Connector Assembly for Furniture

Technical Field

[0001] This invention relates to a connector assembly for use with furniture and a piece of furniture including a connector assembly. More specifically the connector assembly is suitable for use with furniture of the kind including two or more panels such as used in a chest of draws or free-standing book cases. The applicant has developed the connector assembly for an application in relation to connecting two perpendicular panels, and it will be convenient to hereinafter describe the invention with reference to this application. It should be appreciated however the connector may have other applications, including for example connecting two coplanar panels.

Background of Invention

[0002] The following discussion of the background to the invention is intended to facilitate an understanding of the invention. However, it should be appreciated that the discussion is not an acknowledgement or admission that any of the material referred to was published, known or part of the common general knowledge as at the priority date of the application.

[0003] Furniture may generally be defined as movable articles that facilitate making a space suitable for living or working in. Furniture such as book cases, chest of draws, and wardrobes will often include a plurality of timber panels that are each connected to more than one adjacent panel The type of connections between adjacent panels can vary from dovetail joints that don’t require a mechanical fastener, through to butt joints that require some form of screw fastener. These types of connections can easily be made when the furniture is assembled in a factory, however they are not entirely suitable for furniture that is to be assembled on site by a customer where access to appropriate tools and assembly skills are limited.

[0004] Furniture that is assembled onsite is often is often a “flat pack” where the panels for the furniture are pre-cut, supplied with connectors, and packaged with instructions for assembly by the customer. The package is often provided with the bare minimum tools required to assemble the furniture. The connections can include a plurality of timber dowels that locate within predrilled boreholes in the panels that can be fixed with glue. This connection is relatively simple to assemble and can be completed to a standard without any tools. However without temporary clamping mechanism to hold the panels perpendicular while the glue sets, the panels can shift before the glue sets producing a substandard piece of furniture.

Furthermore, the glue can deteriorate over time leading to a less than serviceable piece of furniture. Also the connection does not easily lend itself to disassembly where it might be convenient when the customer is moving house.

[0005] Another connection known to the applicant includes the use of a metal post screwed into the first panel by the customer, the post having a head adapted to engage a cam cylinder in a bore in the second panel whereby the cam cylinder is rotated by the customer to apply a clamping force between the two panels. The flat pack packaging may include a simple hex key or screw driver that must be manually operated. The number of posts that need to be screwed and cam cylinders rotated can produce repetitive strain on the wrist of the customer, or may be beyond the capability of the customer if they have any pre-existing injury.

[0006] The clamping force can be considerable and as such it is important that the post be screwed completely into the first panel otherwise it can be ripped out of the first panel If the post is ripped out, the remedial action necessary to repair the first panel sufficiently to hold the post is often beyond the skills of the customer.

[0007] Further the orientation of the cam cylinder within the bore must be perfectly aligned to capture the post. The alignment of the cam cylinder within the bore can be difficult to confirm by the customer when visual access to the cam cylinder is limited. When cam cylinder is out of alignment, the outcome of failing to capture the post allowing the panels to move relative to each other can be frustrating to the customer. The applicant is aware that the misalignment can also lead to the customer trying to force the capture of the post, which can irreparably damage the post and or the cam cylinder. Generally the packaging only supplies enough posts and cam cylinders to assemble the furniture, so where they are damaged beyond repair the customer will need to source replacements. Accordingly a damaged post and or cam cylinder can delay the assembly of the furniture, and create a less than satisfied customer. [0008] The applicant has appreciated that it would be desirable to provide an alternate connector assembly that was relatively simple to install and at least reduced the need for tools when assembling the furniture.

[0009] Before turning to a summary of the invention, it will be useful to provide an explanation of some of the terms that will be used to define the spatial relationship of various parts thereof. In this respect, spatial references throughout this specification will generally be based upon a connector assembly for use with furniture supported by a surface such as a floor or ground surface.

[0010] It is an object of the present invention to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative.

