Patent Publication Number: US-2023145010-A1

Title: Set of panels with a mechanical locking device

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     The present application is a continuation of U.S. application Ser. No. 17/126,518, filed on Dec. 18, 2020, which claims the benefit of Swedish Application No. 1951508-9, filed on Dec. 19, 2019. The entire contents of each of U.S. application Ser. No. 17/126,518 and Swedish Application No. 1951508-9 are hereby incorporated herein by reference in their entirety. 
    
    
     TECHNICAL FIELD 
     Embodiments of the present invention relate to panels that may be arranged perpendicular to each other and locked together with a mechanical locking device. The panels may be assembled and locked together to obtain a furniture product, such as a bookshelf, a cupboard, a wardrobe, a box, a drawer or a furniture component. The locking device may comprise a flexible tongue. 
     BACKGROUND 
     A furniture product provided with a mechanical locking device is known in the art, as evidenced by WO2017/052456. The furniture comprises a first panel connected mainly perpendicular to a second panel by mechanical locking device. The mechanical locking device can be disassembled by an angling motion. 
     SUMMARY 
     It is an object of certain aspects of the present invention to provide an improvement over the above described techniques and known art; particularly to facilitate assembling of panels configured to be assembled without the need of using any tools. A further object of at least certain aspects of the present invention is to assemble panels which may show a tighter and more aesthetic connection between a frame panel and a back piece of a furniture, such as a bookshelf, a cupboard, a wardrobe, a kitchen fixture, a drawer, or a box for storing or transportation. 
     A further object of at least certain aspects of the present invention may be to manufacture the back piece comprising a mechanical locking device with fewer production steps and lower cost. 
     At least some of these and other objects and advantages that will be apparent from the description have been achieved by a set of panels comprising a first panel with a first main plane with a first main surface and a second panel with a second main plane with a second main surface, wherein the first main plane is essentially perpendicular to the second main plane in a locked position, wherein the second panel comprises a third main surface at a first distance from the second main surface wherein the first and the second panel comprises a locking device for locking a first edge of the first panel to a second edge of the second panel, wherein the locking device comprises an edge groove at the first edge of the first panel, said edge groove comprise a first groove surface and a opposite second groove surface and a first bottom surface wherein the locking device comprises a tongue groove at the second main surface of the second panel, said panel comprises a first edge surface which is facing the first bottom surface in a locked position, the second panel further comprises a second edge surface extending between the tongue groove and the first edge surface, wherein the edge groove comprises a tongue, which is configured to cooperate with the tongue groove in a locked position, for locking the first and the second edges in a first direction which is perpendicular to the first main plane, wherein the first groove surface cooperate with second main surface, at a first contact area in a locked position and the second groove surface cooperate with the third main surface, at a second contact area, to lock the first and second panel in a second direction which is perpendicular to the second main plane wherein the first contact area is positioned, in a locked position, at a second distance from the second contact area, characterized in that the second distance is greater than the first distance, and that the edge groove at the intersection of the first and third main surface has an open space. 
     According to an aspect the second distance may be the closest distance in a perpendicular direction to the first main plane between the first and second contact area. 
     According to an aspect the tongue may protrude from the first groove surface. 
     According to an aspect the tongue may be a flexible tongue. 
     According to an aspect the tongue may be arranged in an insertion groove. 
     According to an aspect the first and second contact area may be positioned at a third distance in a perpendicular direction to the second main plane, wherein the first distance may be greater than the third distance. 
     According to an aspect the part of the second panel, inserted in edge groove, in locked position, may be bent in a direction, towards the first groove surface. 
     According to an aspect the locking device may comprise a first space in locked position, between the second edge surface and the first groove surface. 
     According to an aspect the first groove surface comprises an upper part positioned above the tongue and a lower part positioned below the tongue wherein the lower part is displaced relative the upper part such that a first space may be obtained in the locked position between the second lower part and the second edge surface. 
     According to an aspect the edge groove may comprise a second bottom surface at a greater depth than the first bottom surface. 
     According to an aspect the locking device may comprise a second space in locked position, between the first edge surface and second bottom surface. 
