Modular Sofa Assembly With Sliding Connectors for Compact Delivery

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Solution Overview

Problem

Conventional sofas are bulky and expensive to transport, and their assembly on-site can be challenging due to logistical issues and the need for special tools or training, which can lead to structural integrity problems and safety concerns.

Innovation Solution

A modular sofa assembly system that includes seating and armrest modules with releasable connectors, such as dowel joints and toggle latches, allowing for easy assembly and reconfiguration without specialized tools or training, and incorporating a power cradle for convenient power access.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If conventional sofas are manufactured and assembled at a factory unit and transported as completed products, then the structural integrity and quality of the sofa is maintained, but the transportation cost increases significantly and delivery time is delayed due to the bulky size of the completed sofa

Engineering Contradiction:

Improvetransportation volumeVSAvoidstructural integrity

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The sofa is divided into multiple separate components including seat sections, backrest sections, armrest sections, and connector assemblies. These segmented components can be transported in a compact configuration and then assembled at the destination to form the complete sofa structure, reducing transportation volume while maintaining structural integrity through the connector assemblies

Inventive Principle:

Principle #1Segmentation

2Volume of moving object

If conventional sofas are transported as completed products, then the structural integrity is preserved, but the cost of transport and delivery services increases significantly

Engineering Contradiction:

Improvetransportation volumeVSAvoidassembly complexity

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connector assemblies are designed to enable easy assembly of the sofa components by the consumer without requiring specialized tools or training. The connectors can be manually operated to join the segmented components together, making the assembly process accessible to ordinary consumers

Inventive Principle:

Principle #25Self-service

3Ease of operation

If consumers assemble RTA furniture kits, then the furniture can be assembled in situ without transportation difficulties, but the consumers need special tools and training which are not readily accessible

Engineering Contradiction:

Improveassembly easeVSAvoidstructural integrity

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The connector assemblies are pre-designed and pre-positioned on the sofa components to ensure proper alignment and secure connection during assembly. This beforehand preparation ensures that even untrained consumers can achieve reliable structural integrity without requiring specialized knowledge or tools

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Ease of operation

If heavy subcomponents are aligned and fastened by a single individual, then the assembly can be completed without additional labor, but the structural integrity may be compromised resulting in collapse and injury

Engineering Contradiction:

Improveassembly easeVSAvoidconnection strength

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS11779123B2Modular sofa construction and methods for assembly

Publication Date: 2023.10.10 BURROW INC

AI summary

A modular sofa assembly described herein includes a plurality of seating modules each having a seat section, a backrest section, and side edge surfaces. The backrest section includes first and second portions coupled for movement between a folded configuration and an extended configuration. An armrest module has an armrest side edge surface configured for mating engagement with a side edge surface of a seating module. The modular sofa is assembled by aligning connectors of the seating modules and armrest module, with each respective connectors slidingly engaged along an axis. After bringing the modules together, these connections are secured with the side edge surfaces in abutting engagement. The modular sofa further may include a power cradle mounted at the sofa's bottom surface. The power cradle includes a cubic power outlet near the front of the sofa, and power cable extending beyond the back of the sofa.