FIELD

[0001] The present invention relates to a non-fastener locking system for a product and in particular to a non-fastener locking system for wooden modular cabinetry.

[0002] It should however be appreciated that the locking system described herein could be utilised with any suitable rigid or semi-rigid material such as wood, steel, plastic, stone, ceramic or the like. The product could be any suitable product from a stool, table, a box, a bench, a chair, a bed, a cabinet, an entire wall, house or the like.

BACKGROUND

[0003] The assembly of products in most cases are complicated by use of various common fasteners. That is, screws, nuts, bolts, rivets, adhesives, ties or the like. These fasteners add costs to the sale of the product, provide components that can be lost or damaged and create complexity and add time to the assembly and disassembly of the product.

[0004] If the product comes in a flat pack form, it is common for a significant number of fasteners and tools to be required for assembly and disassembly of the product. This makes such products more difficult for the average person to assemble/disassemble.

[0005] Wear occurs each time a product that is assembled with fasteners is disassembled and reassembled. In the case of a timber product a small number of assembly cycles will typically result in screw holes being worn and enlarged to a point were they are longer serviceable. This problem is particularly exacerbated in in laminated material such as plywood or particle boards as the insertion of a fastener between laminations tends to cause localised delimitation. Ultimately this wear problem results in flat pack products with very limited re-use potential.

[0006] Accordingly, there is a need for components of a product to be delivered in a flat pack modular form that provides a strong joinery lock that needs no fixing with fasteners such as screws, nails, bolts or the like. The lock needs to provide structural rigidity to the product. [0007] There is also a need for a locking system which allows disassembly without damage and ease of reassembly when necessary with no tools and a reduced labour requirement.

[0008] It is an object of the present invention to substantially overcome, or at least ameliorate, one or more of the disadvantages of existing systems, or at least provide a useful alternative.

SUMMARY

[0009] A locking system for a product, the locking system including a plurality of planar panels having a combination of locking joints located thereon, said panels when locked together by said locking joints form said product without the use of fasteners.

[0010] The system including a first locking joint, said first locking joint adjacent a corner of a first panel having a portion recessed from an edge of said panel, said recess having at one side a hook member extending away from said edge, said hook member operatively associated with an opening in an adjacent second panel to lock said first and second panels together.

[0011] Preferably, said opening includes a first dimension wider than a parallel and connecting second narrower dimension.

[0012] The system including a second locking joint, said second locking joint located at a comer of a first panel and having a portion recessed from said corner between perpendicular edges of said panel, said recess having one or more steps receding away from said corner, said steps operatively associated with a hook member extending away from an edge of an adjacent second panel to lock said first and second panels together.

[0013] The system including a third locking joint, said third locking joint including a tab extending away from an edge of a first panel and operatively associated with an opening in an adjacent second panel to lock said first and second panels together.

[0014] Preferably, one of more of the tabs includes a hook formation.

[0015] Preferably, a panel includes a plurality of tabs with or without hook formations in combination. [0016] The system including a fourth locking joint, said fourth locking joint adjacent a comer of a first panel having a T shaped hook member extending away from an edge of said panel, said T shaped hook member operatively associated with a slot in an adjacent second panel to lock said first and second panels together.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Preferred embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0018] Figure 1 is a partial view of an ‘A’ connection locking system;

[0019] Figure 2 is a partial view of an ‘A’ connection locking system;

[0020] Figure 3 is a partial view of an ‘A’ connection locking system;

[0021] Figure 4 is a partial view of a ‘B’ connection locking system;

[0022] Figure 5 is a partial view of an Ή’ connection locking system;

[0023] Figure 6 is a partial view of an Ή’ connection locking system;

[0024] Figure 7 is a partial view of an Έ’ connection locking system;

[0025] Figures 7a,b,c are partial views of an Έ’ connection locking system;

[0026] Figure 8 is a partial view of an Έ’ connection locking system;

[0027] Figure 9 is a partial view of an Έ’ connection locking system;

[0028] Figure 10 is a product having a combination of ‘A, B, E and FT connection locking systems; and