     According to an aspect the first and second contact area may be positioned at a third distance, and the second groove surface and the first bottom surface may be positioned at a fourth distance in a perpendicular direction to the second main plane. 
     According to an aspect the fourth distance may be within the range of about 0.1×third distance to 0.9×third distance, or about 0.25×third distance to 0.75×third distance, or more preferably about 0.5×third distance. 
     According to an aspect a first angle between the second groove surface and the second main plane may be within the range of about 1-30°, or in the range of 2-20° or more preferably about 5-10°. 
     According to an aspect a second angle between the first main surface and the first groove surface may be within the range of about 70-89°, or about 88-80°, or more preferably about 85° such that a first space may be obtained in a locked position between the second edge surface and a lower part of the first groove surface. 
     According to an aspect the first and/or the second panel may comprise a wood fiber based material, such as one or more of HDF, MDF, plywood, solid wood or particleboard, or a reinforced plastic board or a wood fiber composite board. 
     According to an aspect the first and/or second panel may comprise a decorative layer. 
     According to an aspect the edge groove may extend along essentially the entire length of the first edge. 
     According to an aspect the second panel may comprise said tongue groove in at least two of four edges. 
     According to an aspect the locking device may be configured to be unlocked by an angling motion of the panel relative the adjacent panel, such that a third angle γ between the first and second main plane is increasing. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other aspects, features and advantages of which embodiments of the invention are capable of, will be apparent and elucidated from the following description of embodiments of the present invention, reference being made to the accompanying drawings, in which 
         FIG.  1 A  shows a 3D-view of a set comprising four of the first panel, forming a cabinet frame and one of the second panel in an assembled state of an embodiment of the invention. 
         FIG.  1 B  shows a front view of a set comprising four of the first panel, one of the second panel in an assembled state of an embodiment of the invention. 
         FIG.  1 C  shows a cross-section view, in an assembled state of an embodiment of the invention. 
         FIG.  2 A  shows a cross sectional view of a set in an assembled state according to an embodiment of the invention. 
         FIG.  2 B  shows a cross sectional view of a first panel according to an embodiment of the invention. 
         FIG.  3 A  shows a cross sectional view of a set in an assembled state according to an embodiment of the invention. 
         FIG.  3 B  shows a cross sectional view of a second panel according to an embodiment of the invention. 
         FIG.  4 A- 6 B  shows a cross sectional view of a set according to an assembled state in various embodiments of the invention. 
         FIG.  7 A  shows a cross sectional view of a set according to an unassembled state in an embodiment of the invention. 
         FIG.  7 B- 8    shows a cross sectional view of a set in an assembled state in different embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     Specific embodiments of the invention will now be described with reference to the accompanying drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. The terminology used in the detailed description of the embodiments illustrated in the accompanying drawings is not intended to be limiting of the invention. In the drawings, like numbers refer to like elements. 
     The terminology used herein is for the purpose of describing particular aspects of the disclosure only, and is not intended to limit the disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. 
     It should be noted that the word “comprising” does not necessarily exclude the presence of other elements or steps than those listed and the words “a” or “an” preceding an element do not exclude the presence of a plurality of such elements. It should further be noted that any reference signs do not limit the scope of the claims. 
     The different aspects, alternatives and embodiments of the invention disclosed herein can be combined with one or more of the other aspects, alternatives and embodiments described herein. Two or more aspects can be combined. 
     As used herein, the term “about” means±10% of the noted value. By way of example only, an angle of “about 45°” could include from 40.5° up to and including 49.5°. 
     An embodiment of the invention is shown in  FIG.  1 A- 1 C  as an assembled furniture including a set of panels comprising a first panel  10  with a first main plane  11  with a first main surface  12  and a second panel  20  with a second main plane  21  with a second main surface  22 , wherein the first main plane  11  may be essentially perpendicular to the second main plane  21  in a locked position. The second panel  20  comprises a third main surface  25  at a first distance A from the second main surface  22 , wherein the first and the second panel comprises a locking device  50  for locking a first edge of the first panel  10  to a second edge of the second panel  20 . 
       FIGS.  2 A,  3 A,  4 A- 8    show enlargements of embodiments of the locking device  50  comprising an edge groove  30  at the first edge of the first panel  10 , said edge groove comprise a first groove surface  31  and a opposite second groove surface  32  and a first bottom surface  33 . 
