Segmented Chair Base Assembly for Compact Packaging and Shipping
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Solution Overview
Problem
The large diameter chair base of rolling office chairs increases shipping costs due to larger packaging requirements, and while breaking down the chair into subassemblies reduces size, the diameter still dictates the box size, necessitating a smaller packing solution.
Innovation Solution
A ready to assemble chair base is designed into two components: a removable leg component and a hub component with a tapered axial hole and leg receiver, allowing for compact packing and easy assembly with locking posts and wedge mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the chair base is made with a large diameter to ensure stability, then the stability of the chair is improved, but the packaging size increases leading to higher shipping costs
Solution Approach 1:
The chair base is divided into multiple components: a hub component with a central body and radial legs, and separate leg components that can be attached later. This segmentation allows the components to be packaged in a compact arrangement rather than requiring the full diameter of the assembled base, reducing packaging volume while maintaining the stability of the final assembled product
Solution Approach 2:
The leg components are designed to nest within the hub component or within each other during packaging. The radial legs can be positioned to overlap or interlock in a space-efficient manner, allowing the disassembled base to occupy significantly less volume than the assembled base, thereby reducing shipping costs while preserving the large diameter stability when assembled
2Volume of stationary object
If the chair base is disassembled into subassemblies to reduce packaging size, then the packaging volume is reduced, but the assembly complexity increases
Solution Approach 1:
The base is segmented into a hub component and leg components with standardized connection interfaces. The hub includes a central body with a tapered axial hole and radial legs, while leg components have corresponding attachment features. This segmentation enables compact packaging but requires design of simple, robust connection mechanisms to minimize assembly complexity
Solution Approach 2:
Connection elements such as locking posts, wedge mechanisms, or insert fittings serve as intermediaries between the hub and leg components. These intermediaries provide simple, tool-free or minimal-tool assembly procedures where the consumer only needs to insert and secure the leg components to the hub, reducing assembly complexity despite the segmented design
3Volume of stationary object
If removable leg components are used to reduce packaging size, then the packaging volume is reduced, but the reliability of the connection decreases
Solution Approach 1:
The chair base is segmented into a hub component and removable leg components, enabling compact packaging. The segmentation is designed with robust connection features including locking posts, wedge mechanisms, or threaded fasteners that ensure reliable connections when assembled, maintaining structural integrity despite the removable nature of the components
Solution Approach 2:
The connection interface between the hub and leg components incorporates curved or tapered surfaces that provide self-aligning and self-tightening characteristics. For example, a tapered axial hole in the hub with a corresponding tapered leg component creates a friction-fit connection that is both simple to assemble and highly reliable, preventing loosening during use while allowing compact packaging
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enables the chair base to be packed in a smaller volume and easily assembled by consumers, reducing shipping costs and maintaining stability with a uniform appearance.
Implementation Method 1
a rounded wedge formed on the inner end of the blade contacts the wedge walls as the leg is rotated into assembled position to wedge the locking posts firmly into the receiver slots
Implementation Method 2
The top wall of the channel may further include a threaded hole therein to receive a bolt that is inserted through a hole in the underside of the removable leg and engaged with the threaded hole to firmly retain the leg in the assembled position
Data Source
AI summary
A unique and novel ready to assembly chair base is broken down into several component parts so that it can be packed in a smaller volume of space, and then easily assembled by the consumer. The chair base is formed in a manner that the base comes apart into at least two components. A first removable leg component and a second hub component consists of a central support with a tapered hole therein, a plurality of fixed legs and a truncated leg receiver configured and arranged receive and retain the removable leg component when the chair is assembled.