Technical Field

The present invention relates to furniture, and to manufacturing of furniture. More particularly, the present invention is directed towards methods and systems for producing ready-to-assemble furniture modules.

Background

Furniture is manufactured by a variety of different materials. Wood, being one preferred material, is especially suitable for large scale batch production of furniture due to the possibility to produce the furniture parts with dimensions being within the preset tolerances. However, in some cases it is desired to use natural material which cannot be produced in large quantity with well-defined dimensions. It may for example be desired to produce furniture using natural tree trunks, or forming furniture legs directly from certain tree branches or from saplings. Another natural material for furniture is rattan.

Rattan is already extensively used for manufacturing and forming of various furniture such as chairs, tables, sofas, etc. Rattan is a generic name for a plurality of species of climbing palms, all having a flexible wood-like stem. The characteristics of rattan is therefore more of a liana than traditional, common wood. The stem is typically having a diameter of 2-5 cm, being slightly tapered or of variable diameter along its length due to variations during growth.

A piece of rattan used for furniture has a relatively hard and rigid outer shell, and a solid, although substantially more soft, inner core. Rattan furniture is normally hand-made due to variations of dimensions of the rattan material, which also means that rattan furniture is transported as fully assembled. This is however a major drawback, especially when compared to the articles offered by the wooden furniture industry, which has been extremely successfully in developing furniture having a so called “knock-down” configuration. This kind of furniture is ready-to-assemble, i.e. it is sold as a group of separate components with assembly instructions for connecting the components. Hence, such furniture can be flat-packed which offers a number of advantages in terms of cost efficiency and transport/storage.

As rattan is normally used in its natural form and dimensions, there is so far no commercially successful technique for industrial large quantity manufacturing of furniture made of rattan or other natural material of less specific dimensions, still maintaining the original and unique appearance of hand-made articles and allowing the rattan furniture to be sold and distributed in a knock-down configuration. Industrial manufacturing will normally require tight tolerances for high throughput and yield, which is incompatible with the intrinsic properties of rattan and other natural tree parts.

In view of this, new methods of manufacturing furniture are therefore desired.

Summary

It is an object of the present invention to wholly or partly overcome the above disadvantages and drawbacks of the prior art. More specifically, it is an object to provide a method of manufacturing ready -to-assemble furniture modules which can be easily assembled from a knock-down configuration to ready -to-use furniture by an end consumer.

According to a first aspect a method of manufacturing a ready -to- assemble furniture module is provided. The method comprises providing a furniture module, arranging the furniture module at a predetermined position of a fixture, activating at least two drilling units to provide corresponding assembly holes in the furniture module, and controlling the respective position of the at least two drilling units during activation in relation to each other, as well as in relation to the fixture. By controlling the positions of the assembly holes it will be possible to allow for accurate assembly of the furniture module together with another ready-to-assemble furniture module. Even if each furniture module is formed by a material of varying dimensions, the position control ensures proper assembly of the two furniture modules even when the assembly requires two different joining positions corresponding to the positions of the assembly holes.

Providing a furniture module may be performed by connecting a plurality of furniture parts in a planar configuration. The ready-to-assemble furniture module can thereby be stored and transported in a knock-down configuration.

Arranging the furniture module at a predetermined position of the fixture may be performed by aligning a first part of the furniture module with a first reference position of the fixture, and aligning a second part of the furniture module with a second reference position of the fixture. By using two reference positions, preferably being spaced apart, improved positioning of the entire furniture module is accomplished. The furniture module may be aligned only at the first part of the furniture module and at the second part of the furniture module. This is particularly advantageous for furniture modules being made of natural material of slightly varying dimensions, as the fixation at only two positions will allow for variations in size of the furniture module.

Arranging the furniture module at a predetermined position of the fixture may further comprise clamping the furniture module to the fixture, preferably at a plurality of positions of the furniture module. A secure fixation is thereby ensured, providing accurate positioning of the assembly holes.

Clamping the furniture module may be performed by arranging the furniture module in a V-shaped cavity of a clamping device. This is particularly advantageous for rattan material or other round/cylindrical material. Especially for rattan material the above-mentioned clamping operation is of particular advantage; while rattan material has a generally circular cross-section, it is rarely a perfect circle. Yet further, the diameter of a rattan piece normally varies within certain ranges leaving the tolerances comparatively large compared to other processed materials. Clamping, of the type described above, will efficiently compensate for any variations in the rattan material outer periphery and ensure the furniture module is correctly located thereby improving robustness and predictability of the manufacturing process.

The clamping device may comprise two mating V-shaped structures. The furniture module can thereby be securely centered between four contact points, while it is sufficient that only one V-shaped structure is moveable in order to fit the furniture module in the clamping device.

The fixture may be tilted relative a horizontal plane. This allows the drilling units to operate in a vertical direction, still allowing for non-horizontal assembly holes thereby providing improved design, comfort, and functionality of the ready-to-use furniture.

Each drilling unit may comprise a first drilling device and a second drilling device. Activating at least two drilling units may thus be performed by activating first drilling devices engaging with an upper side of the furniture module, and activating second drilling devices engaging with a bottom side of the furniture module, preferably the first and second drilling devices are activated in a sequential order. Assembly holes can thereby be provided, extending from both sides of the furniture module, without requiring repositioning of the furniture module relative the fixture. The first and second drilling device of a common drilling unit may be aligned in a vertical direction. The assembly holes may thereby extend through the furniture module.

Activating the first drilling device may result in a first drilling geometry of the furniture module, and activating the second drilling device may result in a second drilling geometry of the furniture module. Hence, an assembly hole extending through the entire furniture module may have different geometries on opposite sides, thereby allowing for a more sophisticated and robust furniture joint when the assembly hole is used to connect two furniture modules.

According to a second aspect, a method of manufacturing a ready -to- assemble furniture module is provided. The method comprises providing an elongated furniture part, activating a cutting unit to cut the furniture part to a desired length, activating a milling unit to shape an axial end of the furniture part, and activating an axial drilling unit to provide at least one assembly hole at an axial end of the furniture part. The elongated furniture part will thereby not only have a well-defined length and position of the assembly hole, but shaping will also make the furniture part capable of forming very robust furniture joints, even for a natural material like rattan.

The method may further comprise transporting the furniture part between the cutting unit, the milling unit, and the axial drilling unit. Optionally, the method may further comprise clamping the furniture part to a transport device. Clamping the furniture part may be performed by arranging the furniture part between two opposite V-shaped structures. The furniture part can thereby be securely centered between four contact points, while it is sufficient that only one V-shaped structure is moveable in order to fit the furniture part in the clamping device.

Activating the cutting unit may be performed by cutting both axial ends of the furniture part; preferably the cutting of both axial ends is performed simultaneously. Speed and accuracy of the cutting action is thereby accomplished.

Activating the milling unit may result in a cone shaped axial end of the furniture part. This allows for an improved furniture joint when the furniture part is connected to another furniture module, preferably of the type being manufactured by the method according to the first aspect.

The method may further comprise providing a furniture module, arranging the furniture module at a predetermined position of a fixture, activating at least two drilling units to provide corresponding assembly holes in the furniture module, wherein at least one assembly hole is conical, and controlling the respective position of the at least two drilling units during activation in relation to each other, as well as in relation to the fixture. The cone shaped axial end of the furniture part is dimensioned such that, when inserted in the conical assembly hole of the furniture module, the outer surface of the cone shaped axial end will contact the inner surface of the conical assembly hole while leaving an axial gap between the cone shaped axial end and the bottom of the conical assembly hole. In particular, a conical friction engagement may be provided between the conically shaped axial end of the furniture part and the conically shaped interior end of the pre-drilled hole of the furniture module. Preferably the sole point of contact between the axial end of the furniture part and the interior end of the pre-drilled hole of the furniture module is the respective conical surfaces. A number of advantages are thereby accomplished. First, assuming a horizontal joint (i.e. a screw is extending horizontally), vertical loads (static and/or dynamic and/or fatigue loads) during use will not act directly on the screw. Instead, the resulting furniture joint will withstand the load. Secondly, the conical joint will always be tight enough in the axial direction when the screw is tightened. Thirdly, the conical joint will also support to stabilize the construction and robustness of the furniture, as the screw will not be allowed to be easily pulled out of the furniture part.

Activating the milling unit may be performed by milling both axial ends of the furniture part, preferably the milling of both axial ends is performed simultaneously. Speed and accuracy of the milling action is thereby accomplished.

Activating the axial drilling unit may be performed by drilling both axial ends of the furniture part, preferably drilling of both axial ends is performed simultaneously. Speed and accuracy of the drilling action is thereby accomplished.

