Description:FIELD OF THE INVENTION

This present subject matter described herein relates to the field of mechanical joinery in general, and more particularly to an expandable die-cast aluminium joiner for modular furniture and structural frames.
BACKGROUND

Conventional joineries used in furniture and structural framing primarily rely on welding or mechanical fasteners such as screws, bolts, and rivets. Welded joinery, while providing a robust connection, presents several drawbacks. The process of welding introduces thermal expansion and contraction, which can result in dimensional inaccuracies. Additionally, welded structures are bulky and difficult to transport, leading to increased logistics costs. The quality of a welded joint is also highly dependent on the skill level of the welder, making consistency a challenge.

Furthermore, welded joints are permanent, limiting the ability to modify, disassemble, or reconfigure the structure once fabricated. This lack of flexibility increases material waste and restricts adaptability in evolving design applications. The high energy consumption and emission of fumes during welding processes also pose environmental concerns, making traditional joinery methods less sustainable.

Mechanical fasteners, on the other hand, require precise alignment and drilling, which increases manufacturing complexity. Over time, bolted connections may loosen due to vibration and external forces, leading to a reduction in structural integrity. Furthermore, traditional joinery systems lack adaptability, limiting the possibility of modular and reconfigurable structures. Another issue with mechanical fasteners is the dependency on additional components such as nuts and bolts, which increase assembly time and overall system weight.

In modern design applications, there is a growing demand for modular, lightweight, and easy-to-assemble structural systems that maintain high strength and durability. Industries such as furniture manufacturing, interior design, and industrial frameworks require solutions that enable quick installation and easy reconfiguration without sacrificing reliability. To address these limitations, an innovative joinery system is required that balances strength, ease of use, reusability, and efficient assembly.
To overcome the shortcomings of existing solutions, the present invention proposes a die-cast aluminium joinery system that eliminates the need for welding, reduces transportation costs by enabling flat-pack structures, and provides a robust and easy-to-assemble solution. This allows for quick and secure connections without requiring specialized skills, thereby ensuring consistency and ease of manufacturing.
SUMMARY OF INVENTION

In view of the foregoing disadvantages inherently associated with conventional joineries used in furniture and structural framing in the prior art, the present invention provides a mechanical joinery system that facilitates modular furniture assembly without welding.

According to a first aspect, the present invention provides a expandable joinery system comprising: an L shaped joinery housing adapted to receive and secure structural members, wherein the joinery housing is made of aluminium alloy; a fastening mechanism to establish a firm connection between the joinery housing and structural members, wherein the fastening mechanism comprises an expander nut having internal threading; a bolting arrangement to secure a round pipe vertically and a rectangular pipe horizontally; and a modular interface comprising pre-machined grooves, self-threaded holes, and a detachable fastener for quick assembly, disassembly, and reconfiguration.

In one embodiment of the first aspect, the expander nut with internal threading expands upon tightening to grip the structural member securely.

In another embodiment of the first aspect, the expander nut, when tightened by the bolting arrangement, expands to secure the round pipe, preventing movement or rotation under load conditions.

In another embodiment of the first aspect, the bolting arrangement comprises a self-threading mechanism to enhance ease of installation and secure the horizontal rectangular pipe.

In another embodiment of the first aspect, the joinery housing comprises pre-machined grooves or slots to improve alignment and enhance stability during assembly.

In another embodiment of the first aspect, the aluminium joinery is powder-coated for corrosion resistance and aesthetic flexibility.

In another embodiment of the first aspect, the joinery structure is configured for modular furniture, industrial frameworks, and partition systems.

The various embodiments of the present invention aim to enhance dimensional accuracy by eliminating expansion/contraction issues associated with welding, reduce packaging and transportation costs by enabling flat-pack designs. The present invention offers a lightweight yet durable solution using aluminium alloy (LM24) to ensure ease of installation and adaptability for various structural configurations.

These aspects or other aspects in the present disclosure may be clearer and more intelligible in the detail description of the various embodiments. Within the scope of this patent application it is expressly envisaged that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The accompanying drawings are included to provide a further understanding of the present disclosure and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to elaborate the principles of the present disclosure.

Figure 1 illustrates the exploded view of the aluminium joinery system, according to an embodiment of the present invention.

Figure 2 illustrates the assembled view of the joinery with metal pipes, according to an embodiment of the present invention.

Figure 3 illustrates the cross-sectional view showing the fastening mechanism, according to an embodiment of the present invention.

Figure 4 illustrates an application in modular furniture structures, according to an embodiment of the present invention.

Figure 5 illustrates side view of the joinery connection, displaying structural alignment and support, according to an embodiment of the present invention.

Figure 6 illustrates perspective view illustrating modular expandability and load distribution, according to an embodiment of the present invention.

Figure 7 illustrates a sectional view of the fastening mechanism showing engagement between components, according to an embodiment of the present invention.