Summary of Invention

[0011] According to one aspect of this invention there is provided a connector assembly for use in furniture to hold a first panel adjacent to a second panel, the connector assembly including a body for fixing to the first panel, a base for fixing to the second panel, an actuator including a drive surface that interacts with a contact surface on either one of the base or the body so that rotation of the actuator about an actuator axis towards a secure position causes the drive surface to slide over the contact surface producing a camming action to draw the base and the body together.

[0012] The actuator may be adapted for connection to either one of the body or the base and the contact surface is formed on an other of the body or the base. While the embodiment described in greater detail later in the specification has the actuator adapted for connection to the body and the contact surface formed on the base, the contact surface could alternatively be formed on the body and the actuator adapted to connect to the base.

[0013] It is preferred that the actuator be a unitary member that it can initially be separate from the base. This allows the body and the base to engage before the actuator is connected and rotated to the secure position. The applicant has appreciated that this reduces the likelihood of the actuator being damaged by rotating to the secure position before the body and base engage. [0014] The actuator may include a first hinge part, and either one of the body or the base includes a second hinge part which combines with the first hinge part to create a hinged connection between the actuator and either one of the body or the base. It is further preferred that the first hinge part and the second hinge part are adapted to provide a snap hinged connection. The applicant has appreciated that with a snap hinged connection the customer will have a higher degree of certainty as to when the actuator is connected to the body or base by an audible or tactile snap.

[0015] The drive surface and or the contact surface may be eccentric to the axis of rotation so that the sliding of the drive surface over the contact surface produces the camming action. While either one of the drive surface or the contact surface may be eccentric, it is preferred that both the drive surface and the contact surface are eccentric to the actuator axis so as to provide a smooth sliding action while rotating the actuator.

[0016] It is preferred that the actuator and the body are adapted with a detent arrangement therebetween that is operable when the actuator is in the secure position to inhibit movement of the actuator relative to the body when in the secure position. It is further preferred that the detent arrangement is adapted to create an audible sound when the actuator reaches the secure position. The applicant has appreciated that with an audible sound the customer will have a higher degree of certainty as to when the actuator is in the secure position. While the detent arrangement may take any suitable form, the current form includes a combination of a half sphere which locates in a depression when the actuator is in the secure position. Alternatively the detent arrangement may be more complex such that it may produce a “child locking” arrangement, so as to reduce the ability of a child to adjust the actuator from the secure position.

[0017] It is preferred that the body and the base are adapted with a locking arrangement therebetween that is operable to lock the body with the base when the body and the base are brought relatively to a locking position. This arrangement allows in use for the panels to be initially captured before the actuator is attached. It is further preferred that the body and the base are adapted to provide a snap locking arrangement. The applicant has appreciated that with a snap locking arrangement that the customer will have a higher degree of certainty as to when the body is in the locking position by the audible or tactile snap. The locking arrangement may take any suitable form and in one form either one of the body or the base includes a lock tongue and an other one of the body or the base includes a lock surface that is complementary at least in part with the lock tongue so as to engage when in the body and the base are in the locking position. The lock tongue includes a free end having a leading surface that may be sloped so that the lock tongue deflects when bringing the body and the base towards the locking position. The lock tongue preferably includes a shoulder that is sloped and the lock surface is provided with a complementary slope that is engaged by the shoulder when the body and the base are in the locking position. The complementary surfaces of the lock surface and the shoulder allow are preferably sloping so that they remain engaged while allowing for a degree of manufacturing tolerance between those parts.

[0018] The actuator preferably includes an abutment surface and the lock tongue includes a mating surface, the abutment surface and the mating surface are adapted so that rotation of the actuator towards the secure position causes the abutment surface to slide over the mating surface and once in the secure position inhibit movement of the lock tongue.

[0019] The base may include at least one aperture for accommodating a screwed fastener for fastening the base to second panel. Furthermore the body may include at least one aperture for accommodating a screwed fastener for fastening the body to first panel. It is most preferred that both the base and the body include a pair of apertures spaced longitudinally on opposed sides of the respective drive surface and contact surface.

