Patent Description:
A furniture product provided with a mechanical locking device is disclosed in <CIT>. The furniture product comprises a first panel connected mainly perpendicular to a second panel by a mechanical locking device. The mechanical locking device may comprise inclined pins, a back panel and a locking part. Relevant prior art is also disclosed in <CIT>.

The above description of various known aspects is the applicant's characterization of such, and is not an admission that any of the above description is considered as prior art.

Embodiments of the present invention address a need to provide panels that may be easily assembled.

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 facilitate assembling of panels configured to be assembled with a locking device that is easy to manufacture and to use, which reduces the risk of incorrect installation thereof.

A further object of at least certain aspects of the present invention is to facilitate assembling of panels configured to be assembled in a more stable and aesthetic way.

A further object of at least certain aspects of the present invention may be to avoid the need to provide edge-banding of the edges of panels.

At least some of these and other objects and advantages that will be apparent from the description have been achieved by a set comprising a first panel with a first main plane and a first panel surface, a second panel with a second main plane and a second panel surface, a back panel and a mechanical locking device for locking of a first edge surface of the first panel to a second edge surface of the second panel at a junction plane, wherein the first main plane is essentially perpendicular to the second main plane and the junction plane extends at a first angle to the first main plane, the mechanical locking device comprises at least one rod-shaped element at the first edge surface and at least one insertion groove at the second edge surface, the rod-shaped element is configured to be inserted into the insertion groove, the rod-shaped element extends at a second angle from the first edge surface, the insertion groove extends into the second edge surface at a third angle from the second edge surface, the mechanical locking device further comprises a first panel groove on a first panel surface on the first panel, and/or a second panel groove on the second panel surface of the second panel, wherein the back panel is configured to cooperate with at least one of the first panel groove and the second panel groove, and at least one locking gear configured to cooperate with the back panel and at least one of the first panel groove and the second panel groove, for locking of the first panel to the second panel, wherein the first angle between the junction plane and the first main plane is about <NUM>°.

The first panel, the second panel and the back panel may be wood based panels.

The first panel, the second panel and the back panel may be furniture panels.

The first angle between the junction plane and the first main plane may be about <NUM>°. A different angle may be preferred for a set with different thicknesses of the first and the second panel.

The angle may be adapted such that the junction plane extends through an intersection of an outer face of the first panel and an outer face of the second panel to an intersection of an inner face of the first panel and an inner face of the second panel.

The inner face of the first panel may be facing the inner face of the second panel. An outer face of the first panel may be opposite to the inner face of the first panel. An outer face of the second panel may be opposite to the inner face of the second panel.

An outer corner at the junction plane of the first and the second panel may comprise a bevelled edge, preferably covered by a decorative layer. The bevel may increase the strength of the corner. The decorative layer may be a plastic foil, veneer or paint.

According to an aspect a width of at least one of the first panel groove and the second panel groove minus a thickness of the back panel is larger than or essentially the same as an extension of the rod-shaped element along the first edge surface.

According to an aspect the second angle is within the range of about <NUM>° to about <NUM>°, or within the range of about <NUM>° to about <NUM>°, or about <NUM>°.

According to an aspect the mechanical locking device comprises at least two rod-shaped elements.

According to an aspect the mechanical locking device comprises two or more rod-shaped elements, arranged in a row essentially parallel to the first or second edge surface.

According to an aspect the rod-shaped element is arranged in a rod element groove in the first edge surface.

According to an aspect the rod element groove is a drill hole.

According to an aspect the drill hole is a bottom-ended drill hole.

According to an aspect the width of the first panel groove is essentially the same as the width of the second panel groove.

According to an aspect the first panel comprises a third edge surface, the second panel comprises a fourth edge surface, the first panel groove is substantially parallel to the third edge surface and the second panel groove is substantially parallel to the fourth edge surface.

According to an aspect the first panel groove extends substantially along the entire third edge surface and the second panel groove extends essentially along the entire fourth edge surface.

According to an aspect at least one of the first panel groove and the second panel groove is bottom-ended.

According to an aspect the locking gear is configured to further cooperate with the back panel, for locking of the back panel to the first and/or second panel.

According to an aspect the locking gear is flexible.

According to an aspect the locking gear comprises a spring.

According to an aspect the locking gear comprises a wedge element.

According to an aspect an extension of the back panel from the intersection between the first edge surface and the first panel surface of the first panel, when one first panel, one second panel and one back panel have been assembled, is less than an extension of the rod shaped element from said intersection.

