inner cap 400'. However, in this embodiment, in contrast to the embodiment shown in Figs 25 & 26, the inner cap 400' is formed to be over molded with threaded fastener 301' so that the head portion 304' is at least partially encapsulated within and by the inner cap 400'. This is best seen in Figs. 39 and 41 where a circumferential flange 420' of the inner cap 400’ extends radially inward to partially cover a top surface of the head portion 304' of the inner cap 400'. This flange holds the threaded fastener 301' within the recess of the inner cap, preventing it from being removed and from the underside of the head 304' separating from seat 408'.

[0104] As such the inner cap and threaded fastener cannot be separated making them a single part which simplifies assembly. Furthermore, axial movement between the threaded fastener 301', and inner cap 400' is prevented particularly when the outer cap is in a disengaged position. Otherwise the toolless fastener 300' shown in Figs 39 - 42 functions the same as the embodiment shown in Figs 25 & 26.

[0105] As noted above, in this embodiment the flange 420' is formed during molding of the inner cap in a process known as over molding whereby an injection molded part, in this case the inner cap is formed around a preformed part, in this case the threaded fastener 301'. However, in other embodiments, other processes may be used to secure the threaded fastener 301' within the recess of the inner cap 400' including pressing the threaded fastener 301' into the recess and relying on interference or snap fitment.

[0106] The invention extends to an attachment for a threaded fastener comprising the inner and outer caps so as to form a toolless fastener. In this way, standard threaded fasteners, such as a bolt may be converted into a toolless fastener in accordance with the invention. This allows preselection of the dimensions of the fastener, particularly the length of the fastener but also the extent of the threaded portion of the shaft, as required for particular applications. In other embodiments the inner cap may be incorporated as or into the head of the fastener either integrally formed or fixed thereto. Thereby limiting the number of parts to be assembled.

[0107] The invention further extends to a furniture assembly 1 described above including the toolless fastener 400. In such embodiments the toolless fastener 400 is used as fastener 200 meaning that no tools are required to assemble the furniture assembly 1. Thus, the invention, in some embodiments may provide the and benefits of self-assembled or “flat pack” furniture with the convenience of toolless assembly without the dangers of inadvertent disassembly.

Claims

1. A fastener for use in assembling furniture comprising: a threaded shaft having a central longitudinal axis and ahead portion including an engagement shoulder; and an inner cap comprising a through passage having sleeve portion for receiving the threaded shaft and a recess connected to the sleeve portion and configured to receive and radially fix the head of the shaft; and an outer cap connectable to the inner cap and axially movable with respect thereto between an engaged position wherein the inner and outer caps are radially fixed such that torque applied to the outer cap is translated to the inner cap and shaft; and a disengaged position wherein the outer cap is free to rotate with respect to the inner cap.

2. The fastener of claim 1 wherein the inner and outer caps comprise inter-engageable drive formations for transmitting torque between the inner and outer caps when in the engaged position.

3. The fastener of claim 2 wherein the drive formations are configured to deflect the outer cap toward the disengaged position on application of torque in at least one direction of relative rotation of inner and outer caps.

4. The fastener of claim 3 wherein the drive formations include one or more complementary indents and/or protrusions.

5. The fastener of claim 4, wherein clockwise rotation of the outer cap whilst in the engaged position results in contact between a first side of the protrusions and/or recesses on the upper cap and a first side of the protrusions and/or recesses on the lower cap, wherein the first sides of the protrusions and/or recesses are parallel to the central axis.

6. The fastener of claim 4 or 5, wherein anticlockwise rotation of the outer cap whilst in the engaged position results in contact between a second side of the protrusions and/or recesses on the upper cap and a second side of the protrusions and/or recesses on the lower cap, wherein the second sides of the protrusions and/or recesses are nonparallel to the central axis.

7. The fastener of claim 6, wherein the second sides of the protrusions and/or recesses form between a 30° and a 60° angle with a notional plane, the notional plane being perpendicular to the central axis.

