Folding Desk Chair Innovation

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| Drawn, cut, and bent
| Drawn, cut, and bent
| Steel
| Steel
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|-
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| 22
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| Turntable
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| 1
 +
|
 +
| Attaches desk surface to table support and allows desk to rotate 90 degrees for folding.
 +
| Purchased from McMaster-Carr, part # 1797K3
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| Steel
 +
|
 +
|-
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| 23
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| Desk Arm
 +
| 1
 +
|
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| Attaches desk to chair and rotates between open and closed position.
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| Bent pipe
 +
| Steel
 +
|
 +
|-
 +
| 24
 +
| Hinge Top
 +
| 1
 +
|
 +
| Allows table to open up for folding.
 +
| Stamping and folding.
 +
| Steel
 +
|
 +
|-
 +
| 25
 +
| Hinge Bottom
 +
| 1
 +
|
 +
| Allows table to open up for folding.
 +
| Stamping and folding.
 +
| Steel
 +
|
 +
|-
 +
| 26
 +
| Table Support
 +
| 1
 +
|
 +
| Attaches hinge to desk surface.
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| Cutting.
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| Aluminum
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|
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|-
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| 27
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| Desk top
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| 1
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|
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| Serves as a desk surface.
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| Injection Molding
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| HDPE
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|
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|-
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| 28
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| Links
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| 2
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|
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| Stops the desk arm at the appropriate angle.
 +
| Cutting and stamping.
 +
| Aluminum
 +
|
|}
|}

Revision as of 00:50, 2 May 2012

Contents

Executive Summary

Market Analysis

Design Documentation

Bill of Materials

Part # Part Name QTY Weight (g) Function Manufacturing Material Image
1 Large Rivet Nut 4 6 Connects seat (19) to legs (20, 22) Purchased steel Image:Row1.png
2 Spacer 4 1.5 Distances legs from seat, most likely to reduce friction during use Purchased steel Image:Row2.png
3 Washer 4 1.5 Protects coating Purchased steel Image:Row3.png
4 Tapping Screw 6 2.5 Connects seatback (12) to front legs (22) Purchased stainless steel Image:Row4.png
5 Small Rivet Nut 4 4 Connects bracket (6) to legs (20, 22) Purchased steel Image:Row5.png
6 Bracket 2 27 Holds legs (20, 22) together and acts as hinge Stamped steel Image:Row6.png
7 Rubber foot covering 4 4 Protects flooring Injected molding and joined Rubber Image:Row7.png
8 Small machine screw 6 1.5 Connects cushion assembly to seat (19) Purchased Steel
9 Staples Connects fabric (13) to seat back (12) and cardboard seat (18) Purchased Steel
10 Large staple cover bracket 1 10 Covers the area where staples are visible for aesthetic and safety purposes Molded Plastic Image:Row10.png
11 Small staple cover bracket 1 <1 Covers the area where staples are visible for aesthetic and safety purposes Molded Plastic Image:Row11.png
12 Seatback 1 279 Provides back support Molded Plastic Image:Row12.png
13 Fabric Covers 2 55 Covers cusion, keeping foam (16, 17) in place and making the seat aesthetic Woven, dyed, and cut Nylon Image:Row13.png
14 Angle Stop 2 5 Stop front legs at a certain angle and protects material Molded and joined Rubber Image:Row14.png
15 Tee Nut 6 1 Allows screws to hold cushion to seat Purchased Steel
16 Seatback Foam 1 24 Cushions seat back for comfort Cut Polyurethane Image:Row16.png
17 Seatback Foam 1 56 Cushions seat for comfort Cut Polyurethane Image:Row17.png
18 Fiberboard Seat Cover 1 332 Holds screws and staples for seat assembly Cut Fiberboard Image:Row18.png
19 Seat 1 1366 Holds cushion and provides support Forged Steel Image:Row19.png
20 Back leg 2 394 Distributes weight from seat Drawn and cut Steel Image:Row20.png
21 Crossbeam 1 Strengthens back leg Drawn and cut Steel
21 Crossbeam 1 1360 Strengthens front leg Drawn and cut Steel Image:Row21.png
22 Front leg 1 Distributes weight from seat Drawn, cut, and bent Steel
22 Turntable 1 Attaches desk surface to table support and allows desk to rotate 90 degrees for folding. Purchased from McMaster-Carr, part # 1797K3 Steel
23 Desk Arm 1 Attaches desk to chair and rotates between open and closed position. Bent pipe Steel
24 Hinge Top 1 Allows table to open up for folding. Stamping and folding. Steel
25 Hinge Bottom 1 Allows table to open up for folding. Stamping and folding. Steel
26 Table Support 1 Attaches hinge to desk surface. Cutting. Aluminum
27 Desk top 1 Serves as a desk surface. Injection Molding HDPE
28 Links 2 Stops the desk arm at the appropriate angle. Cutting and stamping. Aluminum

House of Quality

Design Analysis

DFMA

Design for Manufacture and Assembly considerations were significant to the prototype and design analysis. As the DFMA implications are expanded to the large scale production regime, several conclusions become apparent. If implemented on a large scale, the folding desk chair would be composed of two major subassemblies: a stock folding chair (likely very similar to the black Target model used in our physical prototype), and the custom desk and arm assembly. This means that other than the simple variations made to the folding chair (holes to mount hardward) after assembly in its own factory, all DFMA considerations for this project lie in the desk, arm and hinge subassembly. Firstly, stock tubing is used to form the main pivot arm. In this and all cases, use of fastners is minimized by using as few parts as possible. In this example, bending stock tubing is the simplest way to make the custom pivot arm. Attaching the main arm to to the chair and hinge on each end is also done using DFMA considerations, by using rivets and spring pins rather than traditional fastners. This is because fastners such as rivets and pins are easier to install, cheaper, and their inherent drawback of permanency doesn't matter in our design. Once the chair is assembled, it need not be disassembled.

FMEA

Failure Mode Effects Analysis was the largest and most important aspect of the Design Aspect facet.

DFE

Mechanical Analysis

Prototype Documentation

Design Process

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