SE2150711A1

SE2150711A1 - Methods and systems of manufacturing furniture

Info

Publication number: SE2150711A1
Application number: SE2150711A
Authority: SE
Inventors: Victor Spirea
Original assignee: Ikea Supply Ag
Priority date: 2021-06-03
Filing date: 2021-06-03
Publication date: 2022-12-04

Abstract

A method of manufacturing a ready-to-assemble furniture module is provided. The method comprises providing a furniture module (10c-d), arranging the furniture module (10c-d) at a predetermined position of a fixture (110), activating at least two drilling units (120a-d) to provide corresponding assembly holes (40a-d) in the furniture module (10c-d), and controlling the respective position of the at least two drilling units (120a-d) during activation in relation to each other, as well as in relation to the fixture (110).

Description

METHODS AND SYSTEMS OF MANUFACTURING FURNITURE Technical Field The present invention relates to furniture, and to manufacturing of furniture. More particularly, the present invention is directed towards methods and systems for producing ready-to-assemble furniture modules.

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

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

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

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

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

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

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

Arranging the furniture module at a predetermined position of the fixture may be performed by aligning a first part of the furniture module with a first reference position of the fixture, and aligning a second part of the furniture module with a second reference position of the fixture. By using two reference positions, preferably being spaced apart, improved positioning of the entire furniture module is accomplished.

The furniture module may be aligned only at the first part of the furniture module and at the second part of the furniture module. This is particularly advantageous for furniture modules being made of natural material of slightly varying dimensions, as the fixation at only two positions will allow for Variations in size of the furniture module.

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

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

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

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

The first and second drilling device of a common drilling unit may be aligned in a vertical direction. The assembly holes may thereby extend through the furniture module.

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

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

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

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

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

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

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

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

According to a third aspect, a method of manufacturing furniture is provided. The method comprises manufacturing a ready-to-assemble furniture module by performing the method according to the first aspect, manufacturing a ready-to-assemble furniture module according to the second aspect, and connecting the furniture modules to form the furniture.

According to a fourth aspect, a system configured to manufacture a ready-to-assemble furniture module is provided. The system comprises a fixture configured to receive a furniture module at a predetermined position, and at least two drilling units configured to provide corresponding assembly holes in the furniture module, wherein the respective position of the at least two drilling units is controlled during activation in relation to each other, as well as in relation to the fiXture.

The fixture may be provided with one or more clamping devices for securing the position of the furniture module.

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

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

The advantages ofthe first aspect are also applicable for this fourth aspect.

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

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

The advantages ofthe second aspect are also applicable for this fifth aspect.

Brief Description of the Drawings The invention and its many advantages will be described in more detail below with reference to the accompanying schematic drawings, which for the purpose of illustration show some non-limiting embodiments and in which Fig. la is an exploded view of a furniture comprising a plurality of ready-to-assemble furniture modules being manufactured by methods according to various embodiments; Fig. lb is an isometric view ofthe furniture modules shown in Fig. la, in a knock-down configuration prior to assembly; Fig. 2a is an isometric view of a ready-to-assemble furniture module being manufactured by a method according to an embodiment; Fig. 2b is an isometric view of a ready-to-assemble furniture module being manufactured by a method according to another embodiment; Figs. 3a-b are cross-sectional views of two different furniture joints connecting two furniture modules, of which at least one furniture module is manufactured by a method according to an embodiment; Fig. 4a is an isometric view of a system for manufacturing a ready-to- assemble furniture module according to an embodiment; Fig. 4b is an isometric view ofthe system shown in Fig. 4a, omitting the drilling units; Fig. 5a is an isometric view of a system for manufacturing a ready-to- assemble furniture module according to another embodiment; Figs. 5b-c are side Views ofthe system shown in Fig. 5a, in different stages of operation; Figs. 5d-e are side Views of enlarged parts ofthe system shown in Fig. 5a, in different stages of operation corresponding to the Views shown in Figs. 5b- C; Figs. 6a-c are top Views of the system shown in Fig. 5 during different manufacturing stages; Figs. 7a-b are schematic Views of methods for manufacturing a ready-to- assemble furniture module according to different embodiments; and Fig. 7c is a schematic View of a method for manufacturing a furniture.

