No-tool assembly chair

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Solution Overview

Problem

The challenge lies in assembling furniture, such as chairs, without tools or loose hardware, while minimizing shipping costs and ensuring consumer convenience, as existing methods often require multiple pieces and complex assembly processes.

Innovation Solution

A chair design featuring a lower and upper frame assembly using a hook mechanism on one side and a latch mechanism on the other, allowing for tool-free assembly by engaging protrusions and orifices, ensuring secure attachment without the need for tools or hardware.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If furniture is shipped in separate pre-assembled pieces, then shipping costs are reduced and packaging size is minimized, but assembly complexity and time increase for the consumer

Engineering Contradiction:

Improvenumber of pieces to shipVSAvoidassembly complexity

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The chair is divided into two main segments: an upper chair frame and a lower chair frame. Each frame is pre-assembled separately, allowing compact shipping while maintaining simplicity of final assembly through integrated attachment mechanisms.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The attachment mechanisms (hooks, latches, protrusions, and orifices) are integrated directly into the frame structures themselves, merging the fastening function with the structural components. This eliminates the need for separate hardware pieces and simplifies the assembly process.

Inventive Principle:

Principle #5Merging (Combining)

2Strength

If traditional attachment means (nuts, bolts, screws) are used, then structural integrity is maintained, but tool-free assembly becomes difficult and consumer convenience decreases

Engineering Contradiction:

Improvestructural integrityVSAvoidease of assembly

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

Instead of using threaded fasteners that require rotation and tightening tools, the design inverts the attachment approach by using protrusions that insert into orifices and hooks that engage with latches. This reversal of the traditional fastening mechanism enables tool-free assembly while maintaining structural integrity through positive mechanical engagement.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The attachment mechanisms are designed to be self-sufficient, with hooks that automatically engage with latches and protrusions that self-align with orifices during assembly. The structures serve their own fastening function without requiring external tools or additional hardware components.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS11464338B2No-tool assembly chair

Publication Date: 2022.10.11 ELITE OUTDOOR INC

AI summary

A chair adapted for no-tool assembly that includes a lower chair frame supported by an upper chair frame. A first, e.g., front, interface prevents relative movement between the chair frames, e.g., via orifice engaging a protrusion of, e.g., a hook member, or engagement of mating caps of the upper and lower chair frames with protrusions and orifices. A second, e.g., second interface includes a latch receiver and latch. In use, the upper chair frame is placed on the lower chair frame. The first interface is engaged for preventing relative movement between the upper and lower chair frames and the second interface between the lower chair frame and the upper chair frame is also engaged.