[0029] Figure 11 is a product made by a combination of the connection locking systems above. [0030] Figure 12 is a partial exploded view of a ‘C’ connection locking system; [0031] Figure 13 is a a partial exploded view of the ‘C’ locking system of Figure 12;

[0032] Figure 14 is a perspective view of the ‘C’ locking system of Figure 12;

[0033] Figure 15 is a perspective view of the ‘C’ locking system of Figure 12;

[0034] Figure 16 is a side view of a ‘D’ connection locking system in accordance with an embodiment of the present invention;

[0035] Figure 17 is a side view of the ‘D’ connection locking system of Figure 16;

[0036] Figure 18 a perspective view of the ‘D’ connection locking system of Figure 16;

[0037] Figure 19 is a perspective view of the ‘D’ connection locking system of Figure 16;

[0038] Figure 20 is a table formed using a ‘F’ connection locking system of the present invention;

[0039] Figure 21 is a side view of the connection system F of Figure 20;

[0040] Figure 22 illustrates a method of product formation using a ‘G’ connection locking system;

[0041] Figure 23 illustrates a method of product formation using an T connection locking system;

[0042] Figure 24 illustrates a connection locking system using a T connection locking system; and

[0043] Figure 25 illustrates a method of product formation using the J connection locking system of Figure 24.

DESCRIPTION

[0044] Referring to the drawings, there is shown a number of embodiments of a non-fastener locking system for a product. As mentioned above, the product could be any suitable type of product and in its assembly/disassembly any combination of the shown locking systems could be utilised. The combination of locking systems and product will, in most cases, be determined by the manufacturer and customer at the time of a customer ordering a non-fastener locking system.

[0045] Once manufactured, the component panels making up the product would be delivered in a flat pack modular form to the customer. The assembly of the product requires minimal labour requirements and when assembled by the customer would provide a strong joinery lock (structural rigidity) that needs no fixing with fasteners such as screws, nails, bolts or the like.

The locking system uses tolerances of less than a millimetre between chamfered surfaces on male and female shapes to create the locking. The surfaces are preferably rounded. The interplay between the shapes creates flex for the shapes to come together and lock. An unsuitable variation in an edge curve or size or shape of the component panels could cause the locking system to fail. Further in a preferred form the interplay brings panels together through wider openings and snapping them down into narrow openings assists with the locking of panels together. Yet further, the use of a combination of light interference fits with rounded edges allow ease of assembly and provides a tight stable product locking system with no fasteners required that can be flat packed.

[0046] Referring specifically to Figures 1 to 3, there is shown a connection type ‘A’ or a double hook joint. Joinery systems such as kitchen cabinets, for example, are typically assembled from a series of individual cabinets or boxes. This arrangement involves substantial material wastage as two thicknesses of material are required where one cabinet adjoins another. The ‘double hook joint’ of an embodiment of the present invention allows for a single thickness of material to be used between adjoining cabinets in a continuous joinery system. The use of a single vertical panel between cabinets where two panels would typically be required contributes to cost savings in materials and manufacturing.

[0047] In Figure 1 is shown two base panels 1 and a dividing panel 2. The base panel 1 of each cabinet is shaped with a total of four hooks 3,4. Two hooks 3 on the right side of the panel 1 are inward facing and offset toward the centre of the panel 1. Two hooks 4 on the left side of the panel 1 are outward facing and offset toward the front and back of the panel 1. [0048] In Figure 2 this ‘in and out’ hook arrangement allows for a continuous offsetting joinery system where base panels 1 can be secured to an opening 6 in a shared vertical dividing panel 2 without interference. The hooks on opposite sides of the base panel are offset either inward or outward to create a counterposing interference fit. The opening 6 is shaped with a chamfer and stepped to permit an interference fit of both hooks 3,4. The stepped form of this opening allows for the hook to be passed through the wider upper opening and then pressed down into the narrower portion of the opening to create a joint that is located securely both through interference and the downward force of gravity. In Figure 3 as the base panel hooks 3,4 face either inward or outward (that is, are opposing each other) on opposite sides of the panel 2, the locking face 5 of any hook 3,4 is opposed by the locking face 5 of the other hook on the same panel side. This arrangement prevents the lateral movement and disengagement of each hook 3,4. The hooks 3,4 enter the opening at a wider zone and are pushed downwardly into a narrower zone to lock as shown in Figure 3.