     The locking device  50  comprises a tongue groove  26  at the second main surface  22  of the second panel  20 , said panel comprises a first edge surface  23  which is facing the first bottom surface  33  in a locked position, the second panel further comprises a second edge surface  24  extending between the tongue groove  26  and the first edge surface  23 , wherein the edge groove  30  comprises a tongue  40 , which is configured to cooperate with the tongue groove  26  in a locked position, for locking the first and the second edges in a first direction D 1  which is perpendicular to the first main plane  11 . 
     The first groove surface  31  cooperate with second main surface  22 , at a first contact area  31 ′ in a locked position and the second groove surface  32  cooperate with the third main surface  25 , at a second contact area  32 ′, to lock the first and second panel in a second direction D 2  which may be perpendicular to the second main plane  21 . The first contact area  31 ′ is positioned, in a locked position, at a second distance H from the second contact area  32 ′. 
       FIG.  2 B  discloses an enlargement of a part of an embodiment of the first panel  10  in unassembled state. 
       FIG.  3 A  discloses an enlargement of an embodiment of the locking device  50  wherein an upper part of the first groove surface  31  positioned above the tongue  40  and a second lower part  38  of the first groove surface  31  positioned below the tongue  40  may be parallel and displaced such that a first space  35  may be obtained in the locked position at the second lower part  38 . 
     Embodiments of the locking device  50  comprises an embodiment of the edge groove  30  comprising an open space  36  at the intersection of the first and third main surface  12 ,  25 . 
       FIG.  3 B  discloses an enlargement of a part of an embodiment of the second panel  20  in an unassembled state of the invention. In this embodiment the second panel comprises no guide chamfers. 
       FIG.  4 A  discloses an enlargement of an embodiment of the locking device  50  wherein the second edge surface  24  is displaced from the second main surface  22  such that a first space  35  may be obtained in the locked position at the second edge surface  24 . 
     According to an embodiment of the invention the second distance H may be greater than the first distance A. 
     According to an embodiment of the invention the second distance H may be the closest distance in a perpendicular direction to the first main plane  11  between the first and second contact area  31 ′,  32 ′. 
     According an embodiment of the invention the first groove surface  31  may comprise a protruding tongue  40 . 
       FIG.  4 B  discloses an enlargement of an embodiment of the locking device  50  wherein the tongue  40  may be formed from the first panel  10 , preferably by milling. 
     According to an embodiment of the invention the locking device  50  may comprise a flexible tongue  40 . 
     The locking device  50  may comprise a tongue  40 , arranged in an insertion groove  13 . The tongue may comprise a polymer material which may be reinforced with filler, such as glass fiber. 
     According to an embodiment the first and second contact area  31 ′, 32 ′ may be positioned at a third distance C in a perpendicular direction to the second main plane  21 , the first distance A may be greater than the third distance C. For example, the first distance A may be at least 3% greater than the third distance C, at least 5% greater than the third distance C, at least 10% greater than the third distance C, or at least 15% greater than the third distance C. 
       FIG.  8    discloses a set according an embodiment of the invention. A portion of the second panel  20 , inserted in edge groove  30 , in locked position, may be bent in a direction B, towards the first groove surface  31 , preferably towards the second lower part  38  of the first groove surface  31 . 
     The thickness of the second panel  20  may vary, due to production tolerances in the panel production process. The bending B of the second panel  20  may compensate for thickness variations. A thicker panel causes a bigger degree of bending, consequently a thinner panel causes less degree of bending. The above described bending enables the exclusion of a production step where the first distance A of the second panel  20  is set by a calibration cut, such a milling with a profiling tool. 
     The bending B may result in a compressive force between the second main surface  22  of the second panel  20  and the first contact area  31 ′ of the edge groove  30  of the first panel  10 . The compressive force may create a tight and more aesthetic connection between the first and second panel. 
     According to an embodiment of the invention the locking device  50  may comprise a first space  35  in locked position, between the second edge surface  24  and the first groove surface  31 . 
     The first space  35  may facilitate the bending B. 
