Furniture and large-scale play structures having ideal modularity
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Solution Overview
Problem
Traditional modular building systems for children fail to provide truly universal and scalable structures due to limitations in component shapes and assembly methods, often requiring tools and resulting in inconsistent dimensions and spacing, which hinder ideal modularity and safety standards.
Innovation Solution
The development of building systems featuring panels with chamfered edges and uniformly spaced holes, allowing for tool-free assembly and attachment at various angles, maintaining consistent and repeatable dimensions and spacing, and incorporating safety features like hinged attachments to prevent pinch points and lid closure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional fastening systems with separate components and tools are used, then assembly strength is improved, but ease of operation deteriorates due to requiring tools and complex assembly procedures
Solution Approach 1:
The fastening element is merged with the panel by being integrally formed as a single piece, eliminating separate fastening components and tools. This allows children to assemble structures easily by simply connecting panels together without requiring screwdrivers, wrenches, or complex assembly procedures, while maintaining strong connections through the integrated fastening design
Solution Approach 2:
The panel includes self-aligning features such as guide pins and recesses that automatically position the fastening element correctly during assembly. The fastening element itself serves as both the connector and the positioning mechanism, eliminating the need for external alignment tools or complex assembly procedures
2Stability of the object's composition
If panels are assembled at right angles with traditional methods, then structural stability is improved, but manufacturing precision deteriorates due to cumulative offset errors in dimensions
Solution Approach 1:
The panel design incorporates asymmetric features including chamfered edges and non-uniform fastening element positioning that compensate for the offset introduced by panel thickness. The chamfered edges specifically are designed to accommodate the thickness offset when panels are joined at right angles, ensuring that external surfaces remain coplanar and dimensions remain consistent across multiple assembled panels
Solution Approach 2:
The fastening element positioning is specifically designed with adjusted parameters to account for panel thickness. The horizontal and vertical spacing of fastening elements is calculated to maintain consistent external dimensions even when panels are assembled at right angles, effectively compensating for the thickness-induced offset through precise parameter selection
3Manufacturing precision
If fixed-location fastening elements are used, then manufacturing precision is improved, but adaptability deteriorates due to limited assembly angles and configurations
Solution Approach 1:
The fastening element design incorporates dynamic characteristics by allowing rotation and movement during assembly. The fastening element can rotate to engage with panels at different angles and positions, providing adaptability for various assembly configurations while maintaining precise positioning once engaged. This dynamic capability enables the same fastening element to accommodate multiple assembly angles and structural configurations
4Strength
If multiple separate fastening components are used, then assembly strength is improved, but device complexity deteriorates due to multiple parts and assembly steps
Solution Approach 1:
Multiple fastening functions are merged into a single integrated fastening element that is formed as one piece with the panel. This eliminates the need for separate screws, washers, nuts, or other fastening components, reducing the total number of parts while maintaining strong connections through the combined design. The single integrated element performs both connection and positioning functions
Solution Approach 2:
The fastening element is designed with universal functionality to perform multiple roles: it serves as the connection element, the positioning element, and the alignment guide. This multi-functional design eliminates the need for multiple specialized components, simplifying the overall assembly system while maintaining strong and precise connections between panels
Data Source
AI summary
A method for building large-scale play structures having an ideal modularity is provided. The method includes providing panels having a thickness, a planar-quadrangle shape including a length, a width and four chamfered edges with a set of holes located along each edge, the holes located at a fixed interval relative to one another, the fixed interval providing a unit of length, a fixed-location fastening element located in each of the holes, respectively; providing a plurality of movable fastening elements each including a hand-grip to allow the respective movable fastening element to be moved between an unsecured position and a secured position without the use of tools when received by any one of the plurality of fixed-location fastening elements; and employing the fasteners to secure a plurality of the panels to one another to provide a structure that has an overall height, an overall length and an overall width, the structure including at least a pair of panels oriented one above the other and at least a pair of panels located at the same elevation and secured at right angles to one another.