Folding mechanism in furniture design

Transcription

1 University of Iowa Iowa Research Online Theses and Dissertations Spring 2018 Folding mechanism in furniture design Joan Kim University of Iowa Copyright 2018 Joan Kim This thesis is available at Iowa Research Online: Recommended Citation Kim, Joan. "Folding mechanism in furniture design." MA (Master of Arts) thesis, University of Iowa, Follow this and additional works at:

2 FOLDING MECHANISM IN FURNITURE DESIGN by Joan Kim A thesis submitted in partial fulfillment of the requirements for the Master of Arts degree in Art in the Graduate College of The University of Iowa May 2018 Thesis Supervisor: Professor Monica Correia

3 Copyright by Joan Kim 2018 All Rights Reserved

4 Graduate College The University of Iowa Iowa City, Iowa CERTIFICATE OF APPROVAL This is to certify that the Master s thesis of MASTER S THESIS Joan Kim has been approved by the Examining Committee for the thesis requirement for the Master of Arts degree in Art at the May 2018 graduation. Thesis Committee: Monica C.G. Correia, Thesis Supervisor Jeremy Swanston James Snitzer

5 ABSTRACT I have an interest in creating furniture with a mechanism that makes the furniture move functionally. Therefore, this paper explains the process and outcomes of designing a chair and a set of furniture with a coatrack, an accent table, and a stackable stool. All the furniture packs flat for storage and shipping purpose with a folding mechanism. The folds happen with fabric hinges that have been experimented with different materials, machinery, and fundamentals. ii

6 PUBLIC ABSTRACT I have an interest in creating furniture with a mechanism that makes the furniture move functionally. Therefore, this paper explains the process and outcomes of designing a chair and a set of furniture with a coatrack, an accent table, and a stackable stool. All the furniture packs flat for storage and shipping purpose with a folding mechanism. The folds happen with fabric hinges that have been experimented with different materials, machinery, and fundamentals. iii

7 TABLE OF CONTENTS LIST OF FIGURES... v INTRODUCTION... 1 CHAPTER 1 - RESEARCH... 5 Japanese wood joinery... 5 IKEA and Modos... 7 CHAPTER 2 FOLDING MECHANISM IN FURNITURE Chair Furniture set, Gather-in Coatrack Accent table Stackable stools CONSLUSION iv

8 LIST OF FIGURES Figure 1. The Geo Lamp with lights off... 2 Figure 2. The Geo Lamp with lights on... 2 Figure 3. Wine tray closed... 4 Figure 4. Wine tray open... 4 Figure 5. AutoCAD file of tray... 6 Figure 6. Sample of IKEA assembly instruction... 7 Figure 7. The wedge dowel mechanism... 9 Figure 8. Modo s connection pieces Figure 9. Modo bookshelf Figure 10. Foam board model of the chair Figure 11. Prototype of the chair Figure 12. Router machine cutting pieces for the chair Figure 13. Jacob s ladder toy Figure 14. AutoCAD file of the coatrack Figure 15. Chicago bolt Figure 16. Foam board model of the coatrack Figure 17. Prototype of the coatrack v

9 Figure 18. Coatrack mechanism Figure 19. Coat hanger for the coatrack Figure 20. AutoCAD file of the coatrack Figure 21. Foam board model of the accent table Figure 22. Accent table mechanism Figure 23. Stool mechanism vi

10 INTRODUCTION According to the Oxford dictionary, a mechanism is "a system of parts working together in a machine; a piece of machinery." A mechanism is created to solve problems and psychologically avoid unpleasant feelings physically and helps the user to become satisfied. To create a functional mechanism that will solve problems, a full understanding analysis in three-dimensional space is required. When I was an undergraduate student, my major was Graphic Design, and I was enjoying assignments in my major that required handcrafts such as packaging design. During the very last semester in the undergraduate program, I registered for a Product Design class in the TDSN (Three-dimensional Design) discipline out of curiosity. The first project in class was to design a lamp (Figure 1 and 2). It seemed very straightforward, but I had a hard time shifting my two-dimensional design mindset into three-dimensional; not only in visual design but also creating a good plan. The assignment required a full understanding of space and how it would be used by the consumer. 1