[0020] The body may include a pair of flanges with each flange having one of said apertures, the base including a pair of cavities each adapted to accommodate one of said pair of flanges, each flange having a thickness and each cavity having a depth whereby the depth of the cavity is greater than the thickness of the flange so as to provide a gap in cavity when the actuator is in the secure position.

[0021] Alternatively, the body includes a housing which includes said at least one aperture for accommodating a screwed fastener, said at least one aperture being aligned centrally of the housing. The at least one aperture in the housing may be oriented substantially perpendicular to the at least one aperture in the base when the connector assembly is in use. In this alternate arrangement the housing may be surface mounted to the first panel. [0022] It is preferred that the drive surface and the contact surface are adapted so that actuator is rotated through no more than 90° to reach the secure position. The applicant has appreciated that this limited movement to secure the panels is more desirable than multiple rotations.

[0023] According to another aspect of this invention there is provided a piece of furniture including at least a first panel and a second panel, and a connector assembly as herein before defined.

Brief Description of Drawings

[0024] The invention will be more clearly understood from the following description of an embodiment thereof, given by way of example only, with reference to the accompanying drawings, in which: -

[0025] Figure 1 is an isometric view of a simplified piece of furniture according to one aspect of this invention.

[0026] Figure 2 is an isometric view of a connector assembly according to another aspect of this invention when connecting a first panel to a second panel

[0027] Figure 3 is an isometric view of the connector assembly from Figure 2 with the first panel separated from the second panel.

[0028] Figure 4 is an exploded isometric view of the connector assembly from Figure 2.

[0029] Figure 5 is a front elevation view of the connector assembly from Figure 2 with the actuator shown in a release position.

[0030] Figure 6 is a cross-sectional view through VI- VI from Figure 5.

[0031] Figure 7 is a cross-sectional view through VII- VII from Figure 5.

[0032] Figure 8 is a cross-sectional view of the connector assembly from Figure 7 with the actuator rotated from the release position towards the secure position. [0033] Figure 9 is a cross-sectional view of the connector assembly from Figure 7 with the actuator rotated to the secure position.

[0034] Figure 10 is an isometric view of an alternate embodiment of the connector assembly surface mounted to a first panel and a second panel.

[0035] Figure 11 is an isometric view of a further alternative connector assembly according to another aspect of this invention when connecting a first panel to a second panel

[0036] Figure 12 is an isometric view of the connector assembly from Figure 11 with the first panel separated from the second panel.

[0037] Figure 13 is an exploded isometric view of the connector assembly from Figure 11.

Detailed Description

[0038] Referring now to Figure 1 which illustrates a piece of furniture 1, or more specifically a simplified version of a bookcase. Whilst it would be common for a bookcase to have multiple shelves 2, most of the shelves 2 are not illustrated so as to simplify the description of the drawings. The furniture 1 illustrated includes the shelf panel 2 positioned between a top panel 3 and a bottom panel 4, each of which are connected to adjacent side panels 5a, 5b. Figure 1 illustrates a plurality of connector assemblies 8 which connect each side panel 5a, 5b to its adjacent shelf panel 2, top panel 3 and bottom panel 4. It ought to be appreciated that the number and location of the connector assemblies 8 may vary from that as illustrated in Figure 1, and to that extent the connector assembly will be hereinafter described with reference to fixing to a first panel 6 and a second panel 7 rather than referring to side panels 5a, 5b, shelf panels 2, top panels 3 and bottom panels 4. Accordingly, Figure 2 illustrates the connector assembly 8 connecting a first panel 6 with an adjacent a second panel 7.

[0039] Figure 3 illustrates the first panel 6 spaced from the second panel 7 and reveals that the connector assembly 8 is formed from a body 9, a base 10, and an actuator 11. The body 9 includes a housing part 12 which is adapted to house the actuator 11 therein (see Figure 2), so that the actuator 11 can lie flush with a surface of the first panel 6 when the housing 12 is received within a recess R1 in the first panel 6. The body 9 also includes a pair of flanges 13a, 13b which are formed integrally with the housing part 12 and abut a side edge of the first panel 6. Referring briefly to Figure 4 it can be noted that the flanges 13a, 13b each include an aperture 14a, 14b formed therein respectively. Whilst it is not apparent from the Figures, the apertures 14a and 14b are adapted to accommodate screw fasteners (not shown) therein for attaching the body 9 to the first panel 6.