According to an aspect the first or second edge surface comprises a tongue, wherein said tongue comprises a first tongue surface and a second tongue surface and the other of said opposite first or second edge surface comprises a tongue groove.

According to an aspect the mechanical locking device comprises a first space between the tongue groove and the first tongue surface and/or the second tongue surface when the set is in a locked position.

According to an aspect the tongue groove comprises one or more rod-shaped elements.

According to an aspect the rod element groove is reinforced by plastic, e.g. thermoplastic and/or liquid, e.g. PVAc-glue.

According to an aspect the core of the first panel and/or of the second panel and/or the back panel may be a wood-based core, such as MDF, HDF, OSB, WPC, plywood or particleboard. The core may also be a plastic core comprising thermosetting plastic or thermoplastic, e.g., vinyl, PVC, PU or PET. The plastic core may comprise fillers.

The first panel and/or the second panel and/or the back panel may also be of solid wood.

The first panel and/or the second panel and/or the back panel may be provided with a decorative layer, such as a foil or a veneer, on one or more surfaces.

At least some of the above identified and other objects and advantages that may be apparent from the description have been achieved by a locking device for a furniture product in accordance with the above.

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 and aspects of the present invention, reference being made to the accompanying drawings, in which.

In the drawings and specification, there have been disclosed exemplary aspects of the disclosure. However, many variations and modifications may be made to these aspects without substantially departing from the principles of the present disclosure. Thus, the disclosure should be regarded as illustrative rather than restrictive, and not as being limited to the particular aspects discussed above. Accordingly, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, for example, definition of dimensions such as width or breadth or height or length or diameter depends on how exemplary aspects are depicted, hence, if depicted differently, a shown width or diameter in one depiction is a length or thickness in another depiction.

It should further be noted that any reference signs do not limit the scope of the claims, that the example aspects may be implemented at least in part by means of both hardware and software, and that several "means", "units" or "devices" may be represented by the same item of hardware.

The different aspects, alternatives and embodiments of the invention disclosed herein may be combined with one or more of the other aspects, alternatives and embodiments described herein. Two or more aspects may be combined.

Embodiments of the set of the invention are shown in <FIG> and <FIG> including a set comprising a first panel <NUM> with a first main plane <NUM> and a first panel surface <NUM>, a second panel <NUM> with a second main plane <NUM> and a second panel surface <NUM>, a back panel <NUM> and a mechanical locking device for locking of a first edge surface <NUM> of the first panel <NUM> to a second edge surface <NUM> of the second panel <NUM> at a junction plane J. The first main plane <NUM> may be essentially perpendicular to the second main plane <NUM>. The junction plane J extends at a first angle α to the first main plane <NUM>. The mechanical locking device comprises at least one rod-shaped element <NUM> at the first edge surface <NUM> and at least one insertion groove <NUM> at the second edge surface <NUM>. The rod-shaped element <NUM> is configured to be inserted into the insertion groove <NUM>. The rod-shaped element <NUM> extends at a second angle β from the first edge surface <NUM>. The insertion groove <NUM> extends into the second edge surface <NUM> at a third angle γ from the second edge surface <NUM>. The mechanical locking device further comprises a first panel groove <NUM> on a first panel surface <NUM> on the first panel <NUM>, and/or a second panel groove <NUM> on the second panel surface <NUM> of the second panel <NUM>. The back panel <NUM> is configured to be inserted into and cooperate with at least one of the first panel groove <NUM> and the second panel groove <NUM>, and at least one locking gear <NUM> configured to cooperate with the back panel <NUM> and at least one of the first panel groove <NUM> and the second panel groove <NUM>, for locking of the first panel <NUM> to the second panel <NUM>. The first angle α between the junction plane J and the first main plane <NUM> may be within a range of about <NUM>° to <NUM>°, or within the range of <NUM>° to <NUM>°, or about <NUM>°.

This results in a very aesthetic look to the set of panels when they are assembled. Further, since the first angle α between the junction plane J and the first main plane <NUM> is about <NUM>°, there is no longer a need for edge-banding of the edges of panels.

The first panel <NUM>, the second panel <NUM>, and the back panel <NUM> may be panels for a furniture product and may be part of a frame of a furniture product.

The first panel <NUM>, the second panel <NUM>, and the back panel <NUM> may be wood based panels.