Figure 8 illustrates an exploded configuration demonstrating adaptability for various modular structures, according to an embodiment of the present invention.

The diagrams are not to scale, but for the purpose of illustration only, hence are not a limitation to the present disclosure.

DETAILED DESCRIPTION

The present invention will be described in further detail with reference to the accompanying drawings and examples. It is to be understood that the specific embodiments described herein are merely illustrative of the invention and are not limiting to the invention.  

The following paragraphs describe in detail the various embodiments of present invention with reference to accompanying drawings. Terms used in embodiments are only used for explaining specific embodiments of the present invention and are not intended to limit this invention. It is clear that the described embodiments are merely the most essential rather than all of embodiments of the present invention. All other embodiments obtained by a person skilled in the art, through workshop modifications on the embodiments described hereinbelow without creative efforts ought to fall within the protection scope of the present invention.
Various objects, features, aspects and advantages of the present disclosure will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like features.

Traditional joinery techniques rely on welding or mechanical fastening, both of which come with drawbacks. Welded joints, while providing structural rigidity, introduce inconsistencies due to heat-induced expansion and contraction. Additionally, welded structures are heavy, costly to transport, and require skilled labour. Mechanical fasteners, such as screws and rivets, may loosen over time and require precise assembly, making them less ideal for modular designs.

To overcome the shortcomings of existing solutions, the present invention proposes an L-shaped aluminium joinery system that ensures secure, repeatable, and modular connections. The aluminium Joiner is made from LM24 aluminium alloy, chosen for its strength, lightweight properties, and excellent casting characteristics. The joinery system consists of two components: an L Joinery Housing and an Expander Nut.

Figure 1 illustrates an exploded view of the aluminium joinery system, according to an embodiment of the present invention. The L joinery housing is designed to provide a robust 90° structural connection, while the expander nut enables a secure fastening mechanism. The expander nut is threaded internally and interfaces with the L joinery housing to provide a firm grip on the vertical pipe. It also depicts the alignment of the horizontal rectangular pipe and how it integrates with the joinery system.

Figure 2 shows the assembled view of the joinery with metal pipes, according to an embodiment of the present invention. As a non-limiting example, the vertical Ø32mm round pipe is inserted into the L joinery housing, while the horizontal rectangular 25mm × 50mm pipe is secured through self-threaded holes in the housing. This arrangement ensures that the structure remains rigid under load-bearing conditions. It highlights the overall compactness of the joinery and how it eliminates the need for welding while maintaining structural integrity.

Figure 3 provides a cross-sectional view of the fastening mechanism, according to an embodiment of the present invention. The expander nut, when tightened, applies outward pressure on the internal surface of the vertical pipe, securing it within the housing. This mechanism ensures that the vertical pipe does not shift or rotate under applied loads. The cross-section also highlights the self-threading bolt and its engagement with the rectangular horizontal pipe, which contributes to the stability of the entire assembly. It demonstrates the efficiency of the fastening mechanism and how it distributes forces evenly across the joinery system.

Figure 4 illustrates an application of the aluminium joinery system in modular furniture structures, according to an embodiment of the present invention. The joinery system facilitates the construction of modular and reconfigurable furniture, allowing users to assemble and disassemble components with ease. The figure demonstrates how the joinery system integrates with common furniture elements such as tabletops, shelving units, and support frames, ensuring stability while enabling easy modifications and extensions.

Figure 5 presents a side view of the joinery connection, according to an embodiment of the present invention. It demonstrates the precise alignment of the structural members and how the fastening mechanism maintains perpendicular stability under various load conditions. The figure also shows how the load is transferred through the joinery components, preventing misalignment and ensuring long-term structural integrity.

Figure 6 provides a perspective view of the aluminium joinery system, according to an embodiment of the present invention. The figure illustrates how multiple units of the joinery system can be connected in a modular fashion, allowing for structural expandability and versatility. The arrangement enables the creation of interconnected frameworks suitable for large modular structures such as exhibition booths, workstations, and partition systems.

Figure 7 shows a detailed sectional view of the fastening mechanism, according to an embodiment of the present invention. It highlights the engagement between the Expander Nut, bolt, and pipes, ensuring a secure and vibration-resistant connection. This figure further explains the internal threading mechanism and how it contributes to load distribution. The sectional view also demonstrates how the fastening components interact under applied forces to prevent loosening over time.

Figure 8 illustrates an alternative configuration of the aluminium joinery system, according to an embodiment of the present invention. The joinery system can be adapted to different orientations and applications beyond furniture, including industrial frameworks and partition systems. The figure shows how the joinery system can be used in larger-scale applications, such as supporting scaffolding structures or modular enclosures, emphasizing its adaptability to different design requirements. in modular furniture structures, according to an embodiment of the present invention. The joinery system facilitates the construction of modular and reconfigurable furniture, allowing users to assemble and disassemble components with ease.