The method may further comprise connecting the cut, milled, and drilled furniture part to additional furniture parts, thereby forming a furniture module.

According to a third aspect, a method of manufacturing furniture is provided. The method comprises manufacturing a ready-to-assemble furniture module by performing the method according to the first aspect, manufacturing a ready-to-assemble furniture module according to the second aspect, and connecting the furniture modules to form the furniture. According to a fourth aspect, a system configured to manufacture a ready-to-assemble furniture module is provided. The system comprises a fixture configured to receive a furniture module at a predetermined position, and at least two drilling units configured to provide corresponding assembly holes in the furniture module, wherein the respective position of the at least two drilling units is controlled during activation in relation to each other, as well as in relation to the fixture.

The fixture may be provided with one or more clamping devices for securing the position of the furniture module. The one or more clamping devices comprises two mating V-shaped structures.

Each drilling unit may comprise a first drilling device and a second drilling device arranged on opposite sides of the furniture module.

The first drilling device may be configured with a first drilling geometry, and the second drilling device may be configured with a second drilling geometry.

The advantages of the first aspect are also applicable for this fourth aspect.

According to a fifth aspect, a system configured to manufacture a ready- to-assemble furniture module is provided. The system comprises a cutting unit, a milling unit, and a drilling unit, said units being arranged in series.

Each unit may comprise a first device and a second device, wherein the two devices of a common unit are configured to process opposite ends of an elongated furniture part, preferably simultaneously.

The advantages of the second aspect are also applicable for this fifth aspect.

Brief Description of the Drawings

The invention and its many advantages will be described in more detail below with reference to the accompanying schematic drawings, which for the purpose of illustration show some non-limiting embodiments and in which

Fig. la is an exploded view of a furniture comprising a plurality of ready-to-assemble furniture modules being manufactured by methods according to various embodiments;

Fig. lb is an isometric view of the furniture modules shown in Fig. la, in a knock-down configuration prior to assembly; Fig. 2a is an isometric view of a ready-to-assemble furniture module being manufactured by a method according to an embodiment;

Fig. 2b is an isometric view of a ready-to-assemble furniture module being manufactured by a method according to another embodiment;

Figs. 3a-b are cross-sectional views of two different furniture joints connecting two furniture modules, of which at least one furniture module is manufactured by a method according to an embodiment;

Fig. 4a is an isometric view of a system for manufacturing a ready-to- assemble furniture module according to an embodiment;

Fig. 4b is an isometric view of the system shown in Fig. 4a, omitting the drilling units;

Fig. 5a is an isometric view of a system for manufacturing a ready-to- assemble furniture module according to another embodiment;

Figs. 5b-c are side views of the system shown in Fig. 5a, in different stages of operation;

Figs. 5d-e are side views of enlarged parts of the system shown in Fig. 5a, in different stages of operation corresponding to the views shown in Figs. 5b- c;

Figs. 6a-c are top views of the system shown in Fig. 5 during different manufacturing stages;

Figs. 7a-b are schematic views of methods for manufacturing a ready-to- assemble furniture module according to different embodiments;

Fig. 7c is a schematic view of a method for manufacturing a furniture;

Figs. 8a-c are isometric views of furniture according to various embodiments;

Fig. 9a is an isometric view of pre-manufactured rattan furniture modules according to an embodiment, shown in a knock-down configuration,

Fig. 9b is an exploded view of a rattan furniture formed by the premanufactured furniture modules shown in Fig. 9a,

Figs. lOa-c are views of a radial engagement of a furniture connector according to an embodiment;

Figs, l la-c are views of another radial engagement of the furniture connector shown in Figs. lOa-c;

Fig. 12a are various views of a washer forming part of the furniture connector shown in Figs. lOa-c, and l la-c; Fig. 12b is an isometric view of a screw forming part of the furniture connector shown in Figs. lOa-c, and l la-c;

Figs. 13a-c show a radial-radial joint according to an embodiment;

Figs. 14a-b show a radial-axial joint according to an embodiment;

Figs. 15a-b show a radial-axial joint according to another embodiment;

Fig. 16a is a cross-sectional view of a radial-axial joint according to an embodiment;

Fig. 16b is a cross-sectional view of a radial-axial joint according to another embodiment; and

Fig. 17 is a schematic view of a method according to an embodiment.

Detailed Description

In Figs, la-b an example of a furniture 1 being manufactured according to an embodiment is shown. The furniture l is a chair made of a plurality of premanufactured and ready-to-assemble furniture modules 10, which are assembled to the final chair 1 by using a plurality of furniture connectors 30, as will be described further on.

Although the furniture is a chair, other furniture types could also be manufactured in line with the embodiments described herein. For example, the furniture may be a book shelf, a sofa table, etc. Although such furniture are different from each other in terms of use and construction, they would all share the common feature of having one or more furniture modules 10 comprising at least one furniture part being made of a natural material, such as rattan, round wood, etc., which makes it very difficult to control its dimensions for normal industrial furniture manufacturing processes.

In the shown example, ready-to-assemble furniture modules 10 have a frame, preferably of rattan, forming the outer boundaries of the furniture module 10. The furniture modules 10 comprises a seat 10a, a back rest 10b, and two side pieces lOc-d. Also, an elongated support beam lOe forms a ready-to-assemble furniture module 10, although it does not have the frame of the previously mentioned furniture modules lOa-d. The seat 10a, the back rest 10b, an optionally also the side pieces lOc-d may be provided with some kind of surface cover, e.g. rattan wicker or similar. The side pieces lOc-d do not only form armrests, but also the legs of the chair 1. In the erected state, as indicated in Fig. la, the rattan chair 1 is a rigid furniture providing solid support for a person using the chair 1.

The frame of each furniture module lOa-d, or at least parts thereof, represents a furniture part 20 forming part of one or more furniture joints 60 (see Figs. 3a-b) when the chair 1 is assembled. It should be noted that also the support beam lOe is considered as being a ready-to-assemble furniture module 10, even if it in the shown embodiment only has a single furniture part 20.

In order to allow the end user to assemble the ready-to-assemble furniture modules lOa-e into the final chair 1 as indicated in Fig. la, it is preferred to provide the furniture connectors 30 being adapted and optimized for connecting the furniture modules lOa-e.

Instead of a fully hand-made furniture 1 of a natural material such as rattan, it has been realized that while each furniture module lOa-e may be produced in a factory, the dimensions will not be identical due to the intrinsic properties of the material. Instead, the furniture 1 is assembled from a knocked- down configuration, as shown in Fig. lb, by an end consumer.

In order to benefit from the advantages associated with knock-down packaging and transport, each one of the pre-manufactured furniture modules lOa-e has a substantially planar shape. The term “planar” is not to be interpreted in a strict sense; a relative meaning should be applied. Hence, as an example the seat 10a and the back rest 10b are each much more planar than if they were to be connected to form an L-shape.

For this, a plurality of furniture connectors 30 are provided. As can be seen in Fig. la two furniture connectors 30 are used to connect a side piece lOc-d to the seat 10a, and one connector 30 is used to connect each side piece lOc-d to the back rest. As is further shown, the support beam lOe is connected to each side piece lOc-d by means of two furniture connectors 30. As is evident from Fig. la, a complex furniture 1 can be assembled using ready-to-assemble furniture modules lOa-e and a kit of connectors 30.

In Fig. 2a a more detailed view of a side piece lOc-d, i.e. a ready-to- assemble furniture module, is shown. The side piece lOc-d is formed by a plurality of furniture parts 20a-d. A first furniture part 20a forms an L-shape, comprising an armrest and a front leg portion. A second furniture part 20b is a linear part forming a back leg portion, being connected at its upper portion to the armrest portion of the first furniture part 20a. A third furniture part 20c forms a linear cross piece being connected to the front leg portion of the first furniture part 20a at one axial end, and to the second furniture part 20b at its opposite axial end. A fourth furniture part 20d has an U-shape and is connected to the first, second, and third furniture parts 20a-c for providing support and robustness to the furniture module lOc-d.

In the shown example, at least the furniture parts 20a-c are of rattan material. The furniture parts 20a-d extend in the same plane, such that the entire furniture module lOc-d is planar. The furniture module lOc-d is preferably premanufactured, e.g. by hand, by connecting the furniture parts 20a-d to each other.