Detailed Description In Figs. la-b an example of a furniture l being manufactured according to an embodiment is shown. The furniture l is a chair made of a plurality of pre- manufactured and ready-to-assemble furniture modules l0, which are assembled to the final chair l by using a plurality of furniture connectors 30, as will be described further on.

Although the furniture is a chair, other furniture types could also be manufactured in line with the embodiments described herein. For example, the furniture may be a book shelf, a sofa table, etc. Although such furniture are different from each other in terms of use and construction, they would all share the common feature of haVing one or more furniture modules l0 comprising at least one furniture part being made of a natural material, such as rattan, round wood, etc., which makes it Very difficult to control its dimensions for normal industrial furniture manufacturing processes.

In the shown example, ready-to-assemble furniture modules l0 haVe a frame, preferably of rattan, forming the outer boundaries of the furniture module l0. The furniture modules l0 comprises a seat l0a, a back rest l0b, and two side pieces l0c-d. Also, an elongated support beam l0e forms a ready-to-assemble furniture module l0, although it does not haVe the frame of the preViously mentioned furniture modules l0a-d. The seat l0a, the back rest l0b, an optionally also the side pieces l0c-d may be proVided with some kind of surface coVer, e.g. rattan wicker or similar.

The side pieces l0c-d do not only form armrests, but also the legs of the chair l. In the erected state, as indicated in Fig. la, the rattan chair l is a rigid furniture proViding solid support for a person using the chair l.

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

In order to allow the end user to assemble the ready-to-assemble furniture modules 10a-e into the final chair 1 as indicated in Fig. 1a, it is preferred to provide the furniture connectors 30 being adapted and optimized for connecting the furniture modules 10a-e.

Instead of a fully hand-made furniture 1 of a natural material such as rattan, it has been realized that while each furniture module 10a-e may be produced in a factory, the dimensions will not be identical due to the intrinsic properties of the material. Instead, the furniture 1 is assembled from a knocked- down configuration, as shown in Fig. 1b, by an end consumer.

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

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

In Fig. 2a a more detailed view of a side piece 10c-d, i.e. a ready-to- assemble furniture module, is shown. The side piece 10c-d is formed by a plurality of furniture parts 20a-d. A first furniture part 20a forms an L-shape, comprising an armrest and a front leg portion. A second furniture part 20b is a linear part forming a back leg portion, being connected at its upper portion to the armrest portion of the first furniture part 20a. A third furniture part 20c forms a linear cross piece being connected to the front leg portion of the first furniture part 20a at one axial end, and to the second furniture part 20b at its opposite axial end. A fourth furniture part 20d has an U-shape and is connected to the first, second, and third furniture parts 20a-c for providing support and robustness to the furniture module l0c-d.

In the shown example, at least the furniture parts 20a-c are of rattan material. The furniture parts 20a-d extend in the same plane, such that the entire furniture module l0c-d is planar. The furniture module l0c-d is preferably pre- manufactured, e.g. by hand, by connecting the furniture parts 20a-d to each other.

Four radial assembly holes 40a-d are provided, all extending through respective furniture parts 20a-c in their radial direction. The first furniture part 20a is provided with a front assembly hole 40a for connecting a front part ofthe seat l0a, and a rear assembly hole 40b for connecting the back rest l0b. The second furniture part 20b is provided with an assembly hole 40c also for connecting the seat l0a, and the third furniture part 20c is provided with an assembly hole 40d for connecting the elongated support beam l0e. Optionally, the second furniture part 20b may be provided with an additional hole (see Fig. la) for receiving a plug ofthe back rest l0b in order to provide further robustness to the final furniture.

In Fig. 2b a more detailed view ofa seat l0a, i.e. a ready-to-assemble furniture module, is shown. The seat l0a is formed by a plurality of furniture parts 20e-j. A front furniture part 20e and a rear furniture part 20f are linear parts, being connected at its axial end portions to side furniture parts 20g-h. Curved furniture parts 20i-j are arranged in between the front and rear furniture parts 20e-f, also being connected at its axial ends to the side furniture parts 20g- h.

In the shown example, each furniture part 20e-j is of rattan material. The furniture parts 20e-j extend essentially in the same plane, such that the entire furniture module l0a is planar. The furniture module l0a is preferably pre- manufactured, e.g. by hand, by connecting the furniture parts 20e-j to each other.