[0049] Referring specifically to Figure 4 and insets A and B, there is shown a connection type ‘B’ or a top panel locking joint. This joint secures a top panel 7 with a side panel 8. To install or remove the top panel 7, substantial lateral force must be applied to the top corner 9 of the side panel 8. Under this lateral force, the side panel 8 bends or otherwise deforms sufficiently to allow the hook 10 on the top corner 9 to pass through a gap 11 in the top panel 7 as shown in Inset A. [please confirm that the arrow points correctly to gap 11]. Once through the top panel 7 the side panel 8 springs back to its vertical position. In this vertical position the side panel hook 10 engages a tab 12 on the leading edge of the top panel 7 to securely locate the top panel 7 as shown in inset B. [please confirm that the arrow points correctly to tab 12]. In one embodiment the largest indent is to allow for the passage of the hook, the 1st step is a tab that is engaged by the hook, the 2nd step is a stop to ensure the proper location of the hook when engaged.

[0050] Referring specifically to Figures 5 and 6 and insets 1 and 2, there is shown a connection type Ή’ or a daisy chain extension joint. The combination of offset tabs 14 and hooks 15 to be received within openings 17 of adjacent panels 19,20,21 enables the joinery system to “daisy chain” continuously or as far as the customer requires. This arrangement reduces substantial sheet material wastage of other systems that require two thicknesses of material where one cabinet, for example, adjoins another. It also allows vertical or horizontal construction more easily. Inset 1 shows the tabs 14 on the vertical edges of the brace panel 21 being offset in relation to each other to avoid interference. This allows any number of brace panels 21 to be used where continuous closure to the rear of the product is required. [Please explain why there are two openings 17 in inset 1] These 2 offset openings correspond with offset tabs in the rear brace panel. This offset prevents interference between tabs on adjacent panels. In inset 2 the ‘double hook joint’ 15 allows for a single thickness of material to be used between adjoining products in a continuous joinery system. Figure 6 shows that the ‘in and out’ hook arrangement allowing for a continuous joinery system where base panels 19 may affix to shared vertical dividing panels 21 without interference. Shelf panels 22 could also be utilized with a similar hooking arrangement.

[0051] Referring specifically to Figures 7, 7a,b,c and 8, there is shown a connection type Έ’.

In Figure 7 products such as boxes 23 are constructed using double hooked tabs 24, slots 25 and tabs 26 of the component panels, ends 27, sides 28 and base 30. As shown in Figure 8, the assembly is described. 1. The end panel 27 is joined simultaneously with the side panels 28 then rotated inwards to a vertical position. Hooked tabs 24 at the bottom prevent the side from travelling past a vertical position and make it necessary to rotate the sides 28 about their horizontal axis for insertion or removal (shown below in Figures 7a-c) into slot 31. 2. The second end panel 27 is engaged with the box front/back and positioned temporarily at an angle of approximately 45°. 3. The tabs 26 on one side of the drawer base 30 are located in slots 25 on the vertically located drawer side. 4. The tabs 24 on the opposite side of the drawer base are rotated down to rest in the slots 31 of the drawer side resting at 45°. 5. The drawer side resting at 45° is rotated to a vertical position. 6. The drawer base 30 is pushed down so that its locating tabs 26 rest in the bottom of the slots 25 in the drawer sides. The drawer base 30 is held securely in this location by gravity. The drawer base 30 is now substantially lower than the front and back panel hooks 24 that retain the draw sides 28; the draw sides 28 are restrained from rotating out from their vertical position by the front and back panel hooks 24 and the drawer base 30. In one embodiment, indent 32 and hole 29 allow for the insertion of a drawer divider. The divider provides no structural function and is a loose fit to allow for easy insertion and removal. Hook 24 is composed of 2 opposing slots. These slots engage with corresponding tabs in the front and back drawer panels to prevent the removal of these panels when assembly is complete.

