Drop-In Webbing Seat Box for Moisture-Permeable Comfort
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Solution Overview
Problem
Conventional seat boxes with rigid planks are impermeable to moisture, leading to reduced cushion lifespan and limited flexibility, while air permeable alternatives are uncomfortable and require full replacement upon damage, making maintenance inconvenient.
Innovation Solution
A drop-in webbing assembly with a flexible webbing frame and central girder, made from wood and/or wood products, that can be separately inserted and replaced, providing permeability, comfort, and easier installation and repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rigid plank is used as the seat support, then the structure is simple and easy to construct, but the plank is impermeable to moisture causing cushions to retain moisture and reducing serviceable life
Solution Approach 1:
The patent replaces the solid rigid plank with a webbing assembly that creates a porous structure. The webbing material is stretched across the main box to form a grid-like pattern with open spaces between the webbing strands, allowing air circulation and moisture evaporation from the cushions while maintaining structural support.
2Reliability
If an air permeable rigid seat plank is used, then moisture can escape, but the limited flexibility of the plank is uncomfortable to seated individuals
Solution Approach 1:
The patent replaces the rigid air permeable plank with flexible webbing material stretched in a tensioned configuration. The webbing strands are flexible and can deflect under load, providing comfort to seated individuals while maintaining the porous structure that allows moisture to escape through the gaps between webbing elements.
3Reliability
If high tensile strength webbing is stretched across the main box, then both permeability and flexibility are achieved, but any damage requires replacement of the entire seat box which is challenging and inconvenient
Solution Approach 1:
The patent divides the seat box into modular components: the main box structure and the removable webbing assembly. The webbing assembly is configured as a separate unit that can be independently removed and replaced without damaging or replacing the entire seat box. This segmentation allows for easy maintenance and repair by simply swapping the webbing assembly when damaged.
4Device complexity
If the webbing assembly is made entirely of wood and/or wood products, then steel cross supports are eliminated, but the assembly must still be securely attached to the main frame
Solution Approach 1:
The patent uses wood and/or wood products to construct the webbing assembly, creating a composite structure that combines the webbing material with wooden cross supports or reinforcement elements. This composite approach provides the necessary strength and rigidity for secure attachment to the main frame while eliminating the need for steel cross supports, maintaining structural simplicity.
Data Source
AI summary
A seat box assembly and method of fabricating utilizing a drop-in webbing assembly secured into a main box and back frame assembly. The webbing assembly has a rectangular frame with elongate members and shorter members and a central girder with a cutout extending between mid-portions of the elongate members. The central girder attachable to the seat box and a central vertical frame member of the back frame assembly. The elongate members having stub portions that fit into slots in the main seat box. A method of repair includes replacing a damaged drop-in assembly with a different drop-in assembly.