Four radial assembly holes 40a-d are provided, all extending through respective furniture parts 20a-c in their radial direction. The first furniture part 20a is provided with a front assembly hole 40a for connecting a front part of the seat 10a, and a rear assembly hole 40b for connecting the back rest 10b. The second furniture part 20b is provided with an assembly hole 40c also for connecting the seat 10a, and the third furniture part 20c is provided with an assembly hole 40d for connecting the elongated support beam lOe. Optionally, the second furniture part 20b may be provided with an additional hole (see Fig. la) for receiving a plug of the back rest 10b in order to provide further robustness to the final furniture.

In Fig. 2b a more detailed view of a seat 10a, i.e. a ready-to-assemble furniture module, is shown. The seat 10a is formed by a plurality of furniture parts 20e-j. A front furniture part 20e and a rear furniture part 20f are linear parts, being connected at its axial end portions to side furniture parts 20g-h. Curved furniture parts 20i-j are arranged in between the front and rear furniture parts 20e-f, also being connected at its axial ends to the side furniture parts 20g- h.

In the shown example, each furniture part 20e-j is of rattan material. The furniture parts 20e-j extend essentially in the same plane, such that the entire furniture module 10a is planar. The furniture module 10a is preferably premanufactured, e.g. by hand, by connecting the furniture parts 20e-j to each other.

Four axial assembly holes 50a-d are provided, all extending into respective axial ends of furniture parts 20e-f in their axial direction. The front furniture part 20e is provided with two opposite front assembly holes 50a-b for connecting a respective front part of the side pieces lOc-d, i.e. the first furniture part 20a of the side pieces lOc-d. The rear furniture part 20f is provided with two opposite rear assembly holes 50c-d for connecting a respective rear part of the side pieces lOc-d, i.e. the second furniture part 20b of the side pieces lOc-d.

Examples of furniture joints 60 are shown in Figs. 3a-b. In Fig. 3a, the furniture joint 60 is a so called radial-axial joint 60a between two furniture modules lOc-d, and 10b or lOe. A furniture part 20a-c of the side piece lOc-d has a radial assembly hole 40a, 40c-d which is aligned with an axial assembly hole 50a-d of a furniture part 20e-f of the seat 10a, or of the cross beam 20e.

A furniture connector 30 is provided to form the robust joint 60a. The furniture connector 30 comprises a screw 32 and a washer 34.

The washer 34 is inserted into the radial assembly hole 40a, 40c-d of the furniture part 20a-c. Although the shown furniture part 20a-c has a cylindrical shape, it should be mentioned that the term “radial direction” would indicate the same, cross-longitudinal direction even if the furniture part 20a-c would have a non-circular cross-section. Once the washer 34 is positioned correctly relative the furniture part 20a-c, the screw 32 is inserted through the washer 34.

The assembly hole 40a, 40c-d can be tilted up to 15°, thereby causing a corresponding direction of the screw 32 once inserted into the assembly hole 40a, 40c-d. Importantly, this tilted configuration does not require any modification of the washer 34, or how it is inserted into the assembly hole 40a, 40c-d. Instead, the washer 34 is dimensioned to accommodate this tilting so that it will appear identical to a completely radial direction of the assembly hole 40a, 40c-d. When viewing the screw 32 from the washer 34 side, its head will appear as fully accommodated within the washer 34.

The furniture connector 30 is further described in co-pending application PCT/CN2020/116448 by the same applicant, and will not be described further herein.

In Fig. 3b, the furniture joint 60 is a so called radial-radial joint 60b between two furniture modules lOc-d, and 10b. A furniture part 20a of the side piece lOc-d has a radial assembly hole 40b which is aligned with a radial assembly hole 52 of a furniture part 20 of the back rest 10b (see also Fig. la, indicating the position of the assembly hole 52). The same furniture connector 30 may also be used for the joint 60b of Fig. 3b.

In order for the joint 60b to benefit from the advantages provided by the furniture connector 30, some details are required by the assembly holes 40a-d, 50a-d. Starting with the assembly holes 40a-d, they are all provided with an exterior conical opening section 42 for receiving a truncated cone of the washer 34. From the exterior section 42, the assembly hole 40a-d extends substantially cylindrical, i.e. to a section 44 of constant diameter. When a radial-radial joint is desired, as shown in Fig. 3b, the cylindrical section 44 of the assembly hole 40b extends through the entire furniture part 20a.

However, when a radial-axial joint 60a is desired, as shown in Fig. 3a, the assembly hole 40a, 40c-d of the furniture part 20a-c is provided with an interior section 46, forming a cone shaped exit section, such that the cylindrical section 44 of the assembly hole 40a, 40c-d is located between the exterior section 42 and the interior section 46.

The assembly holes 50a-d are entirely cylindrical, extending axially and preferably centrally, from an axial end 22 of the elongated furniture part 20e-f. The axial end 22 is tapered.

The cone shaped interior section 46 of the assembly hole 40a, 40c-d is dimensioned to receive the tapered axial end 22 of the furniture part 20e-f. When the joint 60 is formed, the tapered axial end 22 will engage with the cone shaped interior section 46 such that there will be a friction engagement between the furniture parts 20a-c, 20e-f as the screw 32 draws the furniture part 20e-f towards the washer 34.

In Fig. 4, a system 100 for manufacturing a ready-to-assemble furniture module lOc-d is shown. The system comprises a fixture 110 configured to receive the furniture module lOc-d at a predetermined position, and at least two drilling units 120a-d configured to provide corresponding assembly holes 40a-d in the furniture module lOc-d. In the shown example, four drilling units 120a-d are provided.

Each drilling unit 120a-d is configured to provide at least one assembly hole 40a-d of the furniture module lOc-d. Hence, by operating the drilling units 120a-d simultaneously, four or more assembly holes 40a-d will be formed at the same time.

As can be seen in Fig. 4, each drilling unit 120a-d comprises a first drilling device 122a-d and a second drilling device 124a-d arranged on opposite sides of the furniture module lOc-d, and configured to act vertically, in opposite directions (for illustrative purpose the second drilling device 124b is slightly rotated relative the first drilling device 122b of the same drilling unit 120b).

The drilling devices 122a-d, all arranged on the same vertical side of the fixture 110, are preferably identical and configured to provide a drilling geometry resulting in the exterior conical section 42 of the assembly hole 40a-d, as well as the cylindrical section 44 of the assembly hole 40a-d. The drilling devices 122a-d are for this purpose provided with a drill bit 123 having an inner conical drill bit 123a that is extending axially to a cylindrical drill bit 123b. When a drilling device 122a-d is activated, the cylindrical part 123b of the drill bit 123 will cause a cylindrical hole, and as the conical drill bit 123a engages with the furniture module lOc-d the exterior cone section 42 of the assembly hole 40a-d will be formed.

The drilling devices 124a-d, all arranged on the same vertical side of the fixture 110 but opposite the drilling devices 122a-d, are not necessarily identical. In the shown example, two of the drilling devices 124a, 124c are identical and provided with a conical drill bit 125a which, when activated, will provide the cone shaped interior section 46 of the resulting assembly hole 40a, 40c.

The drilling device 124b, vertically aligned with the drilling device 122b, is preferably different from drilling devices 124a, 124c. In the shown example the drilling device 124b is provided with a rectangular drill chuck 126a instead of the round drill chucks 126b provided on the other drilling devices 124a, 124c, and 124d. The rectangular drill chuck 126a is connected to a conical drill bit 125a which, when activated, will provide the cone shaped interior section 46 of the resulting assembly hole 40b. The rectangular drill chuck 126a is also provided with a cylindrical drill bit 125b arranged at a distance from the conical drill bit 125a. When the drilling device 124b is activated, the cylindrical drill bit 125b will cause a cylindrical hole in the furniture module lOc-d, and the conical drill bit 125a will cause an interior cone section 46 of the assembly hole 40b of the furniture module lOc-d, spaced apart from the cylindrical hole caused by the cylindrical drill bit 125b. The cylindrical drill bit 125b is thus adapted to form a cylindrical hole; while the resulting hole may extend through the furniture module lOc-d for the purpose of forming a radial-radial joint 60b, in a preferred embodiment the cylindrical hole is only partially extending in the furniture module lOc-d for the purpose of fitting a pin for extra support.

The drilling device 124d is provided with only a cylindrical drill bit 125b, as the resulting assembly hole 40b is intended to form a radial-radial joint 60b, where there is no need for a cone shaped interior section 46.

The respective position of each drilling units 120a-d is controlled during activation in relation to the fixture 110. Also, there is a fixed position at least between the drilling units 120a-b which are forming the assembly holes 40a-b for connecting the seat 10a to the side pieces lOc-d. If there are variations in dimensions between different side pieces lOc-d, the assembly holes 40a-d would be arranged at different positions on the different side pieces lOc-d if the positions of the drilling units 120a-d were set in relation to positions of the furniture modules lOc-d. However, as the drilling units 120a-d are fixed in position in relation to the fixture 110, as well as in relation to each other, the assembly holes 40a-d will always be in correct position for forming the joints 60.

