GB2604229A

GB2604229A - Apparatus, kit and a method for joining first and second members

Info

Publication number: GB2604229A
Application number: GB2118805.7A
Authority: GB
Inventors: William Edward Fuller John
Original assignee: Jwef Consulting Ltd
Current assignee: Jwef Consulting Ltd
Priority date: 2020-12-23
Filing date: 2021-12-22
Publication date: 2022-08-31

Abstract

Apparatus for forming a joint includes a first member 1 with a screw hole or channel 3 formed in it and a second member 2 against which the first member 1 abuts when fastened to it. A forming means 4 is driven into the second member 2 to form a screw hole or channel in alignment with the screw hole or channel 3 in the first member 1. The forming means 4 is then at least partially withdrawn and either reused as fastening means or is replaced by a fastening means to pass through the screw hole or channel 3 in the first member 1 and into the screw hole or channel in the second member 2 to engage the members together. The screw hole or channel 3 in the first member may be a pocket hole.

Description

Apparatus, Kit and a method for joining First and Second Members This patent application relates to joining or fastening ofmembers, typically, but not necessarily exclusively, in the area of furniture or cabinet manufacturing. In the following description, any reference to the singular includes the plural and vice versa..

There are many ways to join or fasten together different members (such as panels) when manufacturing cabinets or other pieces of furniture. These may include glued joints or screwed joints. Examples of glued joints include dovetail joints, lapped joints, mortice and tenon joints. Such joints tend to be permanent once glued.

Other joints can comprise fasteners such as screws. Screwed joints may sometthaes be held to be weaker or inferior to glued joints. However, they may offer some advantages in that the fastened members may be supplied in kit form for later assembly, potentially at a site other than the site of kit manufacture; further, the members may be disassembled (for example prior to re-installation at another site) following assembly, if desired. One form of joint which includes the use of fasteners is the 'pocket screw joint'; this shall be termed a 'pocket joint' in this description, which uses the example of panels being joined together by way of an example.

In bespoke furniture manufacture which is performed by craftsmen in workshops and with a multitude of tools available to them, such a joint is formed by a hole which is created in a first panel, typically by machining or drilling into an outer face of the panel at an angle of 10 to 15 degrees to the plane of the panel. The pocket hole may typically comprise (i) a large diameter hole set into and located towards the outer face of the panel, the hole being of sufficiently large diameter to accommodate a head of the screw and (i) a hole of smaller diameter located inboard of the outer face of the panel (this being of similar or slightly smaller diameter than the major diameter of the pocket screw thread). Ti) form the joint the first member may typically be clamped to the second member and the pocket screw driven into the pocket hole such that it creates a screw-hole and thread in the second member; in this way the screw head urges the first member towards the second member until the two members become fastened to one another. This is a relatively efficient fastening technique and may be used to join a variety of members such as framing timber and/or panels (such as MDF, hardboard or plywood), but the technique and the invention herein may also be applied to other suitable materials.

One advantage of the pocket joint is that it may be used with panel materials which can have some structural weakness in a direction perpendicular to the plane of the panel; examples of such panels may include plywood and other laminated materials. When pocket joints are used with such materials the angle of the drilled hole has a component in said transverse (the through-thickness) direction with the result that the screw passes through the thickness of the material as it is driven into the second member; this may be contrasted with a screw driven into the side of a plywood or other laminated panel in a direction parallel to the plane of the panel, which may cause the panel to split or delamthate (potentially between Lunthated layers).

However, typical pocket joints can have certain. disadvantages and in particular with regard to furniture which is assembled by the consumer from a plurality of members which have been shaped to the required form and provided in a "flat pack" form for subsequent assembly by relatively unskilled consumers who only have limited tools available.

While furniture supplied in kit form may provide certain advantages such as lower storage costs (for example due to occupying a low volume and/or a compact package) and/or low cost of transport (for example when being shipped between different sites in a product supply chain), the Finished product may be difficult to achieve neatly and accurately and, when achieved, may have a poor overall finish and appearance.