Four axial assembly holes 50a-d are provided, all extending into respective axial ends of furniture parts 20e-f in their axial direction. The front furniture part 20e is provided with two opposite front assembly holes 50a-b for connecting a respective front part of the side pieces l0c-d, i.e. the first furniture part 20a of the side pieces l0c-d. The rear furniture part 20f is provided with two opposite rear assembly holes 50c-d for connecting a respective rear part ofthe side pieces l0c-d, i.e. the second furniture part 20b ofthe side pieces l0c-d.

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

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

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

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

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

In Fig. 3b, the furniture joint 60 is a so called radial-radial joint 60b between two furniture modules 10c-d, and 10b. A furniture part 20a of the side piece 10c-d has a radial assembly hole 40b which is aligned with a radial assembly hole 52 of a furniture part 20 ofthe back rest 10b (see also Fig. 1a, indicating the position of the assembly hole 52). The same furniture connector 30 may also be used for the joint 60b of Fig. 3b.

In order for the joint 60b to benefit from the advantages provided by the furniture connector 30, some details are required by the assembly holes 40a-d, 50a-d. Starting with the assembly holes 40a-d, they are all provided with an exterior conical opening section 42 for receiving a truncated cone ofthe washer 34. From the exterior section 42, the assembly hole 40a-d extends substantially cylindrical, i.e. to a section 44 of constant diameter. When a radial-radial joint is desired, as shown in Fig. 3b, the cylindrical section 44 of the assembly hole 40b extends through the entire furniture part 20a. 11 However, when a radial-axial joint 60a is desired, as shown in Fig. 3a, the assembly hole 40a, 40c-d ofthe furniture part 20a-c is provided with an interior section 46, forming a cone shaped exit section, such that the cylindrical section 44 of the assembly hole 40a, 40c-d is located between the exterior section 42 and the interior section 46.

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

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

In Fig. 4, a system 100 for manufacturing a ready-to-assemble furniture module 10c-d is shown. The system comprises a fixture 110 configured to receive the furniture module 10c-d at a predetermined position, and at least two drilling units 120a-d configured to provide corresponding assembly holes 40a-d in the furniture module 10c-d. In the shown example, four drilling units 120a-d are provided.

Each drilling unit 120a-d is configured to provide at least one assembly hole 40a-d of the furniture module 10c-d. Hence, by operating the drilling units 120a-d simultaneously, four or more assembly holes 40a-d will be formed at the same time.

As can be seen in Fig. 4, each drilling unit 120a-d comprises a first drilling device 122a-d and a second drilling device 124a-d arranged on opposite sides of the furniture module 10c-d, and configured to act vertically, in opposite directions (for illustrative purpose the second drilling device 124b is slightly rotated relative the first drilling device 122b ofthe same drilling unit 120b).

The drilling devices 122a-d, all arranged on the same vertical side ofthe fixture 110, are preferably identical and configured to provide a drilling geometry resulting in the exterior conical section 42 of the assembly hole 40a-d, as well as the cylindrical section 44 of the assembly hole 40a-d. The drilling devices 122a-d are for this purpose provided with a drill bit 123 having an inner conical drill bit 123a that is extending axially to a cylindrical drill bit 123b. When a drilling device 122a-d is activated, the cylindrical part 123b of the drill 12 bit 123 Will cause a cylindrical hole, and as the conical drill bit 123a engages with the furniture module 10c-d the exterior cone section 42 of the assembly hole 40a-d will be formed.

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

The drilling device 124b, vertically aligned with the drilling device 122b, is preferably different from drilling devices 124a, 124c. In the shown example the drilling device 124b is provided with a rectangular drill chuck 126a instead of the round drill chucks 126b provided on the other drilling devices 124a, 124c, and 124d. The rectangular drill chuck 126a is connected to a conical drill bit 125a which, when activated, will provide the cone shaped interior section 46 of the resulting assembly hole 40b. The rectangular drill chuck 126a is also provided with a cylindrical drill bit 125b arranged at a distance from the conical drill bit 125a. When the drilling device 124b is activated, the cylindrical drill bit 125b will cause a cylindrical hole in the furniture module 10c-d, and the conical drill bit 125a will cause an interior cone section 46 ofthe assembly hole 40b of the furniture module 10c-d, spaced apart from the cylindrical hole caused by the cylindrical drill bit 125b. The cylindrical drill bit 125b is thus adapted to form a cylindrical hole; while the resulting hole may extend through the furniture module 10c-d for the purpose of forming a radial-radial joint 60b, in a preferred embodiment the cylindrical hole is only partially extending in the furniture module 10c-d for the purpose of fitting a pin for extra support.