     The first space  35  may facilitate angling of the second panel  20  during disassembly of a set. 
       FIG.  5 A  disclose an enlargement of an embodiment of the locking device  50  wherein the second panel  20  may comprise a guide chamfer  28 . 
     According to an embodiment of the invention the tongue groove  26  may comprise a guide chamfer  27  to improve the installation sequence of the first panel  10  and second panel  20 . 
     According to an embodiment of the invention the second panel  20  may comprise a guide chamfer  29  and/or  28  to further improve the installation of the first panel  10  and second panel  20 . 
     The above described guide chamfers may be an improvement in at least one installation sequence where the second panel  20  is displaced parallel to the second main plane  21  towards the first panel  10  in a perpendicular direction to the first main plane  11  where the second panel  20  is inserted into the edge groove  30  and locked together by the locking device  50 . 
       FIG.  5 B  disclose an enlargement of an embodiment of the locking device  50  wherein the first contact area  31 ′ may be positioned below the tongue  40 . 
       FIG.  6 A  disclose an enlargement of an embodiment of the locking device  50  wherein the first contact area  31 ′ may be positioned below the flexible tongue  40 . 
     According to an embodiment of the invention the edge groove  30  may comprise a second bottom surface  34  at a greater depth than the first bottom surface  33 . 
     According an embodiment of the invention the locking device  50  comprises a second space  37  in locked position, between the first edge surface  23  and second bottom surface  34 . The second space  37  may facilitate an easier disassembly of a set. 
       FIG.  6 B  disclose an enlargement of an embodiment of the locking device  50  wherein a lower part of the first space  35  has a greater width than an upper part of the first space  35 . 
     According to an embodiment of the invention the first and second contact areas  31 ′, 32 ′ may be positioned at a third distance C, and the second groove surface  32  and the first bottom surface  33  are positioned at a fourth distance W in a perpendicular direction to the second main plane  21 . 
     According to an embodiment of the invention the fourth distance W may be within the range of about 0.1×C to 0.9×C, or about 0.25×C to 0.75×C, or more preferably about 0.5×C. 
     According to an embodiment of the invention a first angle α between the second groove surface  32  and the second main plane  21 , in locked position, may be within the range of about 1-30°, or in the range of 2-20° or more preferably about 5-10°. 
     According to an embodiment of the invention a second angle β between the first main surface  12  and the first groove surface  31  may be within the range of about 70-89°, or about 88-80°, or more preferably about 85° such that a first space ( 35 ) may be obtained in a locked position between the second edge surface ( 24 ) and a lower part ( 38 ) of the first groove surface ( 31 ). 
     According to an embodiment of the invention the first and/or the second panel may comprise a wood fiber based material, such as one or more of HDF, MDF, plywood, solid wood or particleboard, or a reinforced plastic board or a wood fiber composite board. 
     According to an embodiment of the invention the first and/or second panel may comprise a decorative layer. 
     According to an embodiment of the invention the edge groove  30  may extend along essentially the entire length of the first edge. 
     According to an embodiment of the invention the second panel  20  may comprise said tongue groove  26  in at least two of four edges. For example, the second panel  20  could include the tongue groove on two opposite edges, and be free of the tongue groove on the remaining two opposite edges. 
       FIG.  7 A  discloses an enlargement of an embodiment of the locking device  50  wherein the locking device may be configured to be unlocked by an angling motion  60  of the panel  20  relative the adjacent panel  10 , such that a third angle γ between the first and second main plane  11 , 21  is increasing. 
       FIG.  7 B  disclose an enlargement of an embodiment of the locking device  50  wherein the first and second panel  10 , 20  may be locked by friction. 
     According to an embodiment of the invention an assembled furniture may include four first panels  10  and one second panel  20 . In an embodiment, all four first panels  10  include the same type of locking device, to enable locking to all four edges of the second panel  20 . In an embodiment, two of the four first panels include the same type of locking device, with a tongue configured to lock with a tongue groove on the second panel, and the remaining two first panels may not include a locking device or may include a locking device that is locked by friction, such as shown in  FIG.  7 B . 
     The different aspects, embodiments and alternatives described above could be combined with one or more of the other described aspects, embodiments and alternatives.