Especially, as the seat 10a requires two joints 60 for each side piece 10c- d, the fixed position between the drilling units 120a-b will always ensure that the seat 10a can be properly connected to the side pieces lOc-d.

In order to ensure correct positioning of the furniture module lOc-d, the fixture 110 is provided with one or more clamping devices 112 for securing the position of the furniture module. The clamping devices 112 are preferably in the form of vertically adjustable members, having a V-shaped cavity facing the furniture module lOc-d. The V-shaped cavity is particularly advantageous when the furniture part to be clamped is cylindrically shaped.

The clamping devices 112 are further shown in Fig. 4b. Especially at the left end of Fig. 4b it can be seen that the furniture module lOc-d is effectively retained in a V-shaped cavity of a V-shaped clamping structure 112a and clamped by the clamping device 112. Optionally, and as illustrated in Fig. 4b, the fixture 110 may be provided with a stationary and mating V-shaped structure 112b. If the furniture module lOc-d is positioned relative the fixture 110, but not fit perfectly with the mating V-shaped structures 112a-b, activation of the clamping device 112 will force the furniture module lOc-d into the correct position as it will be urged to fit inside the cavity. Hence, activation of a clamping device 112 will cause the V-shaped cavity to move vertically downwards until it engages with the furniture module lOc-d, thereby clamping it to the fixture 110.

Clamping the furniture module lOc-d by means of a clamping device having a V-shaped cavity is particularly advantageous for rattan material or other round/cylindrical material. Especially for rattan material the above-mentioned clamping operation is of particular advantage; while rattan material has a generally circular cross-section, it is rarely a perfect circle. Yet further, the diameter of a rattan piece normally varies within certain ranges leaving the tolerances comparatively large compared to other processed materials. Clamping, of the type described above, will efficiently compensate for any variations in the rattan material outer periphery and ensure the furniture module is correctly located thereby improving robustness and predictability of the manufacturing process.

Correct positioning of the furniture module lOc-d may further be accomplished by the fixture 110 having two spaced-apart, and optional, reference positions 114a-b. These reference positions 114a-b are formed as stops, to which specific parts, in the shown example the ends of the U-shaped furniture member 20d adjacent to the feet of the side piece lOc-d, of the furniture module lOc-d may be arranged in contact with. In order to avoid over-definition of the position of the furniture module lOc-d, the reference positions 114a-b could be omitted. In such case, which may be preferred, the furniture module lOc-d may be provided with an additional length of its legs, which are subsequently cut to the desired length post drilling.

As can be seen in Fig. 4 the fixture 110 has the shape of a wedge, forming a planar surface 116 being tilted relative the horizontal plane Z. As the drilling units 120a-d are acting in a vertical direction, the resulting assembly holes 40a-d will non-perpendicular in relation to the plane of the furniture module lOc-d. The fixture 110 is further provided with channels 118 extending through the fixture 110. The channels 118 are aligned with the drilling units 120a-d so that the drill bits 123a-b, 125a-b will not engage with the fixture 110 but instead be allowed to pass through the channels 118.

While the system 100 described with reference to Fig. 4 is suitable for forming radial assembly holes 40a-d, in Fig. 5a a system 200 configured to form axial assembly holes 50a-d is shown.

The system 200 comprises a feeding station 210, receiving one or more elongated furniture parts 20e-f. In relation to the chair 1 described throughout this specification, the furniture parts 20e-f will eventually form part of the seat 10a when connected to additional furniture parts 20g-j, or the furniture part 20e-f will per se form the ready-to-assemble furniture module lOe (see Fig. la).

The system 200 further comprises a transport device 220 being configured to carry a single furniture parts 20e-f from the feeding station 210 to downstream units 230, 240, 250.

These downstream units comprise a cutting unit 230, a milling unit 240, and a drilling unit 250, arranged in series. Each unit 230, 240, 250 comprises two devices 232a-b, 242a-b, 252a-b (see Figs. 6a-c) arranged on opposite sides of the transport device 220 and aligned in the transport direction L in order for the cutting unit 230, milling unit 240, and drilling unit 250 to act on both axial ends of the furniture part 20e-f.

The transport device 220 is further shown in Figs. 5b-c. On each lateral side of the system 200 a clamping unit 221 is provided (while both clamping units 221 are shown in Fig. 5a, only one clamping unit 221 is shown in Figs. 5b- c). Each clamping unit 221 has a fixed vertical position, and comprises two opposite V-shaped clamping devices 221a-b facing each other and being moveable relative each other. In the position shown in Fig. 5b the clamping devices 221a-b are arranged at a longitudinal distance from each other being large enough to allow for a furniture part 20e-f to fall down and position itself between the clamping devices 221a-b.

Before longitudinal activation of the transport device 220, i.e. before the transport device 220 starts moving to carry the furniture part 20e-f towards the downstream units, the clamping devices 221a-b are controlled to move towards each other in order to clamp the furniture part 20e-f and to secure its position relative the transport device 220. Either one, or both of the clamping devices 221a-b may be moved to accomplish the clamping action, as shown in Fig. 5c.

An embodiment of a clamping unit 221 is shown in further details in Figs. 5d-e. At least one of the clamping devices 221a-b of the clamping unit 221 may be driven by an actuator 221c, causing a linear movement of the associated clamping device 221a-b towards the opposite clamping device 221a-b. The two clamping devices 221a-b of a common clamping unit 221 may be connected by a transmission 22 Id; in the shown embodiment the transmission 22 Id is in the form of two racks 22 le in engagement with a pinion 22 If. Each rack 22 le is connected to an associated clamping device 221a-b, and due to their mutual connection by means of the pinion 22 If a centralized clamping action will always be effected when any actuator 221c is actuated.

Other types of clamping units 221 (or clamping devices 221a-b) may be used for providing a secure positioning of the furniture part 20e-f relative the transport device 220. For example, the V-shaped clamping devices 221a-b may be replaced by one or more chucks (not shown), configured to hold the furniture part 20e-f with radial symmetry. The chuck may typically be provided with chuck jaws arranged in a radially symmetrical pattern, which upon tightening (i.e. a radial motion inwards) will provide the desired clamping effect. One chuck, arranged at one axial end of the furniture part 20e-f, may be sufficient to secure the position of the furniture part 20e-f. The opposite axial end of the furniture part 20e-f may be supported by other fixation means, such as a live center. In other embodiments there may be one chuck at each axial end of the furniture part 20e-f.

In Figs. 6a-c operation of the system 200 is shown. Starting in Fig. 6a, the transport device 220 is driving the clamped furniture part 20e-g along a transport path 222. When reaching the position of the cutting unit 230, the transport device 220 is temporarily stopped to allow the cutting unit 230 to operate on the furniture part 20e-f. The cutting devices 232a-b are preferably stationary, but are provided with rotary cutting blades 234 that causes axial cuts of the furniture part 20e-f. The final length of the furniture part 20e-f is thus defined by the distance between the two cutting blades 234.

In Fig. 6b, the transport device 220 is driving the furniture part 20e-g along a transport path 222 away from the cutting unit 230 to the downstream milling unit 240. When reaching the position of the milling unit 240, the transport device 220 is again temporarily stopped to allow the milling unit 240 to operate on the furniture part 20e-f. The milling devices 242a-b are driven to be able to move towards and away from the respective axial ends of the furniture module 20e-f, and in the shown position the milling devices 242a-b have moved to engage with the furniture module 20e-f. Each milling device 242a-b is provided with a mill tool 244 that causes conical re-shaping of the axial ends of the furniture part 20e-f. Hence, the milling unit 240 is configured to form the tapered axial end 22 of the furniture part 20e-f.

In Fig. 6c, the transport device 220 is driving the furniture part 20e-g further along the transport path 222, away from the milling unit 240 to the downstream drilling unit 250. When reaching the position of the drilling unit 250, the transport device 220 is again temporarily stopped to allow the drilling unit 250 to operate on the furniture part 20e-f. As for the milling devices 242a-b, the drilling devices 252a-b are also driven to be able to move towards and away from the respective axial ends of the furniture module 20e-f and in the shown position the drilling devices 252a-b have moved to engage with the furniture module 20e-f. Each drilling device 252a-b is provided with a drill tool 254 (see also Fig. 6b) that upon activation causes an axial hole at the axial end of the furniture part 20e-f, i.e. the assembly hole 50a-d.