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

The respective position of each drilling units 120a-d is controlled during activation in relation to the fixture 110. Also, there is a fixed position at least between the drilling units 120a-b which are forming the assembly holes 40a-b for connecting the seat 10a to the side pieces 10c-d. Ifthere are variations in dimensions between different side pieces 10c-d, the assembly holes 40a-d would be arranged at different positions on the different side pieces 10c-d if the positions ofthe drilling units 120a-d were set in relation to positions of the furniture modules 10c-d. However, as the drilling units 120a-d are fixed in 13 position in relation to the fixture 110, as well as in relation to each other, the assembly holes 40a-d will always be in correct position for forming the joints 60.

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

In order to ensure correct positioning of the furniture module 10c-d, the fixture 110 is provided with one or more clamping devices 112 for securing the position ofthe furniture module. The clamping devices 112 are preferably in the form of vertically adjustable members, having a V-shaped cavity facing the furniture module 10c-d. The V-shaped cavity is particularly advantageous when the furniture part to be clamped is cylindrically shaped.

The clamping devices 112 are further shown in Fig. 4b. Especially at the left end of Fig. 4b it can be seen that the furniture module 10c-d is effectively retained in the V-shaped cavity 112a and clamped by the clamping device 112. Optionally, and as illustrated in Fig. 4b, the fixture 110 may be provided with stationary and mating V-shaped structures 112b. If the furniture module 112 is positioned relative the fixture 110, but not fit perfectly with the stationary mating V-shaped structures 112b, activation ofthe clamping device 112 will force the furniture module 10c-d into the correct position as it will be urged to fit inside the cavity 112a. Hence, activation of a clamping device 112 will cause the V- shaped cavity to move vertically downwards until it engages with the furniture module 10c-d, thereby clamping it to the fixture 110.

Clamping the furniture module 10c-d by means of a clamping device having a V-shaped cavity is particularly advantageous for rattan material or other round/cylindrical material. Especially for rattan material the above-mentioned clamping operation is of particular advantage; while rattan material has a generally circular cross-section, it is rarely a perfect circle. Yet further, the diameter of a rattan piece normally varies within certain ranges leaving the tolerances comparatively large compared to other processed materials. Clamping, of the type described above, will efficiently compensate for any variations in the rattan material outer periphery and ensure the furniture module is correctly located thereby improving robustness and predictability of the manufacturing process.

Correct positioning of the furniture module 10c-d may further be accomplished by the fixture 110 having two spaced-apart, and optional, reference positions 114a-b. These reference positions 114a-b are formed as stops, to which 14 specific parts, in the shown example the ends of the U-shaped furniture member 20d adjacent to the feet ofthe side piece 10c-d, of the furniture module 10c-d may be arranged in contact with. In order to avoid over-definition of the position of the furniture module 10c-d, the reference positions 114a-b could be omitted. In such case, which may be preferred, the furniture module 10c-d may be provided with an additional length of its legs, which are subsequently cut to the desired length post drilling.

As can be seen in Fig. 4 the fixture 110 has the shape ofa wedge, forming a planar surface 116 being tilted relative the horizontal plane Z. As the drilling units 120a-d are acting in a vertical direction, the resulting assembly holes 40a-d will non-perpendicular in relation to the plane of the furniture module 10c-d. The fixture 110 is further provided with channels 118 extending through the fixture 110. The channels 118 are aligned with the drilling units 120a-d so that the drill bits 123a-b, 125a-b will not engage with the fixture 110 but instead be allowed to pass through the channels 118.

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

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

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

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

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

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

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

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

In Fig. 6b, the transport device 220 is driving the furniture part 20e-g along a transport path 222 away from the cutting unit 230 to the downstream milling unit 240. When reaching the position ofthe milling unit 240, the transport device 220 is again temporarily stopped to allow the milling unit 240 to operate on the furniture part 20e-f. The milling devices 242a-b are driven to be able to move towards and away from the respective axial ends of the furniture module 20e-f, and in the shown position the milling devices 242a-b have moved 16 to engage with the furniture module 20e-f. Each milling device 242a-b is provided with a mill tool 244 that causes conical re-shaping ofthe axial ends of the furniture part 20e-f. Hence, the milling unit 240 is configured to form the tapered axial end 22 of the furniture part 20e-f.