[0052] Referring specifically to Figures 9, 10 and 11, there is shown a product 30 assembled using connections ‘A’, ‘B’, Έ’ and Ή’. The combination of connection types enables the joinery system to be assembled in many different configurations such as in Figure 11. The arrangement shows how the joinery systems such as kitchen cabinets and wall cupboards can be created. For example, connection type Έ’ is shown at rear bracing panel 31, connection type ‘B’ as top panel locking joint 32, connection type ‘A’ double hook joint 33 and connection type Ή’ in daisy chain extension joint 34.

[0053] Referring specifically to Figures 12, 13, 14 and 15, there is shown a product 40 using a connection type ‘C’ or rotating tab joint.

[0054] The product 40 includes receiving panel ends 42 that attach to and extend, generally perpendicularly from the base 44. The receiving panel ends 42 include apertures 43 in their lower region. Rotatable brace panels 46 are arranged to engage the base 44 and receiving panel ends 42. The width of the brace panels 46 is longer than the height of the central region of the apertures 43. The ends 45 of the rotatable brace panels 46 include a slot that is arranged to receive the thickness of the receiving end panels. In one embodiment, the ends of the rotatable brace panels 42 include opposed slots, each of the opposed slots being arranged to receive the thickness of the receiving panel ends 42 in use.

[0055] In use, the brace panels 46 are arranged to be passed through aperture 43 into the central section of the base 44. The brace panels 46 are arranged so that the ends 45 of the rotatable brace panels 46 abut the outer face of the receiving panel ends 42 in use. The rotatable brace panels 46 are arranged in use so that the slots in opposite ends 45 align with the thickness of the receiving panel ends 42 at opposite ends of the base 44. The aperture 43 includes ends that are larger, in as much as the extension of the aperture at the ends is larger than the extension of the aperture in the central region, than the central region of the aperture 43 and sized to restrain the ends 45 of the rotatable brace panels 46. The ends of the aperture 43 are profiled as a stepped notch from the central region of the aperture 43. The stepped notched profile may be chamfered into the central portion of the aperture 43. In use, from a position where the width of the rotatable brace panels 46 extend along the length of the aperture 43 and the slots in ends 45 are aligned with the thickness of the receiving panel ends 42 the rotatable brace panels 44 are rotates so that a slot is entered into an upper region of the larger end of the aperture 43. The other slotted region is then rotated downwards to be directly below the upper slotted region. As the other slotted region is rotated to be directly below the upper slotted region a protrusion on the lower edge along the length of the rotatable brace panel 46 enters and restrainingly engages a slot in the base 44. The upper region of the larger end of the aperture is profiled to stop rotation of the rotatable brace panel 46 when the protrusion is engaged with the slot in the base 44. The width of the rotatable brace panel 46 between the slotted portions at one end is greater that the distance between upper and lower sides of the central region of the aperture 43 but is equal to or less than the distance between the upper and lower sides of the larger end region of the aperture 43. The width of the rotating brace panel 46 in the region between the slotted regions at either end of the rotating brace panel 46 is greater than the distance between the upper and lower sides of the larger end region of the aperture 43

[0056] A further embodiment of the present invention is shown in Figures 16 to 19 illustrating a connection locking system ‘D\ With reference to Figures 16 to 19, connection locking system D is a connection 50 between a first panel 52 and a second panel 54. In one embodiment, the first panel 52 is orthogonal to the second panel 54. The first panel 42 includes hook 56 at an end of the first panel 42. Second panel 54 includes recess 66 shaped to conform to the outer profile of the hook 56.

[0057] Hook 56 includes a curved base 58 and curved upper surface 60 that match the curves on the recess upper surface 62 and the recess lover surface 64. To engage the first panel 52 with the second panel 54, the first panel 52 is angled with respect to the second panel 54 so that the end of the first panel 52 distal the recess 66 is raised with respect to the recess 66. The curved upper surface 60 of the hook 56 then enters the recess 66 and the end of the first panel 52 and the end of the first panel 52 distal the recess 66 is lowered to conform the recess upper and lower surfaces 64, 62 with the curve upper surface and base 60, 58. In this position, the hook is restrained from lineal removal from the recess 66 due to the upper and lower curved surfaces 62, 64.

