Patent Description:
A furniture product provided with a mechanical locking device is disclosed in <CIT>. The furniture comprises a first panel connected mainly perpendicular to a second panel by mechanical locking device. The mechanical locking device may comprise one or more inclined pins and a locking part. Other relevant prior art can be found in <CIT>, <CIT>, <CIT>, <CIT>, <CIT>.

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 improve the strength of a mechanical locking device at a mitre joint of a set of panels. The panels may be a part of a furniture product, such as a bookshelf, a cupboard, a wardrobe, a kitchen fixture, a drawer, or a box for storing or transportation.

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, and a second panel with a second main plane and a second panel surface, 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 plain is essentially perpendicular to the second main plane and the junction plane is extending 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 at least one locking groove at the first edge surface or at the second edge surface and at least one locking part at the other of said first or second edge surface, wherein the locking groove comprises at least one locking surface extending at a fourth angle from the first edge surface or from the second edge surface, the locking part is configured to be inserted into the locking groove and lock against the locking surface, and the second angle is different than the fourth angle, the first angle between the junction plane and the first main plane is <NUM>°.

The first angle between the junction plane and the first main plane is <NUM>°.

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 the invention the mechanical locking device is configured to obtain the locked position by displacing the first panel relative the second panel in an assembly direction, which is essentially parallel with the first panel surface and essentially parallel to a length direction and/or axial direction of the rod-shaped element.

According to an aspect the fourth angle is about <NUM>° to about <NUM>° larger than the second angle.

According to the invention, the second angle is within the range of about <NUM>° to <NUM>°, or within the range of <NUM>° to <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 mainly 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 insertion groove and/or 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 locking part is flexible.

According to an aspect the locking part in an unflexed/non-compressed state, is configured to be positioned partly in the locking groove.

According to an aspect the locking part comprises a spring.

According to an aspect the locking part is arranged in a locking part groove, on the first edge surface or on the second edge surface.

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 in locked position.

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

According to an aspect the first panel comprises a first panel groove on the first panel surface and the second panel comprises a second panel groove on the second panel surface.

According to an aspect the set further comprises a back panel configured to be inserted in, and optionally to cooperate with, the first and second panel groove.

According to an aspect the first panel, the second panel and the back panel are wood based panels.

According to an aspect first panel, the second panel and the back panel are furniture panels.

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

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.

This invention may, however, be embodied in many different forms according to the claims 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.

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 claims. 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.

An embodiment of the invention is shown in <FIG> during assembling of a set. The set comprising a first panel <NUM> with a first main plane <NUM> and a first panel surface <NUM>, and a second panel <NUM> with a second main plane <NUM> and a second panel surface <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 plain <NUM> may be essentially perpendicular to the second main plane <NUM> and the junction plane J may extend 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> may be 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 at least one locking groove <NUM> at the first edge surface <NUM> or at the second edge surface <NUM> and at least one locking part <NUM> at the other of said first or second edge surface, wherein the locking groove <NUM> comprises at least one locking surface <NUM> extending at a fourth angle δ from the first edge surface <NUM> or from the second edge surface <NUM>. The locking part <NUM> may be configured to be inserted into the locking groove <NUM> and lock against the locking surface <NUM>, and the second angle β may be different than the fourth angle δ, for example, different by at least <NUM>°. The first angle α between the junction plane J and the first main plane <NUM> is <NUM>°.

The set may be configured to obtain the locked position by displacing the first panel <NUM> relative the second panel <NUM> in an assembly direction AD, which may be essentially parallel with the first panel surface <NUM> and essentially parallel to a length direction L and/or axial direction CA of the rod-shaped element <NUM>.

According an embodiment of the invention the fourth angle δ may be about <NUM>° to about <NUM>° larger than the second angle β.

A locking of the first panel <NUM> to the second panel <NUM> in a direction which is parallel with the second panel surface <NUM> may be obtained by the locking part <NUM> being inserted into the locking groove <NUM> and locking against the locking surface <NUM>.

In embodiments wherein the locking groove <NUM> is a drill hole, the locking surface <NUM> may be a part of the cylindrical surface of the drill hole.

According the invention the second angle β 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 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>.

When the locking groove <NUM> is at the second edge surface <NUM>, the fourth angle δ may be measured in the same plane as the third angle described above. When the locking groove <NUM> is at the first edge surface <NUM>, the fourth angle δ may be measured in the same plane as the second angle described above.