8. The fastener of claim 6, wherein the second sides of the protrusions and/or recesses form about a 45° angle with a notional plane, the notional plane being perpendicular to the central axis.

9. The fastener of any one of the preceding claims wherein the outer cap and inner caps are configured for snap fitting engagement.

10. The fastener of claim 9 wherein the outer cap further comprises an axially extending skirt having circumferentially spaced flange portions comprising radial projections for abutting a circumferential stop ring on the inner cap whilst the outer cap is in the disengaged position, thereby preventing full disconnection of the inner cap and the outer cap.

11. The fastener of any of the preceding claims, wherein the outer cap further comprises a textured annular surface parallel to the central axis.

12. The fastener of any of the preceding claims, wherein the recess of the inner cap is configured to form a tight fit or an interference fit with a head of the bolt.

13. The fastener of any of the preceding claims, wherein the inner cap comprises nylon.

14. The fastener of any of the preceding claims, wherein the outer cap comprises nylon.

15. The fastener of any of the preceding claims, wherein the threaded shaft includes a right hand thread.

16. A furniture assembly kit comprising: two or more structural components requiring fastening together to form a piece of furniture; and one or more of the toolless fasteners of any of the preceding claims configured to fasten together at least two of the structural components.

17. A cot compri sing : two or more structural components fastened together by one or more of the fastening tools of any of claims 1 to 15; wherein the one or more toolless fasteners are located on the underside of the cot.

18. A furniture assembly comprising: at least one pair of supporting members each member having at least one foot; at least one pair of supported side panels, each supported side panel to be connected between and supported by a pair of supporting members; wherein each of the supporting members and supported side panels comprise respective pairs of complementary supporting and supported connectors for connecting a supported side to a supporting member, each pair of complementary connectors configured for uniaxial connecting engagement in a first direction along a connection axis and disengagement along the connection axis in a second direction opposite of said first direction; a respective fastener for fastening each supporting member to a respective supported side panel for selectively restraining relative movement therebetween at least in the second direction of the respective complementary pair of supporting and supported connectors.

19. The furniture assembly of claim 18 wherein said connection axis is substantially vertical when said furniture assembly in an upright, in use configuration.

20. The furniture assembly of claim 19 wherein the at least one pair of supporting members includes first and second end panels and the at least one pair of supported side panels includes first and second side panels; wherein each complementary pairs of supporting and supported connectors comprise at least one hook and/or at least one recess complementary to said hook; and wherein each of the end panels and side panels further comprise at least one plate, each plate comprising at least one aperture for receipt of said fastener, wherein when the furniture assembly is assembled the apertures on the plates of the side panels align with the apertures on the plates of the end panels, such that a one of said fasteners can be inserted through the apertures and thereby prevent vertical movement of the end panels relative to the side panels. 22

21. The furniture assembly of claim 20, wherein the one or more hooks comprise a vertical projection extending from a horizontal portion.

22. The furniture assembly of claim 20 or 21, wherein the hooks are configured to form a tight fit or a friction fit with the recesses.

23. The furniture assembly of any of claims 20 to 22, further comprising a base panel located between the end panels and the side panels.

24. The furniture assembly of claim 23, further comprising spacers located beneath the base panel, wherein the furniture assembly may be assembled both with and without the spacers, thereby altering the height of the base panel.

25. The furniture assembly of any of claims 20 to 24, wherein each end panel comprises four hooks.

26. The furniture assembly of any of claims 20 to 25, wherein each side panel comprises four recesses.

27. The furniture assembly of any of claims 20 to 26, wherein the plates are made of metal.

28. The furniture assembly of any of claims 18 to 27, wherein the furniture assembly comprises a cot.

29. The furniture assembly of any of claims 20 to 28, wherein the fastener is a fastener according to any one of claims 1 to 17.