Modular seat assembly and method of assembly thereof
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Solution Overview
Problem
Modular seat assemblies are difficult to assemble, expensive to manufacture, and challenging to repair due to integrated male and female hardware that requires specialized tooling and is often inaccessible for replacement.
Innovation Solution
A modular seat assembly design featuring male stud connectors and female connectors with a downwardly angled channel and horizontal portion for easy alignment and connection, along with latch systems for additional security, allowing for easier assembly, adjustment, and replacement of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If integrated male and female hardware are used inside modules, then connection strength is improved, but assembly difficulty increases and manufacturing cost increases
Solution Approach 1:
The patent extracts the hardware connectors from the interior of modules and relocates them to exterior surfaces. Male connectors are mounted on the exterior of one module while female connectors are mounted on the exterior of adjacent modules, allowing users to access and assemble connectors without disassembling module interiors or requiring specialized tooling.
2Strength
If integrated male and female hardware are used inside modules, then connection strength is improved, but manufacturing cost increases
Solution Approach 1:
The hardware connectors are extracted from complex integrated interior assemblies and relocated to simple exterior mounts. This allows modules to be manufactured using standard drilling and fastening techniques rather than requiring specialized interior tooling, significantly reducing manufacturing complexity and cost.
3Reliability
If hardware is integrated inside modules, then connection reliability is improved, but ease of repair deteriorates
Solution Approach 1:
Connectors are extracted from inaccessible interior locations and mounted on exterior surfaces where users can easily access them. This allows individuals to independently replace broken male or female connectors without requiring disassembly of modules or professional service, maintaining connection reliability while dramatically improving repairability.
4Manufacturing precision
If precise alignment is required for connectors, then connection precision is improved, but assembly time increases
Solution Approach 1:
The patent incorporates alignment features such as ribs on male connectors that fit into corresponding grooves on female connectors, and downwardly angled channels that guide connector insertion. These preliminary alignment mechanisms are built into the connector design itself, automatically guiding proper alignment during assembly and eliminating the need for time-consuming manual positioning or precision measurement.
Data Source
AI summary
Modular seat assembly having a female connector that is positioned and configured to releasably connect to a corresponding male stud connector on an adjacent seat module. Each female connector includes a plate comprising a raised portion defining an upper opening leading to a downwardly angled channel extending at about 20 degrees to about 70 degrees from a vertical axis into a horizontal portion, such that each male stud connector is slidably and releasably connectable to each corresponding female connector, and such that the channel and the horizontal portion have a width that is narrower than a head of the male stud connector, but wider than a neck of the male stud connector; and wherein said male stud connector is configured to be guided downward by said channel and then loosely contained within said horizontal portion.