Chair Back and Base Frame Assembly for Simpler Recycling
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Solution Overview
Problem
Modern adjustable chairs are complex to manufacture and assemble, leading to high costs and quality issues, while also lacking in ergonomics, simplicity, and environmental sustainability, with a need for reduced components and recyclable materials.
Innovation Solution
A seating unit design featuring a base frame with protruding uprights and a molded back component with cavities for telescopic engagement, a cushion assembly with a recyclable panel structure, and a method for disassembling the seating unit by tearing along weakened areas, utilizing compatible materials for easy recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If modern adjustable chairs include a large number of components to provide comfort and adjustability, then ergonomic performance is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple structural functions into fewer integrated components. The base frame integrates support functions, the molded back component provides both structural support and ergonomic shaping, and the cushion assembly combines cushioning with a recyclable panel structure. This merging reduces the total number of separate parts while maintaining adjustability and comfort features.
Solution Approach 2:
The base frame with protruding uprights serves multiple functions: structural support, connection point for the molded back, and integration for the cushion assembly. The molded back component similarly provides structural support, ergonomic shaping, and attachment functionality. This multi-functionality reduces the need for separate specialized components.
2Ease of repair
If traditional seating constructions use multiple separate components, then ease of repair is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The seating construction is divided into distinct modular segments: the base frame, the molded back component, and the cushion assembly with panel structure. Each segment can be manufactured separately and assembled together, allowing for easier repair by replacing only the defective segment rather than the entire seat. The protruding uprights on the base frame provide clear attachment points that facilitate segment separation and replacement.
3Strength
If seating constructions use integrated materials for durability, then strength is improved, but recyclability decreases
Solution Approach 1:
The cushion assembly and panel structure are constructed from compatible materials that can be recycled together without separation. This homogeneity in material composition maintains structural integrity and durability while enabling straightforward recycling processes. The molded back component also uses materials that can be easily separated and recycled, avoiding exotic or composite materials that would complicate recycling.
4Reliability
If complex assembly procedures are used to achieve robust construction, then reliability is improved, but productivity decreases
Solution Approach 1:
The base frame, molded back component, and cushion assembly are each pre-assembled and prepared with attachment features (protruding uprights, cavities, tabs) before final assembly. This preliminary preparation ensures that when components are brought together, they connect quickly and reliably without requiring complex assembly procedures. The protruding uprights are already positioned and shaped to mate with corresponding cavities, enabling straightforward assembly.
Data Source
AI summary
A seating unit includes a rearwardly-open base frame with a pair of uprights on opposite rear side portions in spaced apart positions. A molded back has corner sections with cavities for matably telescopingly engaging the uprights, and a beam section extending between the corner sections for stabilizing the rear side portions when the molded back is engaging the uprights. A seat fastened to the base frame engages the molded back to retain the molded back on the upright sections. A cushion attached by a line of adhesive is perforated inward of the line, such that a majority of the cushion can be pulled off by tearing along the perforation line, allowing quick separation for recycling. The uprights have reduced an upper diameter for aesthetics but extend upwardly sufficiently to support armrest on the back.