Keyed Modular Frame Assembly for Tool-Free Furniture Installation
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Solution Overview
Problem
The construction of modular zone dividers and other furniture requires skilled installers, making the assembly process complex and labor-intensive.
Innovation Solution
A modular frame system comprising connectors, first frame members with engagement members profiled to key with slots on connectors and second frame members, allowing for easy assembly and versatile configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional modular frame construction methods are used, then structural stability is achieved, but assembly complexity increases and requires skilled installers
Solution Approach 1:
The frame members are segmented into modular sections with standardized engagement members at their ends. Each frame member can be independently assembled by connecting these segmented parts through connectors, allowing complex structures to be built from simple, repeatable units that require minimal skill to assemble.
Solution Approach 2:
The engagement members are designed with self-aligning features including guide surfaces and complementary profiles that automatically orient and secure frame members during assembly. This self-service mechanism eliminates the need for skilled installers to perform complex alignment operations, while maintaining secure connections.
2Productivity
If traditional modular frame construction methods are used, then structural stability is achieved, but installation time increases
Solution Approach 1:
Engagement members are pre-formed with integrated connection features during manufacturing, including predefined slot orientations and engagement profiles. This preliminary preparation eliminates the need for on-site fabrication or complex field assembly operations, dramatically reducing installation time while maintaining structural integrity.
Solution Approach 2:
Traditional mechanical fastening systems requiring multiple steps (drilling, bolting, welding) are replaced with a simplified slot-and-engagement member system. The engagement members slide into slots and lock automatically through geometric interlocking, substituting complex mechanical assembly with a single-step insertion operation that accelerates installation.
3Adaptability or versatility
If customizable modular components are used, then design flexibility improves, but manufacturing complexity increases
Solution Approach 1:
A universal connector design is implemented where engagement members and slots are standardized across all frame members. This universal interface allows the same basic components to serve multiple functions and configurations, enabling design flexibility without requiring complex custom manufacturing for each variant.
Solution Approach 2:
Customization is achieved through parameter variations of the standardized engagement members rather than fundamentally different components. By changing dimensions, slot positions, or engagement profiles within the standardized family, diverse frame configurations can be manufactured using the same basic processes, maintaining manufacturing simplicity while providing design adaptability.
Data Source
AI summary
A modular frame comprising a connector (3), a first frame member (1, 2) and a second frame member (1, 2), wherein the first frame member (1, 2) comprises one or more engagement members (5, 7) profiled to key with a first slot (6) on the connector (3) and a second slot (8) on the second frame member (1, 2).