The first panel <NUM> may comprise a first panel groove <NUM> on the first panel surface <NUM> and the second panel <NUM> may comprise a second panel groove <NUM> on the second panel surface <NUM> as disclosed in <FIG>, <FIG>. The first panel groove <NUM> and the second panel groove <NUM> may align when the first panel <NUM> and the second panel <NUM> are assembled together. The first panel groove and the second panel groove may be configured so that a back panel <NUM> can be inserted in, and optionally cooperate with, the first and second panel grooves <NUM>,<NUM>.

The first panel groove <NUM> and/or the second panel groove <NUM> may be bottom-ended.

The set may be configured to form a furniture without a back panel. A set without the first and second panel groove <NUM>,<NUM> is disclosed in <FIG>.

<FIG> disclose a set during assembly, when the first and second panels <NUM>,<NUM> are assembled together the locking part <NUM> may be compressed and may be substantially positioned in the locking part groove <NUM>. The locking part <NUM> may comprise a spring that facilitates the compression of the locking part <NUM>.

When the first panel <NUM> is displaced in relation to the second panel <NUM> in the assembly direction AD, the rod-shaped element <NUM> becomes inserted into the insertion groove <NUM>. When the locking part <NUM> meets the locking groove <NUM> the locking part <NUM> may expand out in axial direction from the locking part groove <NUM> and protrude into the locking groove <NUM>. The first panel <NUM> and second panel <NUM> will then be locked together, since the positioning of a part of the locking part <NUM> in the locking groove <NUM> hinders the first panel <NUM> from being displaced in relation to the second panel <NUM> in a direction opposite to the assembly direction.

<FIG> disclose a part of the first panel <NUM> according an embodiment of the invention. The mechanical locking device may comprise at least two rod-shaped elements <NUM>.

According an embodiment of the invention the mechanical locking device may comprise two or more rod-shaped elements <NUM>, arranged in a row mainly parallel to the first or second edge surface.

To improve the strength of the mechanical locking device the row of rod-shaped elements <NUM> may be positioned closer to the inner corner, than the outer corner of a set, that is, the row may be positioned between a centre line of the first panel <NUM> intersection of the first panel surface <NUM> and the junction plane J.

The rod-shaped element <NUM> may be arranged in a rod element groove <NUM> in the first edge surface <NUM>.

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

According an embodiment of the invention the rod-shaped element <NUM> may be configured to be glued in the rod element groove <NUM>.

According an embodiment of the invention 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.

According to an embodiment the rod-shaped element <NUM> is made from one or more of a wood based material, a polymer material, which may comprise reinforcement, such as glass fibre or a metal.

According to an embodiment the rod shaped element <NUM> may have a waxed surface to facilitate assembly.

<FIG> disclose a part of the second panel <NUM> according an embodiment of the invention. The insertion groove <NUM> and/or the rod element groove <NUM> may be a drill hole.

According an embodiment of the invention the drill hole is a bottom-ended drill hole.

The insertion groove <NUM> may comprise a chamfer <NUM> or a rounding at the groove opening, which is configured to guide the rod shaped element <NUM> during assembling.

Two or more insertion grooves <NUM> may be arranged in a row mainly parallel to the first or second edge surface <NUM>,<NUM>.

To improve the strength of the mechanical locking device the row of insertion grooves <NUM> may be positioned closer to the inner corner, than the outer corner of a set, that is, the row may be positioned between a centre line CL of the second edge surface <NUM> and the intersection of the second panel surface <NUM> and the junction plane J.

<FIG> disclose a set in locked position according an embodiment of the invention. The first angle α between the junction plane J and the first main plane <NUM> may be about <NUM>°. A different angle may be preferred for a set with different thicknesses of the first and the second panels <NUM>,<NUM>. 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 J of the first <NUM> and the second <NUM> 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 an embodiment of the invention the locking part <NUM> may be flexible.

The locking part <NUM> may in an unflexed/non-compressed state, be configured to be positioned partly in the locking groove <NUM>.

The locking part <NUM> may comprise a spring.

The locking part <NUM> may be arranged in a locking part groove <NUM>, on the first edge surface <NUM> or on the second edge surface <NUM>.

The rod-shaped element <NUM> may have a diameter D1. The diameter D2 of the insertion groove <NUM> may be larger than the diameter D1 of the rod-shaped element <NUM>. The diameter D2 of the insertion groove <NUM> may be about <NUM> to about <NUM> larger than the diameter D1 of the rod-shaped element <NUM> for optimal assembly.