The manufacturing process of the joinery involves Pressure Die Casting (PDC) to form the L Joinery Housing and Expander Nut, followed by shot blasting to refine the surface finish. Precision machining is performed to create threading and bolting holes for assembly. The result is a precisely engineered joinery system with reliable tolerances and high strength.

The assembly process is straightforward. The L Joinery Housing is positioned at the joint where a 90° connection is needed. The Expander Nut is inserted into the vertical Ø32mm round pipe and tightened with a bolt from the top, ensuring a firm grip. The horizontal rectangular pipe (25mm × 50mm) is then bolted into the joinery using self-threaded holes. This configuration ensures that the joint remains rigid and resistant to movement or loosening over time.

The operational mechanism of the joinery provides stability by distributing loads evenly along the perpendicular structure. The Expander Nut creates an outward force when tightened, securing the vertical pipe firmly in place and preventing rotation. The horizontal bolted connection further reinforces the structure, making it suitable for various applications, including modular furniture, partition systems, and industrial frameworks.

In summary, the present invention provides a perpendicular "L" shaped aluminum joinery that enables the creation of 90° structures, which can be extended as needed. The joinery consists of two primary components: (i) the L Joinery Housing, and (ii) the Expander Nut. The Expander Nut has internal threading that allows for fastening with a bolt, thereby securing a vertical Ø32mm round pipe. The horizontal section integrates with a 25mm × 50mm rectangular pipe using a self-threaded bolting mechanism. This ensures robust load-bearing capacity and flexibility for modular structures.

Thus, the present invention is able to provide a robust, modular joinery system that eliminates welding while maintaining high structural integrity. By using a pressure die-cast aluminium alloy, the present invention offers a lightweight yet strong alternative to traditional joinery techniques. The integrated Expander Nut mechanism enhances load distribution, preventing loosening over time. The invention's modular design further facilitates ease of transportation and assembly, significantly reducing costs in manufacturing, logistics, and labour. These advancements collectively improve efficiency, reliability, and scalability, making the present invention highly suitable for modern structural and furniture applications.

Advantages of the Invention:
a. Modularity: Enables quick and easy assembly, disassembly, and reconfiguration;
b. Cost Efficiency: Eliminates the need for welding and reduces labour and material costs;
c. Dimensional Accuracy: Avoids thermal expansion/contraction issues associated with welding;
d. Ease of Transport: Allows for flat-pack packaging, reducing shipping expenses;
e. Durability: Engineered for long-term use, maintaining structural integrity under dynamic loads; and
f. Aesthetic Versatility: Can be customized with powder-coated finishes for improved corrosion resistance and design adaptability.

These advantages collectively make the present invention a highly effective solution for modular joinery applications. It provides significant improvements over conventional methods by enhancing efficiency, cost-effectiveness, and ease of use. This is particularly suitable for furniture manufacturing, construction frameworks, and industrial assemblies where a strong yet flexible joint is required.

It should be noted that the dimensions provided in the description and figures, are exemplary and do not limit the scope of the present invention. The joinery system can be scaled up or down to accommodate different structural requirements, making it adaptable to a wide range of applications.

It is to be noted that the foregoing description is only illustrative of the preferred embodiments of the present invention and the technical principles employed. It will be understood by those skilled in the art that the present invention is not limited to the particular embodiments described herein, but is capable of various obvious changes, rearrangements and substitutions as will now become apparent to those skilled in the art without departing from the scope of the invention. Therefore, although the present invention has been described in greater detail by the above embodiments, the present invention is not limited to the above embodiments and may include other equivalent embodiments without departing from the spirit of the present invention, and the scope of the present invention is determined by the scope of the appended claims.

, Claims:WE CLAIM:

1. An expandable joinery system comprising:
an L shaped joinery housing adapted to receive and secure structural members, wherein the joinery housing is made of aluminium alloy;
a fastening mechanism to establish a firm connection between the joinery housing and structural members, wherein the fastening mechanism comprises an expander nut having internal threading;
a bolting arrangement to secure a round pipe vertically and a rectangular pipe horizontally; and
a modular interface comprising pre-machined grooves, self-threaded holes, and a detachable fastener for quick assembly, disassembly, and reconfiguration.

2. The joinery system of claim 1, wherein the expander nut with internal threading expands upon tightening to grip the structural member securely.

3. The joinery system of claim 1, wherein the expander nut, when tightened by the bolting arrangement, expands to secure the round pipe, preventing movement or rotation under load conditions.

4. The joinery system of claim 1, wherein the bolting arrangement comprises a self-threading mechanism to enhance ease of installation and secure the horizontal rectangular pipe.

5. The joinery system of claim 1, wherein the joinery housing comprises pre-machined grooves or slots to improve alignment and enhance stability during assembly.

6. The joinery system of claim 1, wherein the aluminium joinery is powder-coated for corrosion resistance and aesthetic flexibility.

7. The joinery system of claim 1, wherein the joinery structure is configured for modular furniture, industrial frameworks, and partition systems.