11 Figure 1. The Geo Lamp with lights off Figure 2. The Geo Lamp with lights on 2

12 After figuring out the first project with success, it was the second project that led me to 3D Design. I found myself enjoying the problem-solving process in space and I got interested in creating transformable products with elements that would move for different functions. From many trials and errors, the second assignment accomplished with a wine tray that slides in and out. It was the first moving mechanism I created, and it turned out to be successful. The tray initially holds one bottle of wine with two wine glasses secured by carrying the tray. When one end slides out, it will stop at a certain point where there is a hidden mechanism in the wood to prevent the movement. The transformation allows the tray to hold one more bottle of wine. When the tray is not in use, it simply collapses and can save space when it is stored (Figure 3 and 4). All projects are created from rapid prototyping or CNC (Computer Numerical Control) machining. CNC machines are used for manufacturing that is controlled by computer software. Lathes, mills, routers, plasma cutters and laser machines are example of CNC machines that can cut wood, steel, plastic and etc. In my research, I mostly used the router machine to cut my wood panels. 3

13 Figure 3. Wine tray closed Figure 4. Wine tray open 4

14 RESEARCH For a while, furniture and products that can fit in small spaces, harmonize in different areas, packed flat and were easily move and shipped have been a trend. IKEA was one of the most successful companies who satisfied the consumer. Furniture became transformable, constructible, portable, suitable for various interiors. I aim to follow the trend and create work that has moving elements with visually and technically appropriate mechanisms. Since a majority of my work is done with wood, looking up traditional Japanese wood joinery gave me inspiration and insight. Japanese Wood Joinery Japan is well known for their long history of wood construction that is completed with perfection. The mechanism is sturdy enough to last for hundreds of years in good condition and also visually appealing. Woodworking in Japan could develop because of the nature of an island with sufficient material from abundant timber and volcanic soil. Moreover, the ancient wooden buildings had to survive from natural disasters such as typhoons and earthquakes, which advanced the wood-construction technique. After studying how the wood joinery works, I was able to revisit my wine tray and fix a minor problem that I was not able to figure out previously. Whenever the tray was holding two bottles of wines, the very bottom layer of wood could not stand the weight and would lean slightly. After the research, I found that the locking mechanism on the lowest piece of wood was not tight enough to hold the top piece of wood. Therefore, 5

15 adding another pocket cut to the lowest section made the tray stronger and solved the problem (Figure 5). Figure 5. AutoCAD file of tray 6

16 IKEA and Modos As I mentioned before, IKEA is one of the most successful companies that is known for manufacturing portable assembly furniture. Not only the innovative idea but a reasonable price for the consumer was the primary cause for the success of IKEA. Products may be less finished, less durable and not assembled, but the quality was up to a standard that would satisfy the consumer. IKEA is well known for ready to assemble furniture with instructions, and it was the company's strategy to save labor expenses. Therefore, they always think of a way to break down the furniture to pack flat. It makes it easier to ship and does not waste space, which equals money. However, the consumers started to make noises about how complicated the assemblies were becoming. The furniture has been broken down into so many pieces that it would take hours to read the instructions and built the product (Figure 6). Figure 6. Sample of IKEA assembly instruction 7

17 New furniture startup companies who want to supplement IKEA are entering into the flat package industry. Designers and engineers are figuring out different mechanism and joints that are easier to assemble and last longer. IKEA has realized they should find solutions to defend their crown and according to an interview, they seem to in a process of solving their issues. Again, the company is known for ready to assemble furniture and product that packs flat with a reasonable price. However, the product is not durable enough to last long. The assembly instructions are not easy or simple to follow, and most of the time the consumer needs a specific tool to put them together. IKEA has been realizing their shortcomings and planned to fix their reputation. Since 2014, IKEA has been testing a new mechanism called the wedge dowel (Figure 7). It was an innovation for the company that will make ready to assemble furniture much user-friendly. The wedge dowel has not been generalized yet in IKEA products, but it is in a process to be manufactured and utilized. 8