When the drilling action is completed, the furniture part 20e-f is released from the transport device 220. The furniture part 20e-f may subsequently be connected to additional furniture parts 20g-j in order to form a ready -to-assemble furniture module 10a, or the furniture part 20e-f may be used directly as a ready - to-assemble furniture module lOe in the form of a cross bar, or similar furniture components.

Now turning to Fig. 7a, a method 300 for manufacturing a ready-to- assemble furniture module lOc-d will be described. The method 300 is preferably performed using a system 100 as described with reference to Fig. 4.

In a first step 302, a semi-finished furniture module is provided. In the example described above, the semi-finished furniture module corresponds to a side piece lOc-d having no assembly holes 40a-d. Hence, at this point the furniture module is in a not yet ready-to-assemble configuration. In a subsequent step 304 the furniture module is arranged at a predetermined position of a fixture 110. The method 300 is further comprising a step 306 of activating at least two drilling units 120a-d to provide corresponding assembly holes 40a-d in the furniture module. A step 308 is further performed by controlling the respective position of the at least two drilling units 120a-d during activation in relation to each other, as well as in relation to the fixture 110.

Another method 310 for manufacturing a ready-to-assemble furniture module 10a, lOe is described with reference to Fig. 7b. The method 310 is preferably performed using a system 200 as described with reference to Figs. 5-6.

The method 310 is comprising a first step 312 of providing an elongated furniture part. In a subsequent step 314, a cutting unit 230 is activated to cut the furniture part to a desired length, and a subsequent step 316 is performed by activating a milling unit 240 to shape an axial end of the furniture part, preferably into a truncated cone shape. A step 318 is thereafter performed by activating an axial drilling unit 250 to provide at least one assembly hole 50a-d at the axial end of the furniture part.

The method 310 may further comprise a final step 320 of connecting the furniture part to additional furniture parts, thereby forming a ready-to-assemble furniture module. Such ready-to-assemble furniture module may e.g. be a seat 10a of a rattan chair 1 as explained above.

Another method 330 is shown in Fig. 7c. This method 330 is performed for manufacturing a furniture. The method 330 comprises manufacturing a ready- to-assemble furniture module by performing the method 300, as well as performing the method 310. The method 330 further comprises a step 332 of connecting the furniture modules resulting from methods 300 and 310 to form the furniture. The examples described above allow for a much improved assembly of partly handmade furniture, even when deviations in dimensions are significant and where the tolerances are beyond standard specifications for industrial processes. Especially, the described systems and methods are useful for manufacturing ready-to-assemble furniture modules, which allow for knockdown packaging and distribution of furniture of natural material of varying dimensions, such as rattan.

In the following, examples of such furniture and components thereof will be described. Such furniture and furniture components are preferably and advantageously provided, at least in part, using the above described methods and systems. Although such furniture and furniture components can be manufactured by various methods and systems, it is preferred to combine the manufacturing systems and methods described above with the concepts described in the following.

With regards to furniture and furniture components, it is an object to provide furniture which can be assembled from a knock-down configuration of pre-manufactured furniture parts having certain variations in dimensions, as well as components and methods thereof.

According to an aspect a furniture connector is provided. The furniture connector is configured to establish attachment between two pre-manufactured furniture parts, and comprises a screw, and a washer. The washer is configured to receive the screw and it comprises a plate having a radius, and a through hole arranged in said plate, wherein the periphery of said through hole extends into a truncated cone in a direction away from said plate. The furniture connector will provide support to the strength of a furniture joint as the head of screw will be prevented to cut into or go into the furniture part, which is particularly advantageous for rattan furniture due to non-controllable variations of rattan density.

The plate of the washer may be circular, square, rectangular, elliptical and have other outer shapes as well. The plate is bent, preferably to a curvature having a radius similar to that of the furniture part to which it is to be mounted, and an even embracing of the associated furniture part along the outer surface, having a rounded shape, is thereby accomplished.

The outer dimension of the plate, such as the diameter in case of a circular plate or the side in case of a triangular, square or rectangular plate, may be between 1.5 and 4 cm, preferably between 2 and 3 cm and, more preferably between 2.4 and 2.6 cm. This has proven to be particularly advantageous for pole-shaped rattan furniture parts.

The apex angle of the truncated cone of the washer may be between 40° and 80°, preferably between 55° and 65°. The screw head will thereby be fully accommodated by the washer.

The length of the truncated cone of the washer may be between 2 and 10 mm, preferably between 4 and 6 mm. The screw head may thereby fit inside the truncated cone, while still allowing different angle of extension of the screw.

The radius of the bending of the plate may be between 5 and 35 mm, preferably between 8 and 32 mm, more preferably between 10 and 25 mm, even more preferably between 15 and 20 mm. This has proven to fit well with poleshaped furniture parts, in particular when used for rattan furniture.

The screw may comprise a screw head, a threaded portion, and a nonthreaded portion arranged between the screw head and the threaded portion.

The screw head may be tapered. This configuration will provide improved engagement with the washer, especially allowing for different angles of the screw relative the orientation of the washer.

The length of the optional non-threaded portion of the screw may be between 5 and 30 mm, preferably between 10 and 25 mm, such as 20 mm. An improved engagement of the screw with the two furniture parts is thereby accomplished, and reduced complexity of manufacturing is accomplished as the threads does not extends along the full length of the screw. Another advantage is that the non-threaded portion, due to its smaller diameter compared to the threaded portion, will allow for deviations of the angle of the screw relative the washer.

The thread pitch of the threaded portion of the screw may be between 2 and 4 mm, preferably between 2 and 3 mm. The major diameter of the threads of the screw may be between 4 and 8 mm, preferably between 5 and 7.5 mm, and even more preferably between 5.5 and 7 mm. The minor diameter of the threads of the screw may be between 3 and 6 mm, preferably between 3.5 and 5.5 mm, and even more preferably between 4.0 and 4.5 mm. These dimensions, alone or in combination, have proven to provide excellent engagement with the material of the furniture parts, especially if at least one of the first and second furniture parts is made of rattan.

According to another aspect, a kit for forming a furniture joint is provided. The kit comprises a furniture connector according to the first aspect, a first furniture part and a second furniture part. The screw of the furniture connector is arranged to be inserted in a pre-drilled hole of the first furniture part and to be screwed into a pre-drilled hole of the second furniture part, thereby attaching the first furniture part to the second furniture part.

The pre-drilled hole of the first furniture part has an exterior end arranged to be opposite to the second furniture part and which may have a conical shape, and the cone of the washer may be configured to be received by the exterior end of the pre-drilled hole of the first furniture part. Hence, the washer will fit within the pre-drilled hole, thereby providing a robust accommodation of the force of the screw.

The pre-drilled hole of the first furniture part may extend in a radial direction of a rounded portion of the first furniture part. This allows the furniture parts to be connected to each other at a right angle.

The screw may extend in the radial direction of a rounded portion of the first furniture part, the rounded portion being tilted an angle from being perpendicular to the longitudinal direction of the screw, preferably the angle P being within, ± 15°. Hence, the furniture parts may be connected at different angles while still allowing the washer to be flush with the first furniture part.

Instead of extending in the radial direction, the screw may extend in a tangential direction of a rounded portion of the first furniture part. By tangential is means possibly out of centre, but still perpendicular to the fibre direction of the rounded portion of the first furniture part.

The pre-drilled hole of the second furniture part may extend in a radial direction of the second furniture part, or the pre-drilled hole of the second furniture part may extend in an axial direction of the second furniture part. Different joints are thereby allowed, using the same furniture connector.

The pre-drilled hole of the second furniture part may extend from an axial end of the second furniture part, wherein said axial end may have a conical shape. Having a tapered end allows for facilitated alignment of the second furniture part relative the first furniture part.

The pre-drilled hole of the first furniture part may have an interior end arranged adjacent to the second furniture part and having a conical shape, and the axial end of the second furniture part may be arranged to be at least partly received by the interior end of the pre-drilled hole of the first furniture part. This provides for improved connection between the first and second furniture parts. In particular, a conical friction engagement may be provided between the conically shaped axial end of the second furniture part and the conically shaped interior end of the pre-drilled hole of the first furniture part. Preferably the sole point of contact between the axial end of the second furniture part and the interior end of the pre-drilled hole of the first furniture part being the respective conical surfaces. A number of advantages are thereby accomplished. First, assuming a horizontal joint (i.e. the screw is extending horizontally), vertical loads (static and/or dynamic and/or fatigue loads) during use will not act directly on the screw. Instead, the furniture joint will withstand the load. Secondly, the conical joint will always be tight enough in the axial direction when the screw is tightened. Thirdly, the conical joint will also support to stabilize the construction and robustness of the furniture, as the screw will not be allowed to be easily pulled out of the furniture parts.