Such a kit may comprise members which are to be joined together and, typically, if first and second members are to be joined together, pocket holes are provided in the fir' st members and fastening means such as pocket screws are provided to be passed into said pocket holes, but no-pre-formed screw-holes are provided in the second member and this stage is typically performed at the time of manufacture and these members are then provided and arranged in a. compact arrangement prior to supply of the kit to the consumer for assembly a.t the location of use of the furniture.. When Later assemble& the members need to be positioned, aligned and/or clamped with the aid of a jig before the pocket screws are passed into the pocket holes in the first member and then driven into the second members in order to achieve suitably accurate and joining of the members and this is then repeated typically a number of times during the assembly of the furniture. 't his may be inconvem'ent, incur cost and/or still lead to poor alignment of the members. Even, if the second members are supplied with pre-manufactured screw-holes (for example holes that are formed, cut or drilled) it might appear that the members could be accurately assembled later with ease. However as the fastening means, such as pocket screws are typically adapted to creating holes (for example, by virtue of their sharp self-tapping tips which may bite into the second member) they may act, when driven into the second member, to_modify the pre-manufactured screw-holes or create new screw-holes in the second members with the result that the respective screw-holes in the first and second members which are required to be in alignment may in fact have unsuitable and/or non-op-tun' al geometries, positions and/or orientations; and this may lead to errors in alignment or relative positioning of the first and second members during assembly of the kit.

An aim of this invention is to provide apparatus, kit and a method in which at least one pocket joint for fastening two members together is provided arid_in which the desired alignment or relative positioning of the two members and the respective screw holes for the receipt of the fastening means can be accurately achieved and thereby allow the accurate assembly of the item from the kit.

In a. first aspect of the invention, there is provided apparatus for forming a. joint, said apparatus including a first member with a screw hole or channel formed therein and a second member against which the first panel abuts to be fastened thereto, said screw hole (Jr channel having a first opening into which a fastening means is moved to pass through the same and into the second member so as to join the said members together and wherein a forming means is initially driven into the second member to form a screw hole (Jr channel therein in alignment with the screw hole or channel in the first member and the forming means is then at least partially withdrawn and reused as the fastening means, or replaced by a fastening means to pass through the screw hole or channel in the first member and into the said screw hole or channel in the second member to engage the said members together.

In this context, forming may comprise any one or more of creating, cutting, material removal and material displacement processes.

The forming means may comprise drilling and/or screwing and/or another suitable process. In one embodiment the forming means may be for example a pocket screw which is a screw adapted to create a screw-hole in a member and typically comprising a shaft with threaded section and a flange or other engagement element for urging one member into engagement with another member. The forming means is therefore typically provided to pierce, abut and/or cut into material of the second member to form the channel or screw hole therein.

In one embodiment the fastening means has a head portion and a shaft portion. The said screw hole or channel in the first member may be of a dimension so as to allow the head portion of the fastening means, when the panels are joined together, to lie at or below the surface of said first member in which the opening is formed In one embodiment the said first and second members are panels for an item of furniture.

In one embodiment additional securing means may be used, such as adhesive, which may be inserted in location means and/or at the interface between the members.

In one embodiment the same component is used a.s the forming means and the Listening means.

In one embodiment, the forming means and fastening means are two different components and the configuration of the forming means is different to that of the fastening means.

Thus, in one embodiment, a forming means of a first configuration is used to form an aperture in the second member and then a fastening means of a second configuration is introduced to secure the said first and second members together.

In one embodiment an additional locating feature may be created in the first and/or second members, most typically after fastening the members to one another.

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In one embodiment this additional locating feature may comprise first and second alignment holes formed in respective first and second members. The alignment holes may be created by a. process in which a tool is passed through both members substantially in a single step. In one embodiment the process mav comprise a drilling operation.

In one embodiment the additional locating feature may comprise a locating element such as a dowel which may be optionallv secured to its member and/or glued within one of sa.id alignment holes.

In one embodiment the apparatus and kit includes more than one additional locating feature. Advantageously the pocket screw (or screws) may hold the members in a suitable position or relative alignment whilst sa.id tool is driven through the first and second members to create the respective alignment holes. When subsequently disassembled, the locating element may remain within or secured to its member and the locating element may subsequently be inserted into the mating (i.e. second) alignment hole of the other member in order to facilitate assembly and the members may then be easily fastened together, for example using a screw.

In one embodiment the additional locating feature may comprise respective first and second alignment holes formed in fir. st and second members. Such holes may be coaxial. As such they may serve as means for aligning the members prior to insertion of the fastener. 't he additional locating feature may include frictional parts or parts with an interference fit.