18 Figure 7. The wedge dowel mechanism Modos was created to supplement the complicated and fragile ready to assemble furniture company, such as IKEA. It is not an international company as IKEA, but it a successful company in the states in a manner of what they aim for designing and functionality. The two founders created a simple mechanism to build user-friendly furniture. There are three small metal connectors, branching in different directions (Figure 8). It connects and holds either the maple, walnut or bamboo wood pieces together (Figure 9). They only have three types of furniture in Modos but they grantee the quality, easy assembly, and flat-package. They came up with a simple but robust mechanism to supplement the weak point of commercial markets. 9

19 Figure 8. Modo s connection pieces Figure 9. Modo bookshelf 10

20 FOLDING MECHANISM IN FURNITURE The main design concept of my furniture was to create a mechanism that will enable it to pack flat. Creating several physical models was necessary to test if the mechanism works and to pick which assembly would be more comfortable for the consumer to use, with maintaining its visual attraction. 'Folding' was my solution, but I did not want to use hardware hinges, which will not make a differentiation with other designs in the field. Therefore, I experimented with fabric hinges in a couple of ways. The first was to create a pocket that would hold pieces together, which was used in my chair design. The second mechanism was inspired by the 'Jacob's ladder' toy, which connects pieces with alternated strips. This one was applied to my furniture set of a stackable stool, an accent table, and a coat rack. 11

21 Chair The inspiration of the chair started from a cube. The first step was to break down a chair into simple shapes, forms, and surfaces. It ended up with one U shape with three squares and one L shape with two squares. The U shape became the legs and seating area, and the L shape became the seating and back. The seating surface of the L shape would have channels for the legs to slide in, so the two seating surfaces would collapse and becomes a chair form (Figure 10). Figure 10. Foam board model of the chair 12

22 The prototype of the chair was made by birch plywood and processed by the router machine (Figure 11 and 12). To pack the chair flat, the U shape component will fold into a Z shape, and the L shape would fold in half. However, it was challenging to maintain the back seat fixed to its position while it was assembled and in use. Subsequently, I had to take the two pieces apart and only apply the folding mechanism on the U shape unit's connection. Then I had to figure out how to connect the legs to the seat so one leg folds above the seat and one leg folds under the seat. I did not want to use the ordinary hardware hinges that would easily solve the problem but would not create a difference with other folding products on the market. Investigations in too many materials was made to figure out a durable material and mechanism that would be strong enough to bear the wood's weight and sustain the folds. Leather seemed to be sustainable, but I concluded that it would wear out after it gets folded a few times. Consequently, a fabric pocket was the most suitable material. It was flexible enough to fold in different directions and durable enough to hold the wood weight, with a few layers. The challenge was to create a mechanism that will hold all the pieces together and become a functional chair. A mechanism that would not be too complicated for the consumer to assemble with no hardware is necessary. However, I was not able to figure out a sturdy enough way to hold the frame of the seating and the U shape together that would carry a human weight and also hold it from the gravity. I ended up using three metal dowels that would go through all three pieces and keep them together. To sandwich the dowel between the plywood, I created pocket cuts on two parts and glued them together. Therefore, I was able to eliminate the use of any screwdrivers for the consumer, 13

23 but I still could not figure out a mechanism to hold all pieces together without using any hardware. It was disappointing to finalize the chair without fully accomplishing the objectives, but I learned that differentially purposed objects require a different thinking process. Being successful in developing a wine tray with a mechanism that does not require any hardware, I was looking forward to creating furniture in a similar conception. However, furniture is a much bigger product and has different usages. Therefore, much more elements needed to be considered, thought out and experimented. I concluded that it is impossible to design folding furniture without any hardware. Instead of altogether eliminating the use of metal, I would try to use the least amount of hardware as possible, and at least make sure the consumer does not have to use any device when they assemble the pieces. Also, the violet linen that was used for pocket holding the chair together was visually appealing, but not durable enough. The dark violet and the light birch plywood created a nice contrast in color and made it look very Japanese; however, the fabric was so thin that it would wear and tear with several layers sewed together. I would like to revisit my chair and figure out a mechanism that can be accomplished with less hardware and look for a piece of fabric that is more durable. I would start with the very first model that had the U shape and L shape and think from the basics. 14

