Carrycot Tensioning Frame with Clamped Shell for Smooth Fabric Finish
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Solution Overview
Problem
Existing carrycots face issues with the covering fabric not lying tightly against the framework, leading to a difficult smooth finish and high production variation, with limited design freedom due to the framework's rigidity.
Innovation Solution
A cot design featuring a substantially rigid tensioning frame and a flexible covering fabric, where the fabric is fixedly connected to form a first shell, and a second, firm shell is clamped between the tensioning frame and the fabric, allowing for optimal tension and easy placement of the fabric.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a framework of metal or aluminium tubes is used to support the covering fabric, then the structural strength is improved, but the covering fabric does not lie tightly against the framework and requires a lot of manual work to achieve a smooth finish
Solution Approach 1:
The patent introduces a foam layer (second shell) that acts as a flexible intermediate structure between the rigid framework and the covering fabric. This foam layer can be easily shaped and contoured to match the framework geometry, providing a smooth surface that the fabric can conform to without requiring extensive manual adjustment. The foam shell maintains structural integrity while allowing the fabric to lie tightly and smoothly.
2Strength
If a framework is used to provide structural support, then the strength is improved, but the freedom of form is very limited
Solution Approach 1:
The foam shell (second shell) serves as a versatile intermediate structure that can be manufactured in various shapes and forms while maintaining structural strength through the framework. This allows designers to create different cot configurations and aesthetics without being constrained by the rigid framework geometry, as the foam shell can be contoured to achieve desired forms.
Solution Approach 2:
The patent divides the cot structure into distinct segments: the rigid framework (first shell), the flexible foam layer (second shell), and the covering fabric. This segmentation allows each component to be optimized independently - the framework for strength, the foam for form and comfort, and the fabric for aesthetics - thereby increasing overall design freedom.
3Shape
If the covering fabric is stretched tightly over the framework, then the aesthetic appearance is improved, but the production variation in respect of finishing is relatively great
Solution Approach 1:
The foam shell provides a standardized, pre-formed surface that ensures consistent fabric tension and smoothness across all productions. By attaching the fabric to this uniform foam surface rather than directly to the framework, the variability in finishing is significantly reduced, as the foam shell acts as a buffer that absorbs minor manufacturing tolerances.
Data Source
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AI summary
The present invention relates to a cot and to a cot assembly. The invention further relates to a method fur manufacturing a cot. The invention relates particularly to a so-called carrycot. The cot (200) according to the invention comprises a substantially rigid tension frame (2), a flexible covering fabric (4), an edge of which is fixedly connected to the tensioning frame (2), and a second, substantially firm shell (5). According to the invention, the second shell (5) is clamped between the tensioning frame (2) and the covering fabric (4), wherein the covering fabric (4) covers an outer surface of the second shell (5).