Elastic Sofa Frame Connector for Tool-Free Modular Assembly

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Solution Overview

Problem

Existing sofa chairs are often difficult to disassemble and reassemble, leading to increased shipping and storage costs, and are either uncomfortable or have high production and defect rates due to their complexity.

Innovation Solution

The development of connectors with a first member featuring a through hole and notch for enhanced elasticity, and a second member with a recessed opening, along with optional ribs for strength, allows for easy assembly and disassembly of sofa chair frames, made from materials like plastic or rubber, facilitating the connection of bars and legs in a modular design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If sofa chairs are made fixed and pre-assembled in factories, then assembly simplicity is improved, but shipping and storage space requirements increase

Engineering Contradiction:

Improveassembly simplicityVSAvoidshipping and storage space

Core Design Contradiction:

Ease of operationVSVolume of moving object

Solution Approach 1:

The sofa chair is divided into multiple modular components (seat module, backrest module, armrest module, leg module) that can be disassembled and reassembled. Each module contains standardized connection interfaces that enable quick assembly without tools, while allowing compact storage when disassembled.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection system transitions from fixed permanent joints to dynamic reversible connections. The first and second members provide snap-fit connections that can be easily assembled and disassembled multiple times, enabling the sofa to be reconfigured or stored compactly when not in use.

Inventive Principle:

Principle #15Dynamics

2Volume of moving object

If sofa chairs are designed to be disassembled and re-assembled, then shipping and storage costs are reduced, but assembly complexity increases

Engineering Contradiction:

Improveshipping and storage spaceVSAvoidassembly complexity

Core Design Contradiction:

Volume of moving objectVSDevice complexity

Solution Approach 1:

The first member and second member serve multiple functions: the first member provides both structural support and a connection interface, while the second member simultaneously connects to both the first member and the leg. This multi-functionality reduces the total number of components needed, simplifying assembly despite the disassemblable nature.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The connection structure merges the joining function and the support function into integrated components. The first member combines the connection body with support features, and the second member integrates the connection mechanism with leg mounting, reducing assembly steps.

Inventive Principle:

Principle #5Merging (Combining)

3Volume of moving object

If complex disassemblable designs are used, then shipping costs are reduced, but production cost and defect rate increase

Engineering Contradiction:

Improveshipping spaceVSAvoidproduction cost

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

The sofa is segmented into standardized modules that can be manufactured independently using the same connection components. This modularity allows for economies of scale in producing the first and second members, reducing per-unit production costs despite the increased design capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection system uses material and geometric parameters that balance manufacturability with functionality. The first member is designed with specific elastic properties and geometric features that enable easy manufacturing through common processes while providing reliable connections.

Inventive Principle:

Principle #35Parameter changes

4Adaptability or versatility

If connectors are designed with enhanced elasticity and multiple coupling elements, then adaptability is improved, but connector complexity increases

Engineering Contradiction:

Improvecoupling adaptabilityVSAvoidconnector structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The first member incorporates localized elastic features (notches or flexible sections) only where needed for adaptation, while maintaining a simple overall structure. The elasticity is concentrated in specific regions that enable coupling with various leg types without complicating the entire connector design.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS10231547B2Connector for sofa chair frame and sofa chair frame having same

Publication Date: 2019.03.19 ANYPLACE CONCEPTS

AI summary

Disclosed are connectors, sofa chair frames and sofa chairs. A connector includes first and second members disposed in first and second directions, respectively. The first member includes a through hole along the first direction and a notch in the first direction on a peripheral wall of the first member to enhance an elasticity of the first member. The notch allows the through hole of the first member to couple with any one element in a plurality of first elements, where at least two elements in the plurality of first elements are different from each other. The second member has a first end coupled to a middle portion of the first member, and includes an opening recessed inwardly from a second end in the second direction to accommodate at least a portion of a second element.