WHAT IS ZAISU
Zaisu is a traditional Japanese floor chair born from tatami culture.
It was designed to make floor seating more comfortable, used with floor cushions and low tables.
Today, the Zaisu has evolved into modern designs, featuring reclining mechanisms and high-comfort cushioning.
Structure of a Zaisu
Zaisu chair is composed of three main structural elements: the frame, the cushion, and the cover.
-
Cover
The cover gives the chair its look and feel. It is made from materials such as fabric and synthetic leather. In recent years, more models feature removable covers, making them easier to keep clean and maintain.
Also, with waterproof covers, Zaisu chairs can be used for outdoor activities such as picnics and other open-air settings. - Cushion The cushion is usually made from soft materials such as urethane foam and is the key for sitting comfort. Manufacturers carefully adjust the softness and thickness to match different uses.
- Frame The frame is the strongest structure of the chair and is mainly made of steel pipes. It holds the reclining gears and hinges that move the backrest. Among the gears, KOYO gears are known for their high precision and durability, providing smooth reclining movement and strong reliability for long-term use.
Manufacturing Process
FRAME MAKING
Pipes are cut and bent according to the design drawing. The gears are welded together with the pipes to form the solid frame structure of the Zaisu chair.
CUSHION INSTALLATION
Cushion materials, which determine seating comfort, are precisely assembled and securely fixed to the frame and gear mechanism.
COVER INSTALLATION
Zaisu chairs are complete when attached with a unique piece of fabric. Depending on the model, decorative buttons or accessories are also attached.
Frame Fabrication Process
1 Pipe Cutting
Pipes are cut according to the design drawings.
For standard gears, pipes with a thickness of 1.2 mm are used.
For tall frame designs, pipes with a thickness of 1.6 mm are used.
1.2mm Pipe
1.6mm Pipe
2 Pipe Bending
The pipes are bent according to the design drawing using a pipe bending machine.
During bending, checks are made to avoid crushing, cracking, or wrinkling of the pipes.
Crush
Cracks
Wrinkles
3 Gear Installation and Welding
Gears are welded to the frame according to the design drawings.
・The gears must be attached to the pipe frame without distortion.
・To prevent malfunction, do not weld on inclined areas.
・When releasing the gear lock, tilt the reclining surface fully forward, release the lock, and then return it to a horizontal position.
No Inclination
3° inclination
5° inclination
Install an anti-tip pipe in the seat section or a reinforcement pipe in the backrest section if needed.
Install an anti-tip pipe in the seat section if needed.
Install a reinforcement pipe in the backrest section if needed.
4 Inspection
Inspect the frame for distortion and check the proper functioning of the reclining mechanism.
5 PP Band installation
PP bands are attached to the frame to prevent the cushion from slipping out of place.
Seat: Horizontal wrap
Backrest: Horizontal wrap
For floor-use chairs, install PP bands on both the seat and backrest.
Seat: Cross wrap
Backrest: Horizontal wrap
PPバンド注意点ビジュアル.png)
For high-seat chairs, install bands in both vertical and horizontal cross patterns to reinforce the structure.
Cushion Installation
Install the cushion according to the specifications.
- 1. Leave sufficient clearance around the gear area to ensure proper movement.
- 2. Apply protective fabric to areas where the gear may contact the upholstery to prevent fabric entanglement and floor damage.
Cover Installation
Create the cover according to the desired design.
By using waterproof fabric, the product can also be suitable for outdoor use.
When using a large or continuous piece of fabric, it is recommended to attach drawstrings to prevent cover displacement.
Pass the drawstrings through the slits in the cushioning material and tie them securely to the internal steel rod.
