Chair T-Nut Fastening for Thin Substrates Without Dislodgment
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Solution Overview
Problem
The use of T-nuts in chair manufacturing is limited by the thickness of the structure they are attached to, leading to dislodgment and manufacturing issues, which can result in defective chairs and reduced design options.
Innovation Solution
A method of attaching T-nuts to a substrate by inserting their projections and bending the distal ends into the substrate, providing a secure grip and preventing dislodgment, even with thin substrates, using standard T-nuts and polymeric materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If T-nuts are used to attach skin components to frame components, then fastening capability is improved, but the method becomes unsuitable for thin substrates causing dislodgment
Solution Approach 1:
The patent changes the attachment mechanism from relying on substrate thickness (traditional T-nut barbs) to using a two-step process: first inserting the T-nut through the substrate, then deforming the projections to bend them into the substrate. This parameter change in the attachment method enables secure fastening on thin substrates where traditional T-nuts would fail.
Solution Approach 2:
The patent applies preliminary action by first inserting the T-nut through the substrate before applying the fastening force. The projections are positioned through the substrate first, then subsequently deformed to bend into the substrate. This preliminary positioning allows the fastening mechanism to be adapted to thin substrates without causing dislodgment during the fastening process.
2Reliability
If T-nut barbs are used to attach to structure, then attachment security is improved, but structure thickness must be increased
Solution Approach 1:
The patent inverts the traditional T-nut design by having the projections extend through the substrate and bend into it, rather than having barbs engage from the opposite side. This inversion allows the fastening mechanism to work effectively with thin substrates by utilizing the substrate as a anchor point during the bending process, eliminating the need for increased substrate thickness.
Solution Approach 2:
The patent transitions from a two-dimensional barb engagement (requiring thickness in one dimension) to a three-dimensional deformation process where projections bend into the substrate. This dimensional change allows the same attachment security to be achieved without increasing substrate thickness, as the projections create a mechanical interlock through bending rather than requiring space for barbs.
3Adaptability or versatility
If T-nuts are inserted into thin substrates, then design options are expanded, but dislodgment during fastening occurs
Solution Approach 1:
The patent applies preliminary action by first inserting the T-nut through the substrate to the correct position before deforming the projections. This preliminary positioning ensures the T-nut is securely in place before the fastening action occurs, preventing dislodgment during the fastening process while still allowing use with thin substrates.
Solution Approach 2:
The patent employs self-service by designing the projections to automatically bend into the substrate when the T-nut is inserted and fastened. The deformation process is self-actuating through the insertion and fastening motions themselves, creating a secure attachment without requiring additional steps or tools, thereby maintaining position stability while enabling thin substrate application.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method ensures reliable attachment of chair components, allowing for broader design options and reducing manufacturing issues, with T-nuts able to withstand significant torque and axial forces without dislodging.
Implementation Method 1
The distal ends of the projections are bent into the substrate
Data Source
AI summary
A method of making a chair includes the steps of providing at least one female fastener device. The at least one female fastener device is inserted into a substrate for attaching the at least one female fastener device to the substrate such that at least a portion of that female fastener device's body defining a channel extends into the substrate and the projections extend through the substrate such that the distal ends of the projections extend beyond a second side of the substrate that is opposite a first side of the substrate. The distal ends of the projections are bent into the second side of the substrate. At least one male fastener is inserted into the channel of the at least one female fastener device to attach a chair component to the substrate.