In one embodiment the additional locating feature includes a locating element such as a dowel. One member may comprise a dowel protruding from its alignment hole; such dowel may be inserted into the alignment hole of the second member during assembly by a user. This arrangement may provide a more substantial, rigid and/or less abrasive location means compared with some other options.

In one embodiment the friction or interference (for example between dowel and alignment hole) may facilitate assembly by temporarily holding the members in a suitable relative alignment and/or position while the user completes other operations -for example driving a fastener through first and second members. More than one additional locating feature may be included in the joinery kit in order to create multiple points of alignment between two or more members. In one embodiment the kit may comprise a third member.

In a further aspect of the invention there is provided a. furniture assembly kit to form said item from a plurality of members, and wherein the kit includes information means secured to at least one of the said members.

In one embodiment the said information means are provided in the form of a label, indicator or descriptor. Typically the information means may be a temporary label such that it can be readily removed after assembly without adversely marking or damaging the member. The instruction means may comprise or display a symbol from a commonly known sequential set of symbols (such as an alphabet or a numbering sequencesequence such as "1", "2", "3" ...) thus indicating a suggested or preferred order of assembly and/or fastening of the member.

In one embodiment the instruction means may be proximal or adjacent to the portion of the member to be fastened and/or assembled. Tns true tion means may be located on at least two but preferably on three members. They may be proximal or adjacent to the portions of each member to be Listened and/or assembled to one another. The respective portions of a first member pair to be fastened and/or assembled may comprise a first set of instruction means. These may be located substantially opposite or adjacent to one another. 't they may comprise at least one similar (Jr common symbol (for example, "1"). Likewise, a second member pair may comprise a. second set of instruction means which may be similarly arranged on sa.id second member pair with respect to each of their portions to be fastened and/or assembled. This second set of instruction means may comprise a different symbol which may indicate later or subsequent assembly and/or fastening (for example, "2") compared with that of the first set, thereby indicating or suggesting that the second member pair portions be joined after the first member pair portions. 't his system may be extended to three, four or more member pair portions. In this way the user may be able to quickly identify the portions of each member that are to be juxtaposed, and the order in which they are to be assembled and/or fastened. 't his assembly procedure may be rather self-evident to the user. "t he user may also be able to avoid consulting extensive and complex instructions. The instruction means may comprise a removeable sticker. The sticker may comprise glue or a tack compound.

In one embodiment the kit comprises at least one additional pocket hole into which a first member may be fastened to an external element. Both first and second members may be fastened to the external element. The member or members may be so fastened using a fastener such as a pocket screw. the fastener may be driven through the member or members into the external element. The external element may be a structural element or assembly such as a baton, a building and/or a second item of furniture. Where the external element is a baton, this may be located to the rear of the furniture. The baton may serve to connect the furniture to part of a building such as a wall. Use of such a baton may optionally provide space for location of services (such as plumbing or wiring) between the furniture a.nd wall. Where the external element is a second piece of furniture, such element may be a cabinet. It may be located adjacent to the first piece of furniture. Multiple pocket holes may connect two or more pieces of adjacent furniture thereby creating a strong and rigid compound structure in which individual furniture elements cannot easily move out of alignment Further, the pocket holes and/or fasteners may be heated so as to be not visible and/or hidden from view when the furniture is installed and/or in normal operation thus creating the impression of professional joinery In another aspect of the invention, there is provided a method of forming a joint between first and second members for an item of furniture, said method comprising the steps of forming a channel or screw hole in at least a First member at a prede fined angle with respect of an edge of said member, bringing an edge of said member into abutment with said second member and wherein a. former is advanced through sa.id channel or screw hole to form a channel or screw hole in said second member and at least partially withdrawing said former and advancing a fastening means through the said channel or screw hole in the first member and into the channel or screw hole in the second member so as to engage the said first and second members together.

In one embodiment, the method includes the intermediate step of introducing a fastening or forming means through the said channel in the first panel and driving

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the same into the said second panel so as to form the channel iii t le said second panel.

In one embodiment, the said fastening means which performs the intermediate step is also used to engage the first and second panels together.