[0058] Referring to Figures 20 and 21, a connection locking system ‘F\ connection locking system F 70 includes a top F panel 72 legs 74 and mid brace 73 extending between the legs 74 is illustrated. Covering panel 79 extends over top panel 72. A through hole extends through top panel 72 and a recess extends part way through the thickness of covering panel 79. The trough hole and recess are offset leaving ledge 71.

[0059] Legs 74 are inserted through the through hole in top F panel 72 and into the partial recess in covering panel 79. To set the connection locking system F, the legs 74 are angled away from the centre of the top panel 72 so that an upper portion of the legs 74 abut ledge 71. Mid brace 73 includes protrusions 75 extending from shoulders 78 that are arranged to extend into apertures 84 in legs 74. The angle of the legs 74 place pressure against the through hole in the top surface and the abutment of the protrusions 75 against the sides of aperture 84 to restrain the panels in place.

[0060] With reference to Figure 22, a method of connecting connection locking system ‘G’ is illustrated. Connection locking system G includes stepped apertures 86 in side panels 94 arranged to receive stepped protrusions 87 in opposite ends of support panel 85 that extends between side panels 94. In step 80, the support panel 85 is angled so that stepped protrusions in one end of the support panel 85 are raised above stepped apertures 86. The stepped protrusions 87 in the opposite end of the support panel (to the raised end) are entered into the upper, wider step of the stepped aperture 86. At step 81 the end of the support panel 85 distal the stepped protrusions 87 entered into the upper, wider step of the stepped aperture is lowered to bring the stepped protrusion 87 in that end of the support panel 85 into the wider portion of the stepped aperture in the side panel 94 adjacent that support panel. With stepped protrusions in opposite ends of the support panel 94 into stepped apertures in opposing side panels 94, the support panel 85 is centered with respect to the distance between supporting side panels 94. When centered, the narrow step 88 of the stepped protrusions 87 is lowered into the narrow portion of the stepped aperture 86 to restrain the support panel.

[0061] In one embodiment, the stepped apertures are recesses.

[0062] With reference to Figure 23, a method of connecting connection locking system T is illustrated. Connection locking system G includes extended apertures 96 in side panels 93 arranged to receive protrusions 97 in opposite ends of support panel 95 that extends between side panels 93. In step 90, the support panel 95 is angled so that protrusions 97 in one end of the support panel 95 are raised above stepped extended apertures 96. The protrusions 97 in the opposite end of the support panel (to the raised end) are entered into the lower region of extended aperture 96. At step 91 the end of the support panel 95 distal the protrusions 97 entered into the lower portion of extended aperture 96 are lowered to bring the protrusion 97 in that end of the support panel 95 lower. At step 92 the panel 95 is lowered so that protrusions 97 abut the base of aperture 96. [0063] With reference to Figures 24 and 25, a connection locking system ‘ J’ is illustrated. Connection locking system J 100 includes vertical support 108, top hook support 106 including hook protrusion 102, a longitudinal support 103 and cross brace 101.

[0064] At step 110 top hook support 106 is arranged. T step 120, vertical support 108 is placed at an angle with respect to the top hook support 106 so that hook protrusion 102 is received within aperture 104. The vertical support is then rotated to be normal to the hook support 106. At step 130, a further top support 103, at right angles to the vertical support and hook support 106 receives the hook protrusion 102 trough an aperture. The further top support is then rotated to align with the vertical support 108. At step 140. Cross brace 101 is connected to the base of the vertical support with a protrusion into an aperture at the base of the vertical support 108. Similar connection, not shown, is made at the distal end of the cross brace 101 to the hook support 106.

[0065] The non-fastener locking system described in this application allows for the rapid and unskilled construction of various furniture and joinery items. Further, the jointing techniques described may also be applied to the construction of major components for pre-fabricated housing such as structural joinery modules. CNC (computer controlled numeric) cutting of all components ensures a degree of accuracy that is not achievable with typical joinery and house fabrication. This accuracy contributes to labour and time savings while also improving quality.

[0066] Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.