<FIG> and <FIG> disclose embodiments where the panels are in an unassembled state. <FIG> and <FIG> disclose embodiments where the panels are in an assembled state.

The set may be assembled by displacing the first panel <NUM> relative the second panel <NUM> in an assembly direction AD which is essentially parallel with the first panel surface <NUM>.

The assembly direction AD may be essentially parallel with the second angle β and/or the third angle γ.

The second angle β may be within the range of about <NUM>° to about <NUM>°, or within the range of about <NUM>° to about <NUM>°, or about <NUM>°.

According an embodiment of the invention the third angle γ may be within the range of about <NUM>° to <NUM>°, or within the range of <NUM>° to <NUM>°, or about <NUM>°.

According an embodiment of the invention the second angle β and the third angle γ may be essentially the same.

The second angle β may be measured in a plane parallel to the first panel surface <NUM>.

The third angle γ may be measured in a plane which is perpendicular to the second panel surface <NUM> and parallel to second edge surface <NUM>.

According to an aspect, the mechanical locking device may comprise at least two rod-shaped elements <NUM>. When the mechanical locking device comprises two or more rod-shaped elements <NUM>, the rod-shaped elements <NUM> may be arranged in a row essentially parallel to the first or second edge surface <NUM>,<NUM>.

The first edge surface <NUM> may comprise two or more of said rod-shaped element <NUM> and the second edge surface <NUM> may comprise two or more of said insertion groove <NUM>, and vice versa, which may be arranged linearly, wherein each of the rod-shaped elements <NUM> is configured to be inserted into an insertion groove <NUM>.

The rod-shaped element <NUM> may be configured to cooperate, in a locked position, with the bottom surface of the insertion groove <NUM>.

The sidewalls of the insertion groove <NUM> may comprise material of the core of the first panel <NUM> or the second panel <NUM>, dependent on in which panel the insertion groove <NUM> is made and in which panel the rod-shaped element <NUM> is attached. According to an aspect they may also be enforced with, e.g., metal or glass fibre.

The rod-shaped element <NUM> may be arranged in a rod element groove <NUM> in the first edge surface <NUM>. The rod element groove <NUM> may be a drill hole. In one embodiment the drill hole is a bottom-ended drill hole.

The rod-shaped element <NUM> may be configured to be attached in the rod element groove <NUM> by friction.

The rod-shaped element <NUM> may be configured to be glued in the rod element groove <NUM>.

The rod-shaped element <NUM>, the rod element groove <NUM> and the insertion groove <NUM> may have a substantially circular shape, although other shapes, such as triangular, rectangular, square, etc., are possible.

The rod-shaped element <NUM> may be made from one or more of a wood based material, a polymer material, which may comprise reinforcement, such as glass fibre or a metal. The rod shaped element <NUM> may have a waxed surface to facilitate assembly.

The first panel groove <NUM> may comprise a width W1.

The second panel groove <NUM> may comprise a width W2.

The width W1 of the first panel groove <NUM> may be essentially the same as the width W2 of the second panel groove <NUM>.

The width (W1, W2) of at least one of the first panel groove <NUM> and the second panel groove <NUM> minus a thickness T of the back panel <NUM> may be larger than or essentially the same as an extension E of the rod-shaped element <NUM> along the first edge surface <NUM>; the extension E being measured perpendicularly to the first edge surface <NUM>.

The first panel <NUM> may comprise a third edge surface <NUM>, the second panel <NUM> may comprise a fourth edge surface <NUM>. The first panel groove <NUM> may be substantially parallel to the third edge surface <NUM> and the second panel groove <NUM> may be substantially parallel to the fourth edge surface <NUM>.

According to an aspect the first panel groove <NUM> may extend substantially along the entire third edge surface <NUM> and the second panel groove <NUM> may extend essentially along the entire fourth edge surface <NUM>.

At least one of the first panel groove <NUM> and the second panel groove <NUM> may be bottom-ended.

The first <NUM> and/or second <NUM> panel groove may be formed by mechanical cutting, such as milling or sawing.

The first panel groove <NUM> may be formed in the first panel surface <NUM> and in a core of the first panel <NUM>. The second panel groove <NUM> may be formed in the second panel surface <NUM> and in a core of the second panel <NUM>.

The first panel groove <NUM> and/or the second panel groove <NUM> may be impregnated/enforced with a liquid.

