Chair Back Assembly with Dual-Frame Structure for Localized Support
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Solution Overview
Problem
Existing chair backs struggle to balance comfort, support, and manufacturability, with a wide variety of design materials and ergonomic considerations complicating the development of effective and aesthetically pleasing solutions.
Innovation Solution
A chair back assembly combining an outer frame with a more rigid material and an inner frame of webbing, featuring a crossing-pattern of closed cells, is used to provide localized support, coupled with a foam layer for enhanced comfort and ease of manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid frame material is used for the entire chair back, then structural strength is improved, but comfort and localized support deteriorate
Solution Approach 1:
The chair back is divided into two distinct frame structures: an outer frame made of rigid frame material for structural strength, and an inner frame made of flexible web material for comfort. This segmentation allows each part to serve its specific function - the outer frame provides overall structural integrity while the inner frame provides localized flexible support and comfort to the user's back.
Solution Approach 2:
Different materials with different rigidity properties are applied to different parts of the chair back structure. The rigid frame material is used for the outer frame where structural strength is needed, while the flexible web material is used for the inner frame where comfort and adaptability to user's back contours are required. This local differentiation of material properties resolves the contradiction between strength and comfort.
2Ease of operation
If a complex multi-material structure is used, then localized support and comfort are improved, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into distinct steps: first forming the outer frame, then forming the inner frame, coupling them together, and finally applying the foam layer. This segmentation of the manufacturing process makes the complex multi-material structure manageable by breaking it down into sequential, independent operations rather than attempting to create the entire structure in one complex step.
Solution Approach 2:
The inner frame is nested within the structure defined by the outer frame, and the foam layer is nested around both frames. This nested arrangement allows the components to be assembled in a logical sequence where each component fits into the structure created by the previous components, simplifying the overall manufacturing process despite the multi-material complexity.
3Ease of manufacture
If traditional single-material chair backs are used, then manufacturing simplicity is maintained, but comfort and tailored support are reduced
Solution Approach 1:
The chair back employs a composite structure combining rigid frame material for the outer frame and flexible web material for the inner frame, with a foam layer providing additional cushioning. This composite approach maintains manufacturing simplicity through standardized processes for each material type while achieving superior comfort through the complementary properties of the different materials working together.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides improved comfort and support customization while simplifying production, allowing for tailored ergonomic design and efficient manufacturing processes.
Implementation Method 1
a foam layer enveloping the outer frame and the inner frame and filling the closed cells of the inner frame
Data Source
AI summary
The present disclosure relates to a chair back assembly with an outer frame and an inner frame, wherein the outer frame is manufactured of different material than the inner frame to allow for a variety in support throughout the chair back assembly, resulting in localized support throughout the back of the chair. The availability of localized support results in an improvement in comfort and may also improve production in embodiments utilizing a foam covering. Specifically, the inner frame of the chair back assembly may include at least one vertical member and at least one horizontal member to provide additional support to the user.