[0040] Referring again to Figure 3 we note that the second panel 7 is formed with a recess R2 to accommodate the base 10 so that an upper edge of the base 10 lies flush with a surface of the second panel 7. It should be noted that the base 10 includes a pair of cavities 15a, 15b referring briefly to Figure 4 which illustrates the base 10 is formed with an aperture 16a, 16b at the bottom of each cavity 15a, 15b for accommodating a screw fastener 17a, 17b (see Figure 3), therein. The recesses Rl, R2 formed in the first panel 6 and second panel 7 to accommodate the body 9 and the base 10 respectively are created in the factory, and it is preferred that the body 9 and the base 10 also be attached to the first panel 6 and the second panel 7 in the factory so as to simplify the assembly process for the customer.

[0041] It is preferred that the actuator 11 includes a first hinge part and either one of the body 9 or the base 11 includes a second hinge part which combines with the first hinge part to create a hinged connection between the actuator 11 and either one of the body 9 or the base 10. However in the preferred embodiment illustrated in Figures 3 and 4, the actuator 11 is releasably attachable to the body 9, and is rotatable relative to the body 9 about an actuator axis X-X.

[0042] The preferred form of actuator illustrated in Figures 3 and 4 includes a plate portion 18 with an aperture 19 formed adjacent an upper end thereof. The actuator 11 includes a pair of shafts 20a, 20b formed below the plate portion 18, which for the purpose of the preferred embodiment of the invention can be considered the first hinge part. Each shaft 20a, 20b is formed with an outer portion 21a, 21b of a smaller diameter than an inner portion 22a, 22b. The outer portions 21a, 21b are sized to be captured within C-shaped sockets 23a, 23b formed in the housing part 12 of the body 9. The inner portions 22a, 22b are shaped to mate with bearing surfaces 24a, 24b formed adjacent the C-shaped sockets 23a, 23b in the housing part 12. The C-shaped sockets 23a, 23b and the bearing surfaces 24a, 24b can, for the purpose of the preferred embodiment of the invention, be considered the second hinge part. Whilst the shafts 20a, 20b could be of constant diameter throughout their length, by having the inner portions 22a, 22b of greater diameter assists the shaft in resisting flexing when under load as the actuator 11 moves between the release position and the secure position.

[0043] The actuator 11 includes a hook part 25 which is illustrated in Figure 4 below the shafts 20a and 20b. The hook part 25 is inserted into a slot 26 formed in the base 10, and is adapted to interact with the base 10 in a manner that will be described in greater detail with reference to latter illustrations. Furthermore, the body 9 is formed with a tongue 27 which is adapted to be inserted into the slot 26 for interaction with the base 10 and the tongue 27 in a manner which will also be described in greater detail with reference to latter illustrations. However, it should be noted at this stage that the tongue 27 is formed with a mating surface 28, as it is more easily visible in Figure 4.

[0044] Body 9 is further equipped with a peripheral projection in this case in the form of rib feature 39 to be received in a corresponding aperture or groove machined in the panel recess R1 as seen in Figure 6. The engagement of the rib in the groove locates and secures the body 12 periphery thereby reducing flex of the body 9.

[0045] It is preferred that the actuator 11 and the body 9 be adapted with a detent arrangement therebetween. The preferred detent arrangement illustrated in Figure 4 involves a pair of dimples 29 (only one of which is visible), formed in the body which interact with a pair of domes 30 (only one of which is visible). It is preferred that this interaction provide a snap engagement of the actuator 11 with the body 9 when it reaches the secure position, and that the snap engagement creates an audible and tactile indication to the customer that the actuator 11 has reached the secure position. The detent arrangement may be more complex than the one illustrated such that it may produce a “child locking” arrangement, so as to reduce the ability of a child to adjust the actuator 11 from the secure position.