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

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

Now turning to Fig. 7a, a method 300 for manufacturing a ready-to- assemble furniture module 10c-d will be described. The method 300 is preferably performed using a system 100 as described with reference to Fig. 4.

In a first step 302, a semi-finished furniture module is provided. In the example described above, the semi-finished furniture module corresponds to a side piece 10c-d having no assembly holes 40a-d. Hence, at this point the furniture module is in a not yet ready-to-assemble configuration. In a subsequent step 304 the furniture module is arranged at a predetermined position of a fixture 110. The method 300 is further comprising a step 306 of activating at least two drilling units 120a-d to provide corresponding assembly holes 40a-d in the furniture module. A step 308 is further performed by controlling the respective position of the at least two drilling units 120a-d during activation in relation to each other, as well as in relation to the fixture 110. 17 Another method 310 for manufacturing a ready-to-assemble furniture module 10a, 10e is described with reference to Fig. 7b. The method 310 is preferably performed using a system 200 as described with reference to Figs. 5-6.

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

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

Another method 330 is shown in Fig. 7c. This method 330 is performed for manufacturing a furniture. The method 330 comprises manufacturing a ready- to-assemble furniture module by performing the method 300, as well as performing the method 310. The method 330 further comprises a step 332 of connecting the furniture modules resulting from methods 300 and 310 to form the furniture.

The examples described above allow for a much improved assembly of partly handmade furniture, even when deviations in dimensions are significant and where the tolerances are beyond standard specifications for industrial processes. Especially, the described systems and methods are useful for manufacturing ready-to-assemble furniture modules, which allow for knock- down packaging and distribution of furniture of natural material of varying dimensions, such as rattan.

Claims

1. A method of manufacturing a ready-to-assemble furniture module, comprising: providing a furniture module (10c-d), arranging the furniture module (10c-d) at a predetermined position of a fixture (110), activating at least two drilling units (120a-d) to provide corresponding assembly holes (40a-d) in the furniture module (10c-d), and controlling the respective position ofthe at least two drilling units (120a- d) during activation in relation to each other, as Well as in relation to the fixture (110).

2. The method of claim 1, Wherein providing a furniture module (10c-d) is performed by connecting a plurality of furniture parts (20a-d) in a planar configuration.

3. The method of claim 1 or 2, Wherein arranging the furniture module (10c-d) at a predetermined position of the fixture (110) is performed by: aligning a first part of the furniture module (10c-d) With a first reference position (114a) ofthe fixture (110), and aligning a second part ofthe furniture module (10c-d) With a second reference position (114b) of the fixture (110).

4. The method of claim 3, Wherein the first reference position (114a) is spaced apart from the second reference position (114b).

5. The method of claim 3 or 4, Wherein the furniture module (10c-d) is aligned only at the first part of the furniture module (10c-d) and at the second part of the furniture module (10c-d).

6. The method according to any of the preceding claims, Wherein arranging the furniture module (10c-d) at a predetermined position of the fixture (110) further comprises clamping the furniture module (10c-d) to the fixture (110).

7. The method according to claim 6, Wherein clamping the furniture module (10c-d) is performed at a plurality of positions of the furniture module (10c-d).

8. The method according to claim 6 or 7, Wherein clamping the furniture module (10c-d) is performed by arranging the furniture module (10c-d) in a V- shaped cavity of a clamping device (112).

9. The method according to any ofthe preceding claims, Wherein the fixture (110) is tilted relative a horizontal plane (Z).

10. The method according to any of the preceding claims, Wherein each drilling unit (120a-d) comprises a first drilling device (122a-d) and a second drilling device (124a-d), and Wherein activating at least tWo drilling units (120a-d) is performed by activating first drilling devices (122a-d) engaging With an upper side of the furniture module (10c-d), and activating second drilling devices (124a-d) engaging With a bottom side of the furniture module (10c-d), preferably the first and second drilling devices (122a-d, 124a-d) are activated in a sequential order.

11. The method of claim 10, Wherein the first and second drilling device (122a-d, 124a-d) of a common drilling unit (120a-d) are aligned in a vertical direction.