Alternatively, once the said second channel has been formed in the second panel, the fastening or forming means used to form that channel is removed and a fastening means, of a configuration different to the first fastening or forming means is then inserted so as to engage the first and second panels together. In one embodiment the fastening means is not adapted for cutting and is optionally a thread-forming screw.

In one embodiment, the joint which is formed is a pocket hole joint with the diameter of the channel provided in the first panel greater than the diameter of the channel provided in the second panel.

Accordingly this invention provides a method of producing a joinery kit comprising first and second members, wherein the method includes: an assembly process comprising the steps of (i) creating a pocket hole in the first member, (ii) driving a pocket screw through the first member into the second member thereby fastening the members to one another with a predetermined relative position and/or alignment; and a disassembly process, comprising the steps of (a) loosening said driven pocket screw, and (b) disassembling first and second members.

In one embodiment the pocket screw acts as the forming means and the kit includes a fastening screw for fastening the first member to the second member substantially in the said predetermined relative position and/or alignment once the forffung means has been used.

In one embodiment the fastening screw is the same as used as the forming means or is another pocket screw. In an alternative embodiment the fastening screw is not a pocket screw. In one embodiment the fastening screw is relatively blunt, not adapted for any one or more of biting into, cutting or piercing and/or is a thread-forming screw.

In one embodiment the method includes a step of securing the fastening screw in the pocket hole of the first member after loosening the driven pocket screw.

In one embodiment the fastening screw is secured in the first member by inserting and/or screwing it into the pocket hole. In one embodiment the fastening screw is driven into and through the pocket hole such that it protrudes from the first member.

In one embodiment a screw retention substance is applied to the fastening screw or to the first member, after the driven pocket screw is loosened. In one embodiment the screw retention substance is any or any combination of a glue, mastic-, bitumen-and/or a silicone-based compound.

In one embodiment the method includes the step of adding a. locating, recess and/or countersink feature to the pocket screw hole which was formed in the second member during the assembly process.

In one embodiment the method includes the step of applying a label, indicator or descriptor to at least one and optionally both members.

In one embodiment the method includes a step of arranging the members in a substantially planar or flat-pack configuration after the disassembly process.

In one embodiment the said members are formed of any or any combination of wood, plywood or other fibrous or plastics materials.

In one embodiment the method forms an item of furniture such as a cabinet. In one embodiment the joint formed by the fastening of first and second members is a substantially I.-Olt-angle butt joint or a mitre joint.

In one embodiment the method further comprises aligning or positioning first and second members relative to one another before driving the pocket screw through the first member, and optionally so that one edge of the first member and one edge of the second member lie substantially in the same plane In one embodiment the pocket hoks formed in accordance with the method arc located so as not to be visible and/or hidden from view when the furniture is installed and/or in normal operation and optionally wherein the furniture is a. kitchen cabinet for installation adjacent to a wall.

In one embodiment there is provided an item of furniture assembled using apparatus and/or a method as herein described.

In a further aspect of the invention there is provided a joinery or furniture assembly kit comprising: a first member which includes a plurality of pocket holes; a second member comprising a plurality of screw holes or channels matching said pocket holes and a plurality of fastening gcrews In a yet further aspect of the invention there is provided a. joinery or furniture assembly kit including a plurality of members to be joined together, and wherein the kit includes information means secured to at least one of the said members.

In a yet further aspect of the invention there is provided a joinery or furniture assembly kit utilising the apparatus and/or method as herein described In one embodthient the fastening means is any of a pocket screw, a screw which is relatively blunt, a screw which is blunt, a screw which is not adapted for any one or more of biting into, cutting or piercing and/or a screw which is thread forming screw.

In one embodnnent the kit includes a forming means which may in one embodiment be a pocket hole screw.

In one embodiment the kit includes means to form a locating, recess and/or countersink feature in a a channel formed in a second member which is to be joined to a first member using the kit.

In one embodiment the fasten*, means is secured in the first member and in one embodiment, by inserting and/or screwing it into a. pocket hole formed in the first member.

In one einboditnent the fastening means protrudes from the first member.

In one embodiment the kit includes a. securing substance for retaining the fastening means and members in position and in one embodiment the securing substance includes any or any combination of a. glue, mastic and/or silicone.

In one embodiment the kit * icludes on at least one of the members a label, indicator or descriptor.

