Integrated Seat Back Shell With Elastic Belt Support
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Solution Overview
Problem
Existing backrests with elastic belt structures for seating furniture face challenges in assembly complexity, high production costs, and incomplete transfer of supporting forces due to separate manufacturing processes and intermediate connections, leading to potential detachment and unsightly joints.
Innovation Solution
A one-piece plastic backrest formed by integrating the elastic belt structure and the surrounding frame in a single injection molding process, allowing for different materials and enhanced stability, flexibility, and support comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the elastic belt structure and backrest frame are manufactured separately and connected through intermediate connection elements, then the manufacturing flexibility and material selection are improved, but the assembly complexity increases and connection reliability deteriorates
Solution Approach 1:
The patent combines the elastic belt structure and backrest frame into a single integrated component manufactured through one-piece injection molding. This eliminates the need for separate manufacturing processes and intermediate connection elements, directly resolving the technical contradiction by merging two previously separate parts into one unified structure.
Solution Approach 2:
The injection molding tool is designed to perform multiple functions: it simultaneously manufactures both the elastic belt structure and the backrest frame, and also creates their permanent connection in a single process. This multi-functional approach eliminates the need for separate assembly operations while maintaining material versatility through selective material properties.
2Adaptability or versatility
If separate manufacturing processes are used for the belt structure and backrest frame, then production flexibility is improved, but production costs increase and manufacturing precision deteriorates
Solution Approach 1:
The patent merges the manufacturing of the elastic belt structure and backrest frame into a single injection molding process. This eliminates multiple manufacturing steps, reduces production costs, and improves manufacturing precision by ensuring perfect alignment and connection between the two components without requiring separate assembly operations.
3Adaptability or versatility
If intermediate connection elements are used to attach the belt structure to the frame, then manufacturing adaptability is improved, but connection strength deteriorates and supporting force transfer is compromised
Solution Approach 1:
The patent eliminates intermediate connection elements by integrating the belt structure and frame into a single molded part. This creates a continuous material connection throughout the structure, ensuring maximum connection strength and enabling complete transfer of supporting forces from the user's body through the belt structure to the frame without any weak points or detachment risks.
4Ease of operation
If the belt structure and frame are connected through intermediate connection elements, then assembly flexibility is improved, but joint appearance deteriorates requiring additional cladding
Solution Approach 1:
The patent merges the belt structure and frame into a single integrated component, eliminating the need for separate joints or connection points. This results in a smooth, continuous surface without any visible joints or gaps, removing the need for additional cladding or covering materials while maintaining clean aesthetic appearance.
Data Source
Figure 1~5
Figure 6~11
AI summary
The backrest (1) has a frame-side seat-back shell (2) defining an internal central recess (6) having an elastic strap- or belt structure (4). The elastic strap- or belt structure is connected on the edge side integrally with the frame-side seat-back shell is connected. The plastic material of the belt structure is a resilient plastic material. The plastic material for the back shell is a hard plastic material. Independent claims are included for the following: (1) a seat-back shell with a strap bar; and (2) a method for manufacturing a seat-back shell.