The conically shaped axial end of the second furniture part and the conically shaped interior end of the pre-drilled hole of the first furniture part may thus be designed such that after mounting, an axial gap is provided between the edge of the axial end and the inner end of the interior end.

The axial length of the axial gap may be in the range of 0.5-4 mm, preferably in the range of 1-2 mm.

At least one of the first furniture part and the second furniture part may be at least partly made of rattan. Furthermore, both the first and the second furniture parts may be made from rattan.

The second furniture part may be provided with a dowel extending across the path of the pre-drilled hole of the second furniture part, preferably the dowel is made from a wooden material, more preferably a wood fiber direction of the dowel extends in a direction being perpendicular to the longitudinal direction of the screw. Hence, the strength of the screw connection is increased.

According to a further aspect, a piece of furniture is provided, comprising at least one kit forming a furniture joint according to the second aspect.

At least one of the first and second furniture parts may be made of rattan, or other plant-based species, such as monocots or bamboo.

The first and/or the second furniture part may form part of premanufactured furniture modules, wherein the furniture modules may have a planar shape. Preferably the piece of furniture is entirely made up furniture modules having a planar shape and/or being arranged for being flat-packed. This allows the furniture to be pre-manufactured in modules, and flat-packed to a customer which performs final assembly of the piece of furniture using the furniture connector described earlier.

The piece of furniture may comprise a plurality of pre-manufactured furniture modules forming a seat, a back piece, and two side pieces, respectively, wherein at least one furniture module comprises a first furniture part, and at least one furniture module comprises a second furniture part.

According to a yet further aspect, a method for manufacturing a piece of furniture suitable for being flat-packed is provided. The method comprises i) providing at least two pre-manufactured furniture modules, wherein at least one furniture module comprises a first furniture part, and at least one furniture module comprises a second furniture part, and ii) providing at least one furniture connector according to the first aspect, and/or at least one kit for forming a furniture joint, wherein said first and second furniture parts are configured to be connected by means of said at least one furniture connector and/or by means of said kit.

Starting in Figs. 8a-c, different furniture lOOla-c are shown. In Fig. 8a a shelf 1001a is shown; in Fig. 8b a chair 1001b is shown; and in Fig. 8c a sofa table 1001c is shown. Although these furniture lOOla-c are very different from each other in terms of use and construction, they could all be manufactured so that they share the common feature of having one or more furniture modules 1010 comprising at least one furniture part 1020 being made of a natural material, such as rattan, round wood, etc., which makes it impossible to control its dimensions for normal industrial furniture manufacturing processes.

In Figs. 9a-b, a more detailed example of a furniture 100 Id according to an embodiment is shown. The furniture 100 Id is a chair made of a plurality of pre-manufactured furniture modules 1010, which are assembled to the final chair 100 Id by using a plurality of furniture connectors 1030, as will be described further on.

In Fig. 9a the furniture modules 1010 are shown in a flat, or knocked- down configuration. The furniture modules 1010 comprise a seat 1010a, a back rest 1010b, and two side pieces lOlOc-d. Importantly, in order to benefit from the advantages associated with know-down packaging and transport, each one of the pre-manufactured furniture modules 1010 has a substantially planar shape. The term “planar” is not to be interpreted in a strict sense; a relative meaning should be applied. Hence, as an example the seat 1010a and the back rest 1010b are each much more planar than if they were to be connected to form an L-shape. In the shown example, each pre-manufactured furniture module 1010 has a rattan frame, forming the outer boundaries of the pre-manufactured furniture module 1010. The seat 1010a and the back rest 1010b, and optionally also the side pieces lOlOc-d, may however be provided with some kind of surface cover, e.g. rattan wicker or similar.

The side pieces lOlOc-d do not only form armrests, but also the legs of the chair Id. In the erected state, as indicated in Fig. 9b, the rattan chair 100 Id is a rigid furniture providing solid support for a person using the chair 100 Id.

The rattan frame of each furniture module lOlOa-d, or at least parts thereof, represents a furniture part 1020 forming part of one or more furniture joints (see Figs. 13-16) together with the furniture connectors 1030.

In order to allow the end user to assemble the pre-manufactured furniture modules 1010 into the final chair 101 d as indicated in Fig. 9b, it is necessary to provide the furniture connectors 1030 being adapted and optimized for connecting furniture parts 1020.

Instead of a fully hand-made rattan furniture, it has been realized that while each furniture module 1010 may be produced in a factory, the dimensions will not be identical due to the intrinsic properties of the material. Hence, prior art connectors cannot be used to assemble the furniture modules 1010, as these connectors require tight tolerances. Instead, as can be seen in Fig. 9b, the furniture lOOld is assembled from a knocked-down configuration, as shown in Fig. 9a, by an end consumer.

For this, a plurality of furniture connectors 1030 are provided. As can be seen in Fig. 9b two furniture connectors 1030 are used to connect a side piece lOlOc-d to the seat 1010a, and one connector 1030 is used to connect each side piece lOlOc-d to the back rest. As is further shown, a cross beam lOlOe is connected to each side piece lOlOc-d by means of two furniture connectors 1030. As is evident from Fig. 9b, a complex furniture 100 Id can be assembled using similar, however not necessarily identical, connectors 1030.

In Figs. 10-11, the furniture connector 1030 is shown in further details, together with a furniture part 1020 for facilitating the understanding of the furniture connector 1030 operates. Starting in Figs. lOa-b, each furniture connector 1030 comprises a screw 1032 and a washer 1034.

The washer 1034 is inserted into a pre-drilled hole 1022 of the furniture part 1020, which extends in the radial direction of the furniture part 1020. Although the shown furniture part 1020 has a cylindrical shape, it should be mentioned that the term “radial direction” would indicate the same, crosslongitudinal direction even if the furniture part 1020 would have a non-circular cross-section. Once the washer 1034 is positioned correctly relative to the furniture part 1020, the screw 1032 is inserted through the washer 1034 as shown in Fig. 10b. As shown in Fig. 10c, due to the direction of the pre-drilled hole 1022, the screw 1032 will protrude out from the furniture part 1020 at 90° relative the longitudinal, axial direction.

The same screw 1032 and washer 1034 are shown in Figs, l la-c. However, in this embodiment the pre-drilled hole 1022 of the furniture part 1020 is tilted by 15°, thereby causing a corresponding direction of the screw 1032 once inserted into the pre-drilled hole 1022. Importantly, this tilted configuration does not require any modification of the washer 1034, or how it is inserted into the pre-drilled hole 1022. Instead, the washer 1034 is dimensioned to accommodate this tilting so that it will appear identical to a completely radial direction of the pre-drilled hole 1022, as shown in Figs. lOa-c. When viewing the screw 1032 from the washer 1034 side, its head will appear as fully accommodated within the washer 1034.

The washer 1034 is further shown in Fig. 12a. The washer 1034 has a plate 1034a, being bent to exhibit a radius R. In the shown example, the plate 1034a is bent to form a semi-cylindrical body (e.g. by bending the plate around a cylindrical body). The plate 1034a is circular, however other shapes are also possible such as rectangular, square, elliptical, triangular or any other suitable shape.

A through hole 1034b is provided, preferably at the center of the plate 1034a, and a circular tapered sidewall 1034c extends from the periphery of the through hole 1034b, in the same direction as the curvature of the plate 1034a. Hence, the periphery of the through hole 1034b extends into a truncated cone 1034c in a direction away from the plate 1034a.

Examples of suitable dimensions are as follows. The diameter DI of the plate 1034a, when circular, is preferably in the range of 15 - 40 mm, even more preferably about 25 mm. The curvature of the plate 1034a is made with a radius R of approximately 12-20 mm. The diameter D2 of the through hole 1034b is approximately 15 mm, and the tapered angle a, i.e. the apex angle, of the truncated cone 1034c is about 60° such that the distal diameter D3 of the truncated cone 1034c, when the truncate cone 1034c has a length L of about 5 mm, is about 9 mm. An example of a screw 1032 forming part of the furniture connector 1030 is shown in Fig. 12b. The screw 1032 has a countersunk head 1032a, whereby the countersunk angle is approximately 45°. The height of the screw head 1032a is about 3,5 mm, followed by a non-threaded upper portion 1032b. The diameter of the upper portion 1032b is approximately 4-6 mm, and the length of the nonthreaded portion 1032b is about 15 mm. The screw 1032 has a threaded section 1032c having a length of approximately 35 to 70 mm, depending on the total length of the screw 1032. For the above lengths for the threaded section 1032c, the total length of the screw 1032 (i.e. the total length of the threaded section 1032c, the upper portion 1032b, and the head 1032a) is between 40 and 100 mm.