In one embodiment the members in the kit a.re arranged in a substantially planar flat-pack configuration. In one embodiment at least one of the members is a panel.

In one embodiment the kit is provided as the components to allow the formation of an item of furniture and the members may be formed of any or any combination of wood, plywood, or any other fibrous or plastics material.

In one embodiment the position of the pocket hole relative to an edge of the first member, and the position of the screw hole in the edge of the second member are such that if the fastening screw were driven through the pocket hole and into the screw hole the two said edges would lie substantially in the same plane and, typically the members would lie substantially perpendicular to one another.

The optional inclusion in the kit of a fastening means such as a screw winch is used to fasten the members together once the forming means has been used and to provide the fastening screw of a form other tha.n a. pocket screw in the kit may provide an advantage in that the fastening screw may not tend to bite into the second member or create a new or modified screw-hole in the second member (as this may cause the desired alignment or relative positioning of first and second members to become compromised). 'Hie fastening screw may optionally be a screw not adapted for biting into and/or creating and/or modifying a screw-hole in the second member; the Listening screw may be a thread-forming screw such a screw being adapted to create a thread in a screw-hole or pilot-hole but not adapted for creating a screw-hole. The use of a relatively blunt screw such a.s a thread-forming screw a.s the fastening screw may advantageously be substantially blunt or at least not sharp, which may arguably be safer for the assembler of the members. This may be a particular advantage if the fastening screw is secured in the first member within the kit, as the assembler may touch or brush against the screw whilst handling the members.

The optional inclusion of a locating, recess and/or countersink feature in the screw-hole created in the second member may be advantageous in that it may serve as a guide for the fastening Rcrew; the tip of the fastening screw may thus be guided towards the pre-manufactured (or at least existing) screw-hole in the second member, thus facilitating assembly.

In some instances a fastening screw (such as a thread-forming screw) arranged to protrude from the first member may locate conveniently in a locating, recess and/or countersink feature of the screw-hole of the second member. After such location the fastening screw may be easily tightened by the assembler. In cases where there may be a number of pocket holes arranged on a face of the first member and a number of corresponding fastening screws secured in said pocket holes, this face of the first member may be placed adjacent to the second member such that each fastening screw can conveniently locate in a corresponding locating, recess and/or countersink feature of the second member. the first member may therefore be readily located and positioned on the second member before each fastening screw is tightened. It should be noted that as each fastening screw is guided into the corresponding screw-hole of the second member, it may preferably and advantageously follow the path of the pre-created screw-hole. In this way the final relative position and/or alignment of the two members is as desired, and may be similar (Jr the same as the predetermined relative position and/or alignment of the members, with little positional error.

In one embodiment there is a time delay between the use of the former, such as at a manufacturing location and the use of the fastening means, such as at the location of assembly.

In one embodiment there is a change of location between the location at which the former is used and the location at which the fastening means is used Specific embodiments of the invention are now described with reference to the accompanying drawings; wherein Figure 1 illustrates components of a kit in accordance with one embodiment of the thvention; Figure 2 shows three principle features of a typical pocket screw.

Figure 3 shows a pocket joint formed from the kit of components of Figure 1. Figure 4 shows the assembly of Figure 3, but with the pocket screw removed. Figure 5 shows the two members, disassembled.

Figure 6 shows three principle features of a typical thread-forming germ Ugure 7 shows the assembly of 1;igure 6 with the thread-forming screw inserted into and protruding from the first member.

Figure 8 shows multiple pockets joints on faces of the two members Figure 9 shows a cabinet in which the pocket joints are not visible from the front angle, thereby creating the appearance of a professionally jointed piece of furniture.

Figure 10 illustrates a plan view of an item joined to an external element in accordance with one embodiment of the invention; Figure 11 illustrates a plan view of an item joined to a second item in accordance with one embodiment of the invention; Figures 12a and b illustrates the stages of forming of an item with the optional use of additional locating features in accordance with one embodiment of the invention and; Figures 13a and b illustrate the joining together of members or panels with optional use of instruction means, Referring firstly to Figure 1 there is illustrated a kit of components in accordance with one embodiment of the invention in which there is shown first and second members 1, 2 with screw holes or channels provided in the first member 1 and which, in the embodiments now described, are pocket holes 3. In this embodiment the pocket hole comprises a portion 3a leading from an opening on the surface of the member 1 through which the forming means and fastening means are Mtroduced and which is of a larger bore than a further portion 3b and a further portion 3c which is of a smaller bore than portion 3b. A pocket screw 4 is shown and which is used as the forming means of the invention. The pocket screw 4 is shown m more detail in Figure 2 and includes a. hea.d 4a., a shaft 4b and forming tip 4c which may be pointed and/or sharp and may be adapted for piercing and/or biting into material M. order to create the screw hole.