An extension H of the back panel from the intersection <NUM> between the first edge surface <NUM> and the first panel surface <NUM> of the first panel <NUM>, when one first panel <NUM>, one second panel <NUM> and one back panel <NUM> have been assembled, may be less than an extension of the rod shaped element <NUM> from said intersection <NUM>.

According to an aspect the first or second edge surface <NUM>,<NUM> may comprise a tongue <NUM>, as is shown in <FIG> and <FIG>. This gives an increased stability to the set when assembled. The tongue <NUM> may comprise a first tongue surface <NUM> and a second tongue surface <NUM>.

The other of said opposite first or second edge surface <NUM>,<NUM> may comprise a tongue groove <NUM>, as is shown in <FIG> and <FIG>.

In <FIG> it is shown that when the set comprising the first <NUM> and second <NUM> panel is in a locked position, the mechanical locking device may comprise a first space <NUM> between the tongue groove <NUM> and the first tongue surface <NUM> and/or the second tongue surface <NUM>.

The tongue groove <NUM> may comprise one or more rod-shaped elements <NUM>.

The rod element groove <NUM> may be reinforced. Such reinforcement may be done using e.g. plastic, e.g., thermoplastic, and/or liquid, e.g., PVAc-glue. This reduces the risk that of damages to the rod element groove <NUM> and the surrounding material.

<FIG> show different aspects of a locking gear <NUM> according to embodiments of the invention. The locking gear <NUM> may be configured to cooperate with the back panel <NUM>, for locking of the back panel <NUM> to the first <NUM> and/or second <NUM> panel.

The locking gear <NUM> may be assembled to the set of panels when the first panel <NUM>, the second panel <NUM> and the back panel <NUM> have been assembled. The locking gear <NUM> is inserted in the first panel groove <NUM> and/or the second panel groove <NUM>, and thereby locks the first panel <NUM> to the second panel <NUM>.

The locking gear <NUM> may lock the back panel <NUM> to the first panel groove <NUM> and/or the second panel groove <NUM> and thereby hinder the first panel <NUM> to be displaced in relation to the second panel <NUM> in a direction opposite to the assembly direction AD.

The locking gear <NUM> may be made of, e.g., wood based material, metal, a polymer material, etc..

The locking gear <NUM> may comprise an elastic part.

The locking gear <NUM> may comprise a wedge shaped edge <NUM>,<NUM>.

An embodiment of the locking gear <NUM>, as shown in <FIG>, <FIG>, <FIG>, <FIG> and <FIG>, may comprise a lever arm <NUM> and an eccentric locking head <NUM> at a first end of the lever. The locking gear <NUM> may comprise at an opposite second end of the lever <NUM> a locking part <NUM>. When the eccentric head <NUM> is inserted in the first panel groove <NUM>, the locking part <NUM> may be is inserted in the second panel groove <NUM>, and vice versa.

The locking part <NUM> may comprise friction elements <NUM>. The friction elements <NUM> may assist in the keeping locking part <NUM> in the first panel groove or the second panel groove. The friction elements <NUM> may be made in one piece with the locking gear. The friction elements may be pointed or raised elements.

The lever arm <NUM> may be elastic to enable bending during the insertion of the locking part <NUM> may in the first panel groove <NUM> or the second panel groove <NUM>. The bending of the lever arm <NUM> may create a locking force between the locking part and the first panel groove <NUM> or the second panel groove <NUM>.

An outer part of the eccentric locking head <NUM> may be thicker than a part of the eccentric locking head <NUM> adjacent the first end of the lever.

<FIG> and <FIG> show an embodiment of the locking gear <NUM> which comprises a first wedge shaped edge <NUM> and a second wedge shaped edge <NUM>. The first wedge shaped edge <NUM> may be inserted in the in the first panel groove <NUM> and the second wedge shaped edge <NUM> may be inserted in the in the second panel groove <NUM> to lock the first panel <NUM>, the second panel <NUM> and the back panel <NUM> to a locked position.

The locking gear <NUM> may, have a triangular shape as shown in <FIG> or may optionally have a rectangular or square shape (not shown).

The first wedge shaped edge <NUM> and/or the second wedge shaped edge <NUM> may comprise friction elements <NUM>. The friction elements <NUM> may assist in the keeping first wedge shaped edge <NUM> and/or the second wedge shaped edge <NUM> in the first panel groove and the second panel groove, respectively. The friction elements <NUM> may be made in one piece with the locking gear. The friction elements may be pointed or raised elements.