Preferably, the screw 1032 has a sharp apex 1032d in order to compensate for deviations in drilling tolerances of the furniture parts 1020 and to improve guiding of the screw 1032.

The thread pitch of the threaded portion 1032c is preferably approximately 2.4 mm; it has been discovered that such thread pitch will cut less fibers if the furniture parts 1020 are made of rattan.

Another characteristic of the screw 1032 is the significant difference between the major diameter of the threads and the minor diameter of the threads, which provides additional advantages in case the associated furniture part 1020 is made of rattan. As rattan is relatively soft, the material can easily be damaged if the grip of the material is not strong enough, leading to overturning of the screw 1032. In the shown example, the major diameter MD of the threads is about 6.3 mm, while the minor diameter mD of the threads is about 4.4 mm. The ratio between the major diameter MD of the threads and the minor diameter mD of the threads is thereby in the range of 1.2-2.0, preferably 1.4-1.7, such as around 1.58. The thread angle is approximately 40°.

Now turning to Figs. 13a-c, operation of the furniture connector 1030 is shown according to a first example. Here, the furniture connector 1030 forms a furniture joint 1040 together with two associated furniture parts 1020a-b. As can be seen in Fig. 13a, the furniture connector 1030 is used to rigidly connect a first furniture part 1020a to a second furniture part 1020b in a radial-radial configuration.

Each furniture part 1020a-b forms part of a respective furniture module 1010, as explained earlier with reference to Figs. 9a-b.

As is further shown in Figs. 13b-c, the first furniture part 1020a is provided with a pre-drilled hole 1022 extending through the first furniture part 1020a in a radial direction, i.e. perpendicular to the axial direction of the first furniture part 1020a. The pre-drilled hole 1022 of the first furniture part 1020a is provided with an exterior conical opening section 1022a for receiving the truncated cone 1034c of the washer 1034. From the exterior section 1022a, the pre-drilled hole 1022 extends substantially cylindrical, i.e. to a section 1022b of constant diameter.

The second furniture part 1020b is also provided with a pre-drilled hole 1024, also extending in the radial direction of the second furniture part 1020b. The pre-drilled hole 1024 of the second furniture part 1020b does not extend entirely through the second furniture part 1020b. The diameter of the pre-drilled hole 1024 of the second furniture part 1020b is less than the diameter of the predrilled hole 1022 of the first furniture part 1020a, in particular less than of the cylindrical section 1022b.

The screw 1032 is dimensioned such that it will not grip the first furniture part 1020a, but it can be inserted freely into the pre-drilled hole 1022 of the first furniture part 1020a. When the screw 1032 reaches the pre-drilled hole 1024 of the second furniture part 1020b, the threads will grip the material of the second furniture part 1020b and the screw 1032 can be inserted until the screw head reaches the truncated cone of the washer 1034. As the screw 1032 is further tightened, the second furniture part 1020b will be drawn towards the first furniture part 1020a to establish a firm connection between the first and second furniture parts 1020a-b.

Another example of a furniture joint is shown in Figs. 14a-b. Here, the first furniture part 1020a is almost identical to the first furniture part 1020a of Figs. 13a-c. The connector 1030 is also very similar, although the threaded portion of the screw 1032 can be made longer than what was shown in Figs. 13a- c.

Further, the second furniture part 1020b is in this embodiment quite different from the second furniture part 1022b of Figs. 13a-c, as the second furniture part 1020b is intended to be connected in its axial direction, rather than in a radial direction.

The pre-drilled hole 1024 of the second furniture part 1020b is extending axially, and preferably centrally, from an axial end 1026 of the second furniture part 1020b. The axial end 1026 is tapered, preferably by an angle 6 of approximately 10-20°, such as 15°. As is clear from Fig. 14b, the pre-drilled hole 1022 of the first furniture part 1020a is provided with an interior section 1022c, forming a cone shaped exit section, such that the cylindrical section 1022b of the pre-drilled hole 1022 is located between the exterior section 1022a and the interior section 1022c.

The cone shaped interior section 1022c is dimensioned to receive the tapered axial end 1026 of the second furniture part 1020b. When the joint 1040 is formed, as shown in Fig. 14b, the tapered axial end 1026 will engage with the cone shaped interior section 1022c such that there will be a friction engagement between the first and second furniture parts 1020a-b as the screw 1032 draws the second furniture part 1020b towards the washer 1034.

Preferably, the dimensions of the tapered axial end 1026 and the cone shaped interior section 1022c are designed such that there will be an axial gap 1028 between the edge of the axial end 1026 and the inner end of the interior section 1022c. This axial gap 1028 ensures that there will in fact be a friction engagement on the side walls of the end section 1026, rather than an axial fixation between the two furniture parts 1020a-b. The axial gap 1028, preferably being in the range of 0.5-4 mm, such as 1-2 mm in the axial direction, also secures manufacturing tolerance and facilitated customer assembly. However, most important the axial gap 1028 ensures that vertical loads during use (either static or fatigue load) will not affect directly on the screw 1032, but instead the furniture joint 1040 will withstand the load.

The axial gap 1028 thus provides for a connection where the sole point of contact between the axial end 1026 of the second furniture part 1020b and the interior section 1022c of the pre-drilled hole 1022 of the first furniture part 1020a is the respective conical surfaces.

Figs. 15a-b show another example of a furniture joint 1040, using two furniture parts 1020a-b and a furniture connector 1030. In this example, the first furniture part 1020a and the furniture connector 1030 are identical to what has been described with reference to Figs. 14a-b. The second furniture part 1020b is provided with a radial hole 1029a at a certain axial distance from the axial end 1026; the distance is selected such that the screw 1032 will be extending through the radial hole 1029a when the joint 1040 is assembled.

The radial hole 1029a is fitted with a dowel 1029b. The dowel 1029b is preferably provided with a through hole 1029c, extending in the axial direction of the second furniture part 1020b, but in the radial direction of the dowel 1029b. Depending on how critical the furniture joint 1040 is, the cross dowel 1029b can be added to strengthen the connection of the screw 1032 as the screw 1032 will in fact grip into the drilled hole 1029c of the dowel 1029b. Also, in case of rattan material of the second furniture part 1020b, the fiber direction of the rattan part 1020b will be axial. Thanks to the fiber direction of the dowel 1029b, which is in the axial direction of the dowel 1029b and hence perpendicular to the fiber direction of the furniture part 1020b, the dowel 1029b will improve the attachment of the screw 1032. The cross dowel 1029b may e.g. be made of rattan or solid wood.

A comparison between two furniture joints 1040 is shown in Figs. 16a-b. The first example, shown in Fig. 16a, is identical to the furniture joint 1040 of Fig. 15b. The furniture joint 1040 is forming a perpendicular connection between the first furniture part 1020a and the second furniture part 1020b, as the predrilled hole 1022 of the first furniture part 1020a extends in the radial direction only, i.e. perpendicular to the axial direction of the first furniture part 1020a.

In Fig. 16b the pre-drilled hole 1022 of the first furniture part 1020a is tilted by an angle P of approximately 15° relative the radial direction of Fig. 16a. This means that the first furniture part 1020a is tilted by the same angle P relative the vertical direction, assuming that the second furniture part 1020b is in a horizontal orientation. The washer 1034 will still accommodate the screw head 1032a entirely, as clearly shown in Fig. 16b which means that the furniture connector 1030, comprising the screw 1032 and the washer 1034, will work perfectly even if the furniture joint 1040 is not perpendicular.

Before turning to Fig. 17, it has been described above that the furniture connector 1030 is particularly suitable for use with rattan furniture, and for furniture parts 1020a-b being made of rattan.

Rattan is a generally soft material. The density of a rattan piece is not constant in the radial direction, but the outer layer is much harder and stiffer as compared to the core material, which generally has a lower density. The furniture connector 1030 described herein has proven to be particularly advantageous not only for rigidly connecting two rattan pieces, i.e. two furniture parts 1020a-b being made of rattan, but also to accommodate variations in dimensions of the furniture parts 1020a-b.

In Fig. 17, a schematic view of a method 1100 for manufacturing a furniture is shown. The method 1100 is performed by a first step 1102 of providing at least two pre-manufactured furniture modules 1010, wherein at least one furniture module 1010 comprises a first furniture part 1020a, and at least one furniture module 1010 comprises a second furniture part 1020b. A second step 1104 is subsequently performed by providing at least one furniture connector 1030 as described above, wherein said first and second furniture parts 1020a-b are configured to be connected by means of said at least one furniture connector 1030.