<FIG> disclose a first panel and <FIG> disclose a second panel according an embodiment of the invention. The first or second edge surface <NUM>,<NUM> may comprise a tongue <NUM>, wherein said tongue may comprise a first tongue surface <NUM> and a second tongue surface <NUM> and the other of said opposite first or second edge surface <NUM>,<NUM> comprise a tongue groove <NUM>.

The tongue <NUM> and/or the tongue groove <NUM> may extend along essentially the whole panel edge.

<FIG> disclose a side view of a set according an embodiment of the invention. The set may be an embodiment of the set of panels shown in <FIG>,<FIG>. 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> in locked position.

The first space <NUM> may have the effect that a gap is avoided at the inner and outer corner of the junction plane J between the first and second edge surface <NUM>,<NUM> since a greater contact pressure may be obtained at the inner and outer corner. The first or the second panel <NUM>,<NUM> comprising the tongue groove <NUM> may be combined with a first or a second panel <NUM>,<NUM> without a tongue <NUM>, forming a joint comprising a space between the first or second edge surface <NUM>,<NUM> and the tongue groove <NUM>.

The first panel <NUM> comprising the tongue groove <NUM> may form a set with a second panel <NUM> comprising a tongue groove <NUM>' forming a joint comprising a space between the tongue groove <NUM> and the tongue groove <NUM>'.

According an embodiment of the invention the tongue groove <NUM> may comprise one or more rod-shaped elements <NUM>.

The tongue <NUM> may comprise one or more insertion groove <NUM>. Positioning of the insertion groove <NUM> at least partly in the tongue <NUM> may increase the engagement area of the rod-shaped element <NUM> and the insertion groove <NUM>. The advantage may be a greater stability of the joint.

<FIG> disclose a furniture product comprising two of the first panel <NUM>, two of the second panel <NUM> and a back panel <NUM>. The back panel <NUM> may be configured to be inserted in, and optionally cooperate with, the first and second panel grooves <NUM>,<NUM>.

The furniture product may be a bookshelf, a cupboard, a wardrobe, a box or a drawer.

According an embodiment of the invention the first panel <NUM> may comprise one first edge surface <NUM> and one second edge surface <NUM>.

According an embodiment of the invention the first and the second panel <NUM>,<NUM> may be mainly identical. In this embodiment the first panel comprises the first edge surface <NUM> and the second edge surface <NUM> on opposite sides of the first panel. Above described embodiment enables to form a furniture frame with <NUM> mainly identical panels.

The sidewalls of the insertion groove <NUM> and the locking groove <NUM> may comprise material of the core of the first panel <NUM> or the second panel <NUM>, dependent on in which panel they are made.

According an embodiment of the invention the insertion groove <NUM> and/or the rod element groove <NUM> may be reinforced with plastic, e.g., thermoplastic, and/or liquid, e.g., PVAc-glue.

The insertion groove <NUM> and/or the rod element groove <NUM> may be reinforced with metal, such as zinc or zinc alloy.

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

The first panel <NUM> and/or the second panel <NUM> and/or the back 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 may be 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 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.

The aspects described above may comprise a wood base core, such as HDF, MDF, plywood, particleboard, OSB or Masonite.

Claim 1:
A set comprising a first panel (<NUM>) with a first main plane (<NUM>) and a first panel surface (<NUM>), and a second panel (<NUM>) with a second main plane (<NUM>) and a second panel surface (<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 main plain (<NUM>) is perpendicular to the second main plane (<NUM>) and the junction plane (J) is extending 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 at least one locking groove (<NUM>) at the first edge surface (<NUM>) or at the second edge surface (<NUM>) and at least one locking part (<NUM>) at the other of said first or second edge surface, wherein the locking groove (<NUM>) comprises at least one locking surface (<NUM>) extending at a fourth angle (δ) from the first edge surface (<NUM>) or from the second edge surface (<NUM>), the locking part (<NUM>) is configured to be inserted into the locking groove (<NUM>) and lock against the locking surface (<NUM>), and the second angle (β) is different than the fourth angle (δ),
wherein the first angle (α) between the junction plane (J) and the first main plane (<NUM>) is <NUM>°, and
wherein the mechanical locking device is configured to obtain the locked position by displacing the first panel (<NUM>) relative the second panel (<NUM>) in an assembly direction (AD), which is parallel with the first panel surface (<NUM>) and parallel to a length direction (L) and/or axial direction (CA) of the rod-shaped element (<NUM>), characterised in that the second angle (β) is within the range of <NUM>° to <NUM>°, or within the range of <NUM>° to <NUM>°, or <NUM>°.