24 Figure 11. Prototype of the chair Figure 12. Router machine cutting pieces for the chair 15

25 Furniture Set, Gather-in I have been working on a furniture set of a coat rack, an accent table and a stacking stool since last semester. It is a continuous project from my previous chair that can fold and pack flat. I also experimented with designs that would make use of most of the material that would waste as little material as possible. Irregular shapes with big and deep pocket cuts were what I tried to avoid. And using simple shapes and forms would also make the folding mechanism more achievable. To create a smoother folding mechanism, I borrowed the assembly idea from the 'Jacob's ladder' toy (Figure 13). Figure 13. Jacob s ladder toy Each unit of the toy is connected with a simple strip that can be folded back and forth. I adopted the idea of how it makes the fabric hinges make the folding in both directions compared to a regular metal hinge. Also, each unit of the piece will fold into a bigger unit, completely nesting each other (Figure 14). When the furniture is completely opened, it will be fixed with a wooden beam to hold horizontal loads. 16

26 Figure 14. AutoCAD file of the coatrack After figuring out the form, the challenge was to create the fabric hinges that would make the folding movement smooth and easy, but sturdy and tight enough to hold the pieces without dangling. The first material I chose was the thick leather strip that was used for belts. However, the leather belt was so thick and sturdy that it was unable to completely fold. After a few tests of different types of fabrics, I concluded a duck canvas would be tough enough to last long and flexible enough to fold in any angles. Since I enjoyed the color contrast between the light beige color of the birch plywood and the dark color of the violet linen on my chair, I used a dark navy canvas to continue the color scheme on the furniture set. At last, the canvas strips should hold the wooden frames together to accomplish the folding movement. The barrel nut and bolt, which is also called as a Chicago bolt (Figure 15), were used to keep the two materials together. A Chicago bolt is a type of fastener with a barrel-shaped flange with an internally threaded boss. 17

27 Figure 15. Chicago bolt However, the canvas hinges with the Chicago bolts did not turn out to be the best solution. The material was durable and flexible enough, but it was not tight enough to hold all the units together without shifting. I am still in the process of figuring out if the cause of shifting is from the fabric, the bolt or my crafting skill. There is a possibility that the texture of the duck canvas is too tough, or the bolts might have to be placed in a different area, or it may require more bolts for sturdiness. The furniture set Gather In was named after the moving motions. It looks like the small unit was gathering into a bigger unit, nesting into each other perfectly. 18

28 1. Coatrack My first approach to the furniture set was the coat rack. The basic form was triangles embedded into each other and folding outwards to open and create surfaces to stand. It looked very sculptural with the spikes (Figure 16). Figure 16. Foam board model of the coat rack However, I changed my direction from a triangular form into a rectangular form (Figure 17), because an angled surface was not efficient to be used to hang multiple items in a row. The change also allowed me to create less waste and make use of the whole 4' x 8' sheet of wood. The new design lost the impact of looking like a central piece of work that would be in a living room or a hallway but became more functional and harmonious within the space. By separating the board into three sections that would nest into each other, each unit created a linear frame silhouette. The horizontal frames enabled the coatrack to hang coat hangers, scarfs and bags. However, there was only one horizontal 19

29 frame on the top of each unit, which made the 5 feet tall vertical frames unstable. As a solution, I added beams to the bottom section, which made the folding action to happen in only one angle. The beam on the bottom constrained how much the units can fold back, and it made the nesting concept even stronger as if each unit had a defined space to fit inside of the other. The piece of furniture could be overlapped when needed (Figure 18). Figure 17. Prototype of the coat rack 20

30 Figure 18. Coatrack mechanism There is also a coat hanger that goes with the coat rack (Figure 19). Since the coat rack cannot hang many clothes at once, there is a small section on the bottom of the coat hanger where pants and skirts can be hung. The form of the overall hanger is rectangular to stay cohesive with the coat rack. Each corner is slightly rounded, preventing the clothes getting damaged from sharp edges. 21