As a final assembly step, the method 1100 may also involve a step 1106 of connecting the furniture modules 1010 by means of at least one furniture connector 1030.

The examples described above allow for a much improved assembly of partly handmade furniture, even when deviations in dimensions are significant and where the tolerances are beyond standard specifications for industrial processes. Especially, the furniture connector 1030 provides for a robust connection of the pre-manufactured furniture modules 1010, which allows for knock-down packaging and distribution of furniture lOOla-d of natural material of varying dimensions, such as rattan.

Various aspects of the present invention may be appreciated from the following enumerated example embodiments (EEE’s), which may be combined with the aspects defined by the appended claims:

EEE1. A furniture connector (1030) for establishing attachment between two pre-manufactured furniture parts (1020a-b), said furniture connector (1030) comprising a screw (1032), and a washer (1034) configured to receive the screw (1032) and comprising a plate (1034a) having a radius (R), and a through hole (1034b) arranged in said plate (1034a), wherein the periphery of said through hole (1034b) extends into a truncated cone (1034c) in a direction away from said plate (1034a).

EEE2. The furniture connector (1030) according to EEE1, wherein the plate (1034a) of the washer (1034) is circular, rectangular, square, triangular or elliptical.

EEE3. The furniture connector (1030) according to any of the preceding EEEs, wherein the outer dimension, such as the diameter (DI), of the plate (1034a) is between 1.5 and 4 cm, preferably between 2.4 and 2.6 cm. EEE4. The furniture connector (1030) according to any of the preceding EEEs, wherein the apex angle (a) of the truncated cone (1034c) of the washer (1034) is between 40° and 80°, preferably between 55° and 65°.

EEE5. The furniture connector (1030) according to any of the preceding EEEs, wherein the length (L) of the truncated cone (1034c) of the washer (1034) is between 2 and 10 mm, preferably between 4 and 6 mm.

EEE6. The furniture connector (1030) according to any of the preceding EEEs, wherein the radius (R) of the plate (1034a) is between 5 and 35 mm, preferably between 8 and 32 mm, more preferably between 10 and 25 mm, such as between 15 and 20 mm.

EEE7. The furniture connector (1030) according to any of the preceding EEEs, wherein the screw (1032) comprises a screw head (1032a), a threaded portion (1032c), and a non-threaded portion (1032b) arranged between the screw head (1032a) and the threaded portion (1032c).

EEE8 .The furniture connector (1030) according to EEE7, wherein the screw head (1032a) is countersunk.

EEE9. The furniture connector (1030) according to EEE7 or EEE8, wherein the length of the non-threaded portion (1032b) is between 5 and 30 mm, such as 10-25 mm.

EEE10. The furniture connector (1030) according to any of EEE7-9, wherein the thread pitch of the threaded portion (1032c) of the screw (1032) is between 2 and 4 mm, preferably between 2 and 3 mm.

EEE11. The furniture connector (1030) according to any of EEE7-10, wherein the major diameter (MD) of the threads of the screw (1032) is between 4 and 8 mm, preferably between 5 and 7.5 mm, and even more preferably between 5.5 and 7 mm.

EEE12. The furniture connector (1030) according to any of EEE7-11, wherein the minor diameter (mD) of the threads of the screw (1032) is between 3 and 6 mm, preferably between 3.5 and 5.5 mm, and even more preferably between 4.0 and 5.0 mm.

EEE13. A kit for forming a furniture joint (1040), the kit (1030, 1020a, 1020b) comprising a furniture connector (1030) according to any of the preceding EEEs, a first furniture part (1020a), and a second furniture part (1020b), wherein the screw (1032) of the furniture connector (1030) is arranged to be inserted in a pre-drilled hole (1022) of the first furniture part (1020a) and to be screwed into a pre-drilled hole (1024) of the second furniture part (1020b), thereby attaching the first furniture part (1020a) to the second furniture part (1020b).

EEE14. The kit according to EEE13, wherein the pre-drilled hole (1022) of the first furniture part (1020a) has an exterior end (1022a) arranged to be opposite to the second furniture part (1020b) and having a conical shape, and wherein the cone (1034c) of the washer (1034) is configured to be received by the exterior end (1022a) of the pre-drilled hole (1022) of the first furniture part (1020a).

EEE15. The kit according to EEE13 or 14, wherein the pre-drilled hole (1022) of the first furniture part (1020a) is extending in a radial direction of a rounded portion of the first furniture part (1020a).

EEE16. The kit according to any of EEE13-14, wherein the screw (1032) is extending in the radial direction of a rounded portion of the first furniture part (1020a), the rounded portion being tilted an angle 0 from being perpendicular to the longitudinal direction of the screw (1032), preferably the angle 0 being within ± 15°.

EEE17. The kit according to any of EEE13-16, wherein the pre-drilled hole (1024) of the second furniture part (1020b) is extending in a radial direction of a rounded part of the second furniture part (1020b).

EEE18. The kit according to any of EEE13-16, wherein the pre-drilled hole (1024) of the second furniture part (1020b) is extending in an axial direction of the second furniture part (1020b). EEE19. The kit according to EEE18, wherein the pre-drilled hole (1024) of the second furniture part (1020b) extends from an axial end (1026) of the second furniture part (1020b), wherein said axial end (1026) is having a conical shape.

EEE20. The kit according to EEE19, wherein the pre-drilled hole (1022) of the first furniture part (1020a) has an interior end (1022c) arranged adjacent to the second furniture part (1020b) and having a conical shape, and wherein the axial end (1026) of the second furniture part (1020b) is arranged to be at least partly received by the interior end (1022c) of the pre-drilled hole (1022) of the first furniture part (1020a).

EEE21. The kit according to EEE20, wherein a conical friction engagement is provided between the conically shaped axial end (1026) of the second furniture part (1020b) and the conically shaped interior end (1022c) of the pre-drilled hole (1022) of the first furniture part (1020a), preferably the sole point of contact between the axial end (1026) of the second furniture part (1020b) and the interior end (1022c) of the pre-drilled hole (1022) of the first furniture part (1020a) being the respective conical surfaces.

EEE22. The kit according to EEE20 or EEE21, wherein the conically shaped axial end (1026) of the second furniture part (1020b) and the conically shaped interior end (1022c) of the pre-drilled hole (1022) of the first furniture part (1020a) are designed such that after mounting, an axial gap (1028) is provided between the edge of the axial end (1026) and the inner end of the interior end (1022c).

EEE23. The kit according to EEE22, wherein the axial length of the axial gap (1028) is in the range of 0.5-4 mm, preferably in the range of 1-2 mm.

EEE24. The kit according to any of EEE 13 -23, wherein the second furniture part (1020b) is provided with a dowel (1029b) extending across the path of the pre-drilled hole (1024) of the second furniture part (1020b), preferably the dowel (1029b) is made from a wooden material, more preferably a wood fiber direction of the dowel (1029b) extends in a direction being perpendicular to the longitudinal direction of the screw (1032).

EEE25. The kit according to any of EEE13-24, wherein at least one of said first furniture part (1020a) and said second furniture part (1020b) is at least partly made of rattan, preferably both the first and the second furniture parts (1020a, 1020b) are made from rattan.

EEE26. A piece of furniture (lOOla-d), comprising at least one kit (1030, 1020a, 1020b) for forming a furniture joint (1040) according to any of EEE13- 25.

EEE27. The piece of furniture (100 Id) according to EEE26, wherein the first and/or the second furniture part (1020a-b) forms part of a pre-manufactured furniture module (lOlOa-e), and wherein the furniture module (lOlOa-e) has a planar shape, preferably the piece of furniture (lOOld) is entirely made up furniture modules (lOlOa-e) having a planar shape and/or being arranged for being flat-packed.

EEE28. The piece of furniture (100 Id) according to any of EEE26-27, comprising a plurality of pre-manufactured furniture modules (lOlOa-e) forming a seat (1010a), a back piece (1010b), and two side pieces (lOlOc-d), respectively, and wherein at least one furniture module (lOlOa-e) comprises a first furniture part (1020a), and at least one furniture module (lOlOa-e) comprises a second furniture part (1020b).

EEE29. A method for manufacturing a piece of furniture suitable for being flat-packed, comprising providing at least two pre-manufactured furniture modules, wherein at least one furniture module comprises a first furniture part, and at least one furniture module comprises a second furniture part, and providing at least one furniture connector according to any of claims 1- 12, and/or at least one kit for forming a furniture joint according to any of claims 13-25, wherein said first and second furniture parts are configured to be connected by means of said at least one furniture connector and/or by means of said kit.