[0046] When assembling the furniture 1, the customer must insert tongue 27 into the slot 26 before the actuator 11 is attached to the body 9. It can be appreciated from Figure 7 and 7a that the tongue has a free end with a leading surface that is sloped. While the actuator 11 is detached from the body 9, the leading surface 31 would slide over a rear wall of the base 10, causing the free end of the tongue 27 to deflect (not shown). Once the first panel 6 abuts the second panel 7, the tongue snap locks into position preferably providing an audible and tactile indication to the customer that the body 9 has appropriately engaged with the base 10. The free end of the tongue 27 is also formed with a shoulder 32 that engages a lock surface 33 of the base 10 so as to inhibit disengagement of the body 9 from the base 10 when in the engaged position. It ought to be appreciated that an alternative arrangement is also possible whereby the base 10 is formed with the tongue 27 whilst the body 9 is formed with the slot 26 having a lock surface 33, and the embodiment illustrated is merely preferred.

[0047] Once the body 9 engages the base 10, the actuator 11 can be attached to the body 9 as illustrated in Figure 7 and 7a. It can be noted that the hook part 25 of the actuator 11 includes an abutment surface 34 that is adapted to interact with the mating surface 28 as the actuator 11 rotates. Comparing Figure 7a with Figure 8b it can be noted that the abutment surface 34 slides over the mating surface 28 as the actuator 11 moves towards a secure position. Further rotation of the actuator 11 to the secure position as illustrated in Figure 9 and 9a, illustrates the abutment surface 34 adjacent to the mating surface 28 so that the free end of the tongue 27 is positioned between the hook part 25 and the rear wall of the baselO. This will inhibit the tongue 27 from deflecting from the lock position as illustrated. Furthermore, this arrangement will facilitate resisting a force applied to the first panel 6 causing it to pivot towards the second panel 7 via the interaction between the lock surface 33 and the shoulder 32. Furthermore, by forming the shoulder 32 and the lock surface 33 at an angle other than a perpendicular angle to the rear wall of the base 10, allows for a degree of manufacturing tolerance between the tongue 27 and the base 10.

[0048] Referring again to Figure 7a which illustrates the hook part 25 formed with a drive surface 35 on a side of the hook part 25 opposed to the abutment surface 34. Whilst the abutment surface 34 has a substantially constant radius about the actuator axis X-X, the drive surface 35 is slightly eccentric to the actuator axis X-X. Figure 7a also illustrates the base 10 being formed with a contact surface 36 which is also slightly eccentric to the actuator axis X- X. It can be appreciated when comparing Figures 7a, 8a and 9a that rotation of the actuator 11 about the actuator axis X-X causes the drive surface 35 to slide over the contact surface 36. While it can’t be readily appreciated from the illustrations, with the slight eccentricity of the drive surface 35 and the contact surface 36 this will create a camming action drawing the base 10 and the body 9 together. Furthermore whilst it is not apparent from the illustrations it is preferred that the height of the flanges 13a, 13b be less than a depth of the cavities 15a, 15b so that when the first panel 6 abuts the second panel 7, the flanges 13 a, 13b fail to bottom out in the cavities 15a, 15b. This will allow the camming action produced by the drive surface 35 sliding over the contact surface 36 to securely retain the body adjacent the base. Another alternative not illustrated is for the flanges 13a, 13b and the cavities 15a, 15b to be tapered so that the flanges 13 a, 13b wedge into the cavities 15a, 15b under the camming action. Furthermore, in the event that pressure is applied to the furniture 1 to urge the first panel 6 to pivot away from the second panel 7, this will be resisted by the camming action between the drive surface 35 and the contact surface 36.

[0049] It ought to be appreciated when comparing Figures 7, 8 and 9 that the customer need only rotate the actuator through no more than 90 degrees from the release position shown in Figures 7 to the secure position as shown in Figure 9 to securely attach the base 10 to the body 9. Furthermore, in the event that the furniture needs to be disassembled, the customer can simply slide their finger into the aperture 19 formed in the actuator 11 and rotate the actuator 11 from the secure position to the release position. The ease with which the furniture can be disassembled, will increase the likelihood that the furniture will be re-used if the customer needs to move house for any reason.