31 Figure 19. Coat hanger for the coatrack One new problem to solve for the coat rack was cutting a 4' x 8' on a 4' x 4' router machine. I did not want to break the coat rack in half and connect it due to the lack of machinery dimension we have. The vertical frames were the strong elements of the coat rack and if the frame breaks into a top and bottom piece, it will distract the visual effect that pleases the viewer. Therefore, I created groove on a 4' x 8' sheet of plywood and made a rail on the machine that will fit in the groove. I had to create two files on AutoCAD (Figure 20), processed the 1 st file first and pushed the plywood to the other half and ran the second file. As a result, I was able to make the coat rack into one piece without any horizontal lines breaking the piece. 22

32 Figure 20. AutoCAD file of the coatrack 23

33 2. Accent table If the challenge for the coat rack was maintaining its height, the accent table s challenge was locking the horizontal surface with the vertical frames (legs). The legs of the table open and closes in the same manner with the coat rack (Figure 22). There was not enough surface on the legs to create a strong locking mechanism. The top surface will be locked in place when it is sitting on the ground; however, it would loosen the locks if a user tries to hold the table from the table top. To prevent the user from holding the horizontal surface, the frame of the leg segments had to become more dominant as a handle. I made the table top surface lower and smaller and placed the handle at a height where people would usually grab (Figure 21). Figure 21. Foam board model of the accent table 24

34 I also had issues with the table looking visually unstable. The smallest legs were too skinny, but there was a limited range of width that could be addressed. Since each piece of leg embeds into each other, the width of each frame gets wider and wider. However, the table is an accent table, which could not get too big. Consequently, I adjusted the thickness of each leg slightly to keep it visually balanced and lowered the table surface. As a result, the table looks more stable with the proper size of a table top. Figure 22. Accent table mechanism 25

35 3. Stacking stools The stacking stool can stack and pack flat (Figure 23). Flat packing is mainly my focus area to make it easier to ship and save space when it is not in use. The low stool that I aimed to design is small enough that it makes it easier to store multiples in stacks. Unfolding and assembling it each time would be more work and inconvenient. Therefore, I constructed the stool to be stackable for storage purpose, and pack flat for shipping purpose. The beams that hold the stool elements together when it is open also works as a step for the other stool to load on top. Again, the form and folding mechanism are figured, but the fabric hinges were not tight enough to hold the back section and the bottom section of the stool together. When the stools are stacked, the problem becomes more noticeable. The bottom piece of the top stool looks as if it is hanging and not secured with the canvas hinge. There are still a few technical issues to be addressed. I was focusing too much on individual mechanisms on the stool, that I missed how it would look when it stacks. I might have to use a different mechanism for the folding stool, but I would like to continue with my research and conclude with a solid solution. 26

36 Figure 23. Stool mechanism 27

37 CONCLUSTION Many product and furniture in the field are transformable to grab the user s attention. However, when the transformation is not functional, the attention fades quickly. The wine tray led me to experiment with furniture that can transform, move, fold and assemble to become a flat-packing piece. Though not all of the furniture was successful as the wine tray, the problems can be solved in the future, as I was able to figure out the issue of the wine tray after having a better understanding in material and mechanism and also making improvement in technical skills. The chair was built stable and functional, but the mechanism did not reach the goal. I would like to reduce the amount of metal or hardware that I used or design a mechanism that would hide the hardware inside the structure. Also, a sturdier fabric should be used to last longer and hold the pieces tighter. The Gather-in furniture set will be cut in bamboo plywood that has an interesting horizontal edge created with layers of bamboo. The pieces may look nice on solid wood; however, CNC is more appropriate for plywood since they create less waste material. Moreover, the online cut will help me make use of most of the material with the least amount of waste. The Chicago bolts can be sewed inside of the vinyl strips, so it will not be visible. The accent table will need a stronger joint between the table top and the legs, which requires a sturdier locking mechanism between the wood. The stools need a stronger fabric, for example, a vinyl, and mechanism that would hold the horizontal pieces even tighter. 28

38 Designing furniture with unusual mechanisms is an interesting project. It trains my space perception ability, technical skills, and knowledge in different materials. For example, I was able to utilize the CNC router machine to cut plywood that is bigger than its capability after fully understanding the machine from experience. Functional furniture and product should always fulfill its job and design a piece to solve a problem is what a 3D designer should do. You should understand the problem, come up with a solution that is also visually appealing to the audience. I am excited to continue the furniture project and complete with a right solution. 29