Divisible Seat Shell Design for Compact Packaging and Transport
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Solution Overview
Problem
Bucket seats, commonly used in race and rally simulators, pose challenges in efficient packaging and transportation due to their integrally formed design, which results in larger packaging sizes and increased storage and transport costs.
Innovation Solution
The shell is divided into two releasably connected parts along a large-area dividing plane, allowing for efficient disassembly and reassembly, with edges and flanges providing a strong connection while minimizing protrusions and maintaining seating comfort, and can be manufactured from plastic or composite materials for cost-effectiveness and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the shell is integrally formed, then the seat structure is simple and strong, but the packaging size is large and transport costs increase
Solution Approach 1:
The shell is divided into two separate shell parts that can be disconnected from each other. This segmentation allows the parts to be nested during transport, significantly reducing packaging volume while maintaining structural integrity when assembled. The division plane is strategically positioned to optimize both transport efficiency and structural strength.
2Volume of moving object
If the shell is divided into parts, then the packaging efficiency improves, but the connection strength and stability may be compromised
Solution Approach 1:
The two shell parts are connected through a robust connection mechanism involving flanges and connecting elements. The flanges extend from the edges of each shell part and are designed to overlap and secure together, creating a strong mechanical bond that restores the shell's structural integrity after segmentation for transport.
3Strength
If flanges are added for connection, then the connection strength increases, but protruding parts may affect seating comfort
Solution Approach 1:
The flanges are strategically positioned at the edges of the shell parts, specifically in areas that do not contact the user during seating. This localized placement ensures that the connection mechanism achieves maximum strength while the critical seating surfaces remain smooth and comfortable for the user.
4Volume of moving object
If the dividing plane is positioned to optimize packaging, then the transport efficiency improves, but the distribution of stresses during use may be affected
Solution Approach 1:
The dividing plane is strategically positioned to pass through areas of lower structural stress, such as along the lateral sides of the shell. This optimization allows the shell parts to nest efficiently during transport while ensuring that the connection point does not compromise the overall structural integrity or stress distribution during normal use.
Data Source
AI summary
A shell for a seat, particularly for a simulator, includes a seat surface, a backrest and side parts. The shell includes two or more shell parts connected releasably to each other. The shell parts are connectable to each other along a dividing plane. The dividing plane can run substantially parallel to or enclose a small angle with a plane which connects a front side of the seat surface to an upper side of the backrest, and the shell parts can extend substantially equally far from the dividing plane in a direction transversely thereof. A method for transporting a shell for a seat includes: providing two shell parts which can be connected releasably to each other to form the shell; placing the shell parts in each other; and placing the shell parts which are placed in each other in a packaging.