Adjustable lift chair frame
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Solution Overview
Problem
The manufacturing of lift chair frames is complicated by the variety of sizes required, which hinders automation and increases costs due to the need for custom-designed frames that must be both strong and lightweight, while also accommodating users with physical limitations such as the elderly or those with disabilities who struggle to stand up from chairs.
Innovation Solution
A lift chair frame design featuring adjustable components such as a discrete chair frame, seat back frame, and chair shell frame, utilizing standardized parts that can be configured to various dimensions through alignment features and fasteners, allowing for multiple width, height, and depth adjustments, thereby simplifying manufacturing and reducing the number of parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If custom-designed frames are used for each model and size, then the frame can satisfy the desired weight rating and dimensions, but the manufacturing process becomes more complicated and the number of parts increases
Solution Approach 1:
The patent applies universality by designing a standardized frame structure that can serve multiple functions across different chair models and sizes. The adjustable support bars and modular components allow a single frame design to accommodate various width, height, and depth requirements, eliminating the need for completely custom-designed frames for each model.
Solution Approach 2:
The patent implements dynamics through adjustable support bars that can be repositioned along the frame structure. This adjustability allows the frame to dynamically adapt to different configuration requirements while maintaining structural integrity, resolving the contradiction between standardization and customization.
2Manufacturing precision
If custom-designed frames are used for each model and size, then the frame can satisfy the desired weight rating and dimensions, but manufacturing costs increase due to inability to fully automate
Solution Approach 1:
The standardized frame design with universal components enables full automation of the manufacturing process. The consistent structure across different models allows robotic assembly systems to efficiently produce frames without requiring custom tooling or programming for each variant, thereby reducing costs while maintaining precision.
Solution Approach 2:
The frame is segmented into modular components including adjustable support bars, seat frames, and backrest assemblies. This segmentation allows each component to be manufactured independently using automated processes, then assembled systematically, improving both manufacturing precision and ease of manufacture.
3Ease of manufacture
If standardized components are used for adjustable dimensions, then manufacturing is simplified and production costs are reduced, but the frame must be sufficiently strong to maintain structural integrity
Solution Approach 1:
The standardized components are pre-engineered and pre-tested to ensure they meet strength requirements before assembly. The support bars and connection points are designed with predetermined load-bearing capacities, allowing simplified manufacturing while guaranteeing structural integrity through preliminary design validation.
Solution Approach 2:
The frame utilizes composite construction combining lightweight materials with strategic reinforcement at stress points. This allows the use of standardized, easily manufactured components while maintaining sufficient structural strength through material selection and design optimization at critical locations.
Data Source
AI summary
A lift chair frame is disclosed having an adjustable seat including a front support bar assembly including a left member and a right member connected to the left member, a rear support bar assembly opposite the front support bar assembly along a longitudinal direction, a left support bar connected to the front and rear support bar assemblies, and a right support bar opposite the left support bar along a lateral direction that is perpendicular to the longitudinal direction and connected to the front and rear support bar assemblies. The lift chair frame also includes an adjustable back coupled to the adjustable seat, where each of the left and right members includes a plurality of alignment features positioned in predetermined locations that correspond to predetermined adjustable seat widths, such that during assembly one of the predetermined adjustable seat widths can be achieved by 1) aligning one of the alignment features of the left member with one of the alignment features of the right member, and 2) securing the left member to the right member.