Figure 3 illustrates the first and second members 1,2 of Figure 1 having been brought together by the location of the pocket screw 4 into the pocket hole 3 in the first member and into channel 3 now formed in the second member 2 by driving the pocket strew 4 into the second member and being guided by the strew hole or channel 3 provided in the first member 1.

Once the formation of the channel 5 in the second member 2 has been achieved the pocket screw 4 is withdrawn as illustrated in the Figure 4. The pocket screw 4 has therefore been used as the forming means of the invention.

At this stage and in this embodiment, the first and second members are placed with the screw hole or channel 3 in alignment with the newly formed channel 5 in the second member 2 by moving the same into position as indicated by the arrows in 'igure 5. A fastening means such as a. thread forming screw 6 of the_fiTe shown in Figure 6 which may comprise a head 6a, shaft Gb and tip Gc which is blunt, relatively blunt and/or may not be adapted for biting into, cutting and/or piercing member 2, can then be introduced along the screw hole or channel 3 in the first member 1 as shown in I;igure 7 and in which the head of the screw is positioned in the screw hole or channel 3 and is optionally below the surface of the first member in which the opening into the screw or channel..3 is located. The tip 9 of the screw 6and a portion of the screw shaft, protrudes from fir. st member 1. As fir. st and second members 1, 2 are moved closed closer to one another the tip of screw 9 enters and/or locates in the countersink feature 8 of the channel 5. The countersink feature 8 serves as a guide for the tip 9 of screw 6, and therefore facilitates alignment of first and second members 1, 2.. Screw 6 may be driven further into the assembly (such that it enters screw-hole 5 of the second member) until tight, thus joining the first and second members 1,2 together in an abutting relationship with the faces of the members 1,2 abutted to one another so that the relative positions and/or alignment of members 1,2 become similar to that in Figures 3 and 4.

This process will typically be repeated a number of times to join the first and second members 1,2 together at spaced locations with the respective screws 6 driven though channels 3,5 and Figure 8 illustrates an example of a number of pocket joints to be formed with the screws 6 located in respective channels 3 in_member 1 and protruding from the same so that the tips 9 of the screws 6 engage with the respective countersink features 8 of the channels 5 in the second member 2 and thereby allow the members 1,2 to be readily located together by, for illustration purposes rotating the member 1 about the axis 10 into the correct abutting relationship and the screws 6 can then be driven into position to join the members 1,2 together.

This procedure can be repeated for a plurality of members 11,12,13,14, 15 and used as required to form a final item of furniture and an example of this is shown in Figure 9 in which there is shown a cabinet 19 which is shown in an assembled position and from the front as illustrated in Figure 9d the pocket joints formed by channels 3 and fastening screws 6 as herein described are not visible and therefore are only visible at the top as shown in Figure 9a, the back as illustrated in Figure 9b, and the bottom as illustrated in Figure 9c on lines 11, 11' and 12 and thereby create the appearance of a professionally jointed piece of furniture.

Figure 10 shows a plan (top) view of a cabinet comprising two side panels 111, 111', a top panel 114 and rein member 112. Fasteners (not shown) driven via pocket holes 103 into screw-holes 105 connect the panels 111, 111', 112 and 114. Additional pocket holes 122 in top panel 114 allow for fasteners to be driven through top panel 114 and rear panel 112 into batten 116 which may itself be fastened or anchored to the wall of a building or other external structure or assembly (not shown). Extended screw-holes 120 formed for example by driving long fasteners into said panels and external member fasten said panels and batten together, thereby optionally anchoring all of these parts to the external structure or assembly. Although the arrangement is shown in the context of the top / rear portion of the cabinet, it may be applied be applied the bottom, side and/or other portions of the cabinet.