12. The method of claim 10 or 11, Wherein activating the first drilling device (122a-d) is resulting in a first drilling geometry of the furniture module (10c-d), and activating the second drilling device (124a-d) is resulting in a second drilling geometry of the furniture module (10c-d).

13. A method of manufacturing a ready-to-assemble furniture module, comprising: providing an elongated furniture part (20e-f), activating a cutting unit (230) to cut the furniture part (20e-f) to a desired length, activating a milling unit (240) to shape an axial end (22) of the furniture part (20e-f), and activating an axial drilling unit (250) to provide at least one assembly hole (50a-d) at the axial end (22) ofthe furniture part (20e-f).

14. The method according to claim 13, Wherein activating the cutting unit (230) is performed by cutting both axial ends (22) of the furniture part (20e-f).

15. The method according to claim 14, Wherein cutting both axial ends (22) is performed simultaneously.

16. The method according to any of claims 13-15, Wherein activating the milling unit (240) is resulting in a cone shaped axial end (22) ofthe furniture part (20e-f).

17. The method according to claim 16, further comprising: providing a furniture module (10c-d), arranging the furniture module (l0c-d) at a predetermined position of a fixture (110), activating at least two drilling units (l20a-d) to provide corresponding assembly holes (40a-d) in the furniture module (10c-d), Wherein at least one assembly hole (40a-d) is conical, and controlling the respective position ofthe at least two drilling units (l20a- d) during activation in relation to each other, as Well as in relation to the fixture (110), Wherein the cone shaped axial end (22) ofthe furniture part (20e-f) is dimensioned such that, When inserted in the conical assembly hole (40a-d) ofthe furniture module (l0c-d), the outer surface of the cone shaped axial end (22) Will contact the inner surface of the conical assembly hole (40a-d) While leaving an axial gap between the cone shaped axial end (22) and the bottom ofthe conical assembly hole (40a-d).

18. The method according to any of claims 13-17, Wherein activating the milling unit (240) is performed by milling both axial ends (22) ofthe furniture part (20e-f).

19. The method according to claim 18, Wherein milling both axial ends (22) is performed simultaneously.

20. The method according to any of claims 13-19, Wherein activating the axial drilling unit (250) is performed by drilling both axial ends (22) ofthe furniture part (20e-f).

21. The method according to claim 20, Wherein drilling both axial ends (22) is performed simultaneously.

22. The method according to any of claims 13-21, further comprising connecting the cut, milled, and drilled furniture part (20e-f) to additional furniture parts (20g-j), thereby forming a furniture module (10a).

23. A method of manufacturing furniture, comprising manufacturing a ready-to-assemble furniture module (10c-d) by performing the method according to any of claim 1-12, manufacturing a ready-to-assemble furniture module (10a, 10e) according to any of claims 13-22, and connecting the furniture modules (10a,c-e), optionally With one or more additional furniture modules (10b), to form the furniture (1).

24. A system (100) configured to manufacture a ready-to-assemble furniture module, the system comprising: a fixture (110) configured to receive a furniture module (10c-d) at a predetermined position, and at least two drilling units (120a-d) configured to provide corresponding assembly holes (40a-d) in the furniture module (10c-d), Wherein the respective position ofthe at least tWo drilling units (120a-d) is controlled during activation in relation to each other, as Well as in relation to the fixture (110).

25. The system according to claim 24, Wherein the fixture (110) is provided With one or more clamping devices (112) for securing the position of the furniture module (10c-d).

26. The system according to claim 24 or 25, Wherein each drilling unit (120a-d) comprises a first drilling device (122a-d) and a second drilling device (124a-d) arranged on opposite sides ofthe furniture module (10c-d).

27. The system according to claim 26, Wherein the first drilling device (122a-d) is configured With a first drilling geometry, and the second drilling device (124a-d) is configured With a second drilling geometry.

28. A system (200) configured to manufacture a ready-to-assemble furniture module, the system comprises a cutting unit (230), a milling unit (240), and a drilling unit (250), said units (230, 240, 250) being arranged in series.

29. The system (200) according to claim 28, Wherein each unit (230, 240, 250) comprises a first device (232a, 242a, 252a) and a second device (232b, 242b, 252b), Wherein the two devices (232a-b, 242a-b, 252a-b) of a common unit (230, 240, 250) are configured to process opposite ends of an elongated furniture part (20e-f), preferably simultaneously.