<FIG> and <FIG> show the locking gear with the eccentric locking head <NUM> in the second locking groove <NUM> and the locking part <NUM> in the first panel groove <NUM>. The eccentric locking head <NUM> end may have a rounded back side and a gripping edge on a front side. The locking part <NUM> may have a smaller width than the eccentric locking head <NUM>. The locking gear may be installed by placing the eccentric locking head <NUM> in a panel groove and rotating the locking gear along the rounded back side, such that the locking part <NUM> is rotated towards the back panel <NUM>. The locking part <NUM> may angle away from the back panel <NUM>. The locking gear may be configured, such that upon installation the locking part <NUM> may exert a force on an outside wall of panel groove.

The first panel <NUM> may comprise two or more of said first edge surfaces <NUM> according to the above. Put in another way, one or more rod-shaped elements <NUM> may be positioned at two or more of the edge surfaces of the first panel <NUM>, as disclosed in <FIG>.

The second panel <NUM> may comprise two or more of said second edge surfaces <NUM> according to the above. Put in another way, one or more insertion grooves <NUM> may be positioned at two or more of the edge surfaces of the second panel <NUM>.

The core of the first panel <NUM> and/or of the second panel <NUM> may be a wood-based core, such as MDF, HDF, OSB, WPC, plywood or particleboard. The core may also be a plastic core comprising thermosetting plastic or thermoplastic, e.g., vinyl, PVC, PU or PET. The plastic core may comprise fillers.

The first panel <NUM> and/or the second panel <NUM> may also be of solid wood.

The first panel <NUM> and/or the second panel <NUM> may be provided with a decorative layer, such as a foil or a veneer, on one or more surfaces.

According to an aspect the set of panels are resilient panels. The resilient panels may comprise a core comprising thermoplastic material. The thermoplastic material may be foamed.

The thermoplastic material may comprise polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof. The core may be formed of several layers.

The aspects described above may comprise a decorative layer, such as a decorative foil comprising a thermoplastic material. The thermoplastic material of the decorative layer may be or comprise polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof. The decorative foil is may be printed, for example by direct printing, rotogravure, or digital printing. According to an aspect the decorative layer comprises melamine, a high pressure laminate (HPL) or a veneer.

The aspects described above may comprise a wear layer such as a film or foil. The wear layer may comprise thermoplastic material. The thermoplastic material may be polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.

Claim 1:
A set comprising a first panel (<NUM>) with a first main plane (<NUM>) and a first panel surface (<NUM>), a second panel (<NUM>) with a second main plane (<NUM>) and a second panel surface (<NUM>), a back panel (<NUM>) and a mechanical locking device with a junction plane (J), wherein the mechanical locking device is configured for locking a first edge surface (<NUM>) of the first panel (<NUM>) to a second edge surface (<NUM>) of the second panel (<NUM>) at the junction plane (J), wherein the first panel (<NUM>), the second panel (<NUM>) and the back panel (<NUM>) are wood based furniture panels,
wherein the first main plane (<NUM>) is perpendicular to the second main plane (<NUM>) and the junction plane (J) extends at a first angle (α) to the first main plane (<NUM>),
wherein the mechanical locking device comprises at least one rod-shaped element (<NUM>) at the first edge surface (<NUM>) and at least one insertion groove (<NUM>) at the second edge surface (<NUM>),
wherein the rod-shaped element (<NUM>) is configured to be inserted into the insertion groove (<NUM>),
wherein the rod-shaped element (<NUM>) extends at a second angle (β) from the first edge surface (<NUM>),
wherein the insertion groove (<NUM>) extends into the second edge surface (<NUM>) at a third angle (γ) from the second edge surface (<NUM>),
wherein the mechanical locking device further comprises a first panel groove (<NUM>) on a first panel surface (<NUM>) on the first panel (<NUM>), and/or a second panel groove (<NUM>) on the second panel surface (<NUM>) of the second panel (<NUM>), wherein the back panel (<NUM>) is configured to cooperate with at least one of the first panel groove (<NUM>) and the second panel groove (<NUM>), and at least one locking gear (<NUM>) configured to cooperate with the back panel (<NUM>) and at least one of the first panel groove (<NUM>) and the second panel groove (<NUM>), for locking of the first panel (<NUM>) to the second panel (<NUM>), and
wherein the first angle (α) between the junction plane (J) and the first main plane (<NUM>) is <NUM>°.