[0050] While the connector assembly 8 has been described and illustrated in a form that is recessed within the first panel 6 and second panel 7, the connector assembly 8 may alternatively be surface mounted. This alternate embodiment is illustrated in Figure 10, and it can be noted that the housing 112 is formed with a pair of apertures (obscured) centrally aligned therethrough, to receive the screwed fasteners 137a, 137b. The base 110 is formed with a pair of apertures (obscured) to accommodate screwed fasteners 117a, 17b, in a similar arrangement that that previously described with reference to Figures 1 to 9. Furthermore, the actuator 111 operates in the same manner as described with reference to the embodiment illustrated in Figures 1 to 9. This embodiment may be considered more suitable for furniture manufacturers that may not have routing facilities to form recesses in the first panel 106 and second panel 107, or may be simpler to manufacture the furniture without forming the recesses.

[0051] A further alternate embodiment of a connector assembly 208 is illustrated in Figures 11 to 13. In this embodiment the base 210 is surface mounted to the second panel 207 while the housing 212 including body 209, and pair of flanges 213a, 213b are recessed into first panel 206. In use when connected together and as seen in Figure 11 , connector assembly 208, as with connector assembly 8, is substantially flush with the surface of first and second panels. However, in contrast to connector 8, while the housing 212 is received within recess R201, the flanges 213a, 213b and base 210 are accommodated within an intersecting recess R20 la in the first panel. As such, fitment of connector 208 requires machining of only the first panel 206, and not the second panel 207 since the base 210 may be surface mounted to the second panel Since recesses R201 and R201a may advantageously be machined from the same side setup time for machining of each joint may be effective halved.

[0052] In addition, the flanges 213a, 213b are extended which allows for an increased spacing of apertures 214a, 214b formed therein respectively. The increased spacing of the apertures 214a, 214b in turn results in an increased spacing of screw fasteners (not shown) therein for attaching the body 209 to the first panel 206 thereby to reduce the likelihood of splitting of the second panel.

[0053] Body 209 is further equipped with a projection 239 to be received in an aperture in the panel recess R201 to locate and secure the upper end of body 212 once screw fasteners extending through apertures 214a, 214b fix the body to the first panel at the upper end of the body 209 thereby reducing flex of the body 209.

[0054] The actuator 211 operates in the same manner as described with reference to the embodiment illustrated in Figures 1 to 9 and 10. The actuator 211 includes a hook part 225 which is illustrated in Figure 13 below the shafts 220a and 220b. The hook part 225 is inserted into a slot 226 formed in the base 210, and is adapted to interact with the base 210 in a manner that described in respect of the first embodiment shown in Figures 1 to 9. Furthermore, the body 209 is formed with a tongue 227 which is adapted to be inserted into the slot 226 for interaction with the base 210 and the tongue 227 in a manner described in respect of the first embodiment.

[0055] It is preferred that the body 9, 109, 209, base 10, 110, 210 and actuator 11, 111, 211, be formed as a moulded product, preferably from a combination of nylon with glass fibre reinforcing. Another alternative is for the components to be formed from metal such as a diecast zinc alloy, particularly if the connector assembly 8, 108, 208 is required to produce significant camming action between the drive surface and the contact surface. [0056] It ought to be appreciated from the foregoing that the connector assembly 8, 108, 208 as hereinbefore described provides relatively simple mechanism for connecting furniture panels 6, 7 without the need for the customer to utilise specialist tools. Furthermore, the ability of the tongue 26, 126, 226 to temporarily snap engage with the base 10, 110, 210 during the process of assembling the furniture 1, makes it easier for the customer to assemble the furniture, particularly when they are assembling it on their own.

[0057] Future patent applications may be filed in Australia or overseas on the basis of or claiming priority from the present application. It is to be understood that the following provisional claims are provided by way of example only, and are not intended to limit the scope of what may be claimed in any such future application. Features may be added to or omitted from the provisional claims at a later date so as to further define or re -define the invention or inventions.