Modular Chair Frame with Hinged Segments for Simplified Assembly
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Solution Overview
Problem
Existing chair manufacturing processes are lengthy and complex, with intricate coupling mechanisms that complicate fabric tensioning and require significant storage space for components, making it difficult to coordinate procurement and assembly efficiently.
Innovation Solution
A modular chair design featuring a frame with hinges that allow for easy assembly and tensioning of fabric, using composite fibers and automated knitting machines to control mechanical properties, and a guide system for secure attachment, enabling quick assembly and reduced component dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional chair manufacturing processes are used with intricate coupling mechanisms, then the chair structure can be assembled, but the construction time becomes very long and the assembly process becomes complex
Solution Approach 1:
The chair is divided into modular components (frame, fabric, filling) that can be manufactured separately and assembled quickly. The frame is segmented into multiple parts that connect through simple insertion mechanisms rather than complex coupling, enabling parallel manufacturing and rapid assembly.
Solution Approach 2:
The fabric tensioning system is extracted from the traditional complex coupling mechanism. The fabric is attached separately using a simplified attachment mechanism that allows tensioning without requiring intricate assembly steps, thereby reducing construction time while maintaining structural integrity.
2Productivity
If traditional chair manufacturing with ad hoc frame and component fabrication is used, then the chair can be assembled, but the procurement coordination becomes complex and storage space requirements increase
Solution Approach 1:
The frame components are designed with universal connection features that can accommodate different fabric types and configurations. This standardization allows a single frame design to serve multiple chair variations, simplifying procurement coordination and reducing the need for multiple specialized components.
Solution Approach 2:
The frame, fabric, and filling are manufactured as ready-to-assemble modules in advance. The fabric is pre-cut and pre-attached to the frame using the simplified attachment mechanism, so that when components are delivered, they require minimal assembly steps, thereby improving manufacturing efficiency and reducing storage requirements.
3Reliability
If complex coupling mechanisms are used for fabric attachment, then the fabric can be secured to the frame, but the tensioning process becomes complicated and may cause breakage
Solution Approach 1:
An intermediary attachment mechanism is introduced between the fabric and frame. This mechanism includes a fabric holder and tensioning elements that distribute stress evenly, allowing secure fabric attachment without the risk of breakage that occurs with direct complex coupling. The intermediary components protect both the fabric and frame during the tensioning process.
Data Source
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Figure 3~5b
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AI summary
A modular chair (1) is provided for, comprising at least a support portion (2) to allow the support of a user on it and including a frame (20) and a fabric (21), wherein the fabric (21) defines a surface (210) suitable to support the user and a perimetral area (211) defined by the edges of the surface (210), wherein the frame (20) defines, in use, a closed profile and is suitable to support the fabric in tension (21) along at least part of the perimetral area (211), and comprises at least two parts (200) separate and reciprocally loosely connected by two hinges (201) arranged respectively at the ends of said parts (200) in such a way as to define a configuration of use in which the parts (200) form the frame (20) and a configuration of rest in which the parts (200) are folded together, and in which the hinges (201) define two respective axes of rotation (2a) mutually aligned, and the frame (20) tensions the fabric (21) only when the parts (200) are in the configuration of use.