Figure 11 shows a plan (top) view of two cabinets juxtaposed and connected using fasteners which pass through two additional pocket holes 117 in top panel 114 of a first cabinet, through screw-holes 123 which extend through side panel 111' of the first cabinet and into side panel 111" of the adjacent (i.e. second) cabinet. 't he extended screw-holes 123 may be formed by driving relatively long fasteners through said panels or by other means. This arrangement may be applied to the top, bottom and/or any other cabinet portions, thereby ensuring that two or more cabinets may be securely comiected to each other.

Figure 12a. shows a plan (top) view of a cabinet in which pocket screws 104 have been driven through the face of top panel 114 and into side panels 111, 111' and rear panel 112 thereby joining said panels in a suitable position or desired relative alignment to form the top portion of the cabinet. Additional locating features comprising holes 121 are then drilled through side panels 111, 111' into the sides of top panel 114. A dowel 118 is then pressed into each hole 121 such that it resides within a portion of a side panel 111 (or 111') and a portion of the top panel 114. Each dowel may optionally be secured to its side panel (111, 111') using glue. Figure 121 shows the same structure but with the Listeners 104 now removed and the side panels 111, 111' and rear panel 112 disassembled, and alignment holes 121 now divided into inner portions (121a) and outer portions (121b) in top panel 114 and side panels (111, 111') respectively. 't he dowels 118 remain secured or bonded within but protruding inwardly from the outer alignment holes 21b. Subsequent or later assembly of the cabinet by a. user may now be facilitated by locating the protruding portion of each dowel 118 in respective inner alignment holes 121a in top panel 114 thereby locating the side panels 111, 111' in top panel 114 and/or temporary securing said panels in a desired relative position while fasteners (pocket screws, thread-forming screws or other fastening means) are put or driven into place. Use of such locating elements may limit risk of damage during assembly. The structure may also be more accurately assembled using this method than if using fasteners alone.

Figure 13a shows first and second members 101 and 102 arranged in a desired relative position or orientation with respect to one another during assembly of members in a. joinery kit. A pair of removable stickers 123 are temporarily attached to members 101, 102, each sticker 123a, 123b of the pair' being attached to a face of respective said members. Each sticker 123a, 123b is in close proximity to the interface 127 which defines the member (101, 102) portions to be joined (for example abutted prior to being fastened) to one another and/or assembled. Mutually facing arrow symbols 125 depicted on each sticker 123a, 123b clearly indicate interface 127 to the user. Also depicted on each sticker 123a, 123b is the number "1" (124) indicating which is the first interface 127 to be formed (and therefore which member edges or portions are to be the first to be joined and/or assembled). Turning to Figure 13b a pair of removable stickers 126 are temporarily attached to a third member 122 and second member 102, each sticker 126a, 126b being in close proximity to the interface 128 which defines the member (122, 102) edges or portions to be joined to one another and/or assembled. Arrow symbols 130 depicted on each sticker 126a, 126b clearly indicate interface 128 to the user. Also depicted on each sticker 126a, 126b is the number (129) indicating which is the second interface (128) to be formed (and therefore which member edges or portions are to be the second to be joined and/or assembled).

Thus, the assembly instruction sequence is clearly defined for the benefit of the user/assembler of the joinery kit. Pocket holes may optionally be included in such an arrangement. By way of an example, downward-facing pocket holes may be located on the far (rear, away-facing) vertical face of first member 101 a.s shown in Figure 13a. In this example fasteners such as pocket screws may be inserted into said pocket holes and driven into the upper (horizontal) face of second member 102 thereby joint* the lower edge of first member 101 to the far upper edge of second member 102 at interface 127. Such pocket joints are out of view and therefore would not be visible in Figure 13a.

It should be appreciated that although the provision of indication means, such as labels, is herein described with reference to the assembly of the item shown in the Figures the use of the indication means may be beneficial for use in the assembly of other items and/or utilised to advantage with items which do not require the use of the assembly process and components of the apparatus and kit as herein described and may therefore be independently beneficial and is believed to he novel and inventive in its own right.

Claims

Claims 1 Apparatus for forming a joint, said apparatus including a first member with a screw hole or channel formed therein and a second member against which the first panel abuts to be fastened thereto, said screw hole or channel having a. first opening into which a fastening means is moved to pass through the same and into the second member so as to join the said members together and wherein a forming means is Mitially driven into the second member to form a screw hole (Jr channel therein in alignment with the screw hole or channel M. the first member and the forming means is then at least partially withdrawn and reused as the fastening means, or replaced by a fastening means to pass through the screw hole or channel in the first member and into the said screw hole or channel M. the second member to engage the said members together.
2 Apparatus according to claim 1 wherein the fastening means has a head portion and an at least partially threaded shaft portion.
3 Apparatus according to claim 2 wherein' the screw hole or channel in the first member is of a dimension so as to allow the head portion of the fastening means to lie at or below the surface of said first member in which the opening into the aperture or channel is formed.
4 Apparatus according to any of the preceding claims wherein the first and second members are panels for an item of furniture.
5. Apparatus according to any of the preceding claims wherein the same component is used as the forming and fastening means.
6 Apparatus according to any of the claims 1-4 wherein the configuration of the forming means is different to that of the fastening means.
7 Apparatus according to any of the preceding claims wherein one or more location means are created in sa.id first and/or second members to respectively align and retain the first and second members in position dun* engagement of the members.
8 Apparatus according to claim 7 wherein the location means include first and second alignment holes formed in respective first and second members.
9 Apparatus according to claim 8 wherein the locating means is retained in position during the disassembly and reassembly of the members.
Apparatus according to claim 8 wherein the fit of the locating element in at least one of the alignment holes is a friction or interference fit.
11 Apparatus according to any of the preceding claims wherein the apparatus includes instruction means at least temporarily secured to at least one of the said members.
12 Apparatus according to claim 11 wherein the instruction means are located proximal to the abutting edges or engaging edges or faces of the members and/or location at which the fastening means are to be used to fasten and assemble the members together.
13 Apparatus according to any of the preceding claims wherein at least one additional pocket hole is formed and via which at least one of said members is Listened to an external clement using a fastening means.
14. Apparatus according to any of the preceding chinas wherein the first member includes a pocket hole, said pocket hole including said screw hole or channel.
A method of forming a joint between first and second members for an item of furniture, said method comprising the steps of forming a channel or screw hole in at least a first member at a predefined angle with respect of an edge of said member, bringing an edge of said member into abutment with said second member and wherein a former is advanced through said channel or screw hole to form a channel or screw hole in said second member and at least partially withdrawing said former and advancing a fastening means through the said channel or screw hole in the first member and into the channel or screw hole in the second member so as to engage the said first and second members together.
16 A method according to claim 15 wherein the said former and fastening means is the same component.
17 A method according to claim 15 wherein. the former is provided of a different configuration to the fastening means which includes a. head portion and an at least partially threaded shaft
18 A method according to claim 17 wherein when the first and second members are engaged a head of the fastening means is substantially flush or within the channel in the first member.
19 A method according to any of claims 15-18 wherein the joint which is formed is a pocket hole joint with the diameter of the channel or screw hole provided in the first member greater tha.n the diameter of the channel (Jr screw hole provided in the second member.
A method according to any of claims 15-19 wherein the method tn. dudes the step of adclUtg, a locating, recess and/or countersink feature to the channel or screw hole formed in the second member.
21 A method according to any of claims 15-20 wherein the method includes the step of applying a label, indicator or descriptor to at least one of said members.
22. A method according to any of claims 15-21 wherein the method includes a step of arranging the members in a substantially planar or flat-pack configuration after the withdrawal of the former.
23. A method according to any of the claims 15-22 wherein there is a time delay and/or change of location between the use of the former and the use of the fastening means.
24 A method according to any of claims 15-23 wherein the method includes the step of engaging location means between said first and second members to assist in locating the first and second members as they are engaged.23.An item of furniture assembled using apparatus and/or method as herein described in the claims 1-24.26 A joinery or furniture assembly kit comprising: a first member which includes plurality of pocket holes; a second member comprising a plurality of screw holes or channels matching said pocket holes and a plurality of fastening screws.27 A joinery or furniture assembly kit including a plurality of members to be joined together, and wherein the kit includes information means secured to at least one of the said members.28 A joinery or furniture assembly kit utilising the apparatus and/or method as set out in claims 1-24