Shell for seats, and corresponding method
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Solution Overview
Problem
Current methods for producing seat shells are costly and time-consuming, limiting design flexibility and personalization, and are not suitable for small serial productions due to high industrialization costs and the inability to create complex shapes or varying levels of rigidity and softness.
Innovation Solution
A seat shell composed of a frame with metal sub-frames and nets, where the nets are shaped to match the sub-frames and padded with expanded material of defined density and rigidity, allowing for customizable ergonomic zones and a support base that can be easily adapted for various shapes and sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mold-based methods are used to produce seat shells, then uniform rigidity and shape are achieved, but manufacturing time and costs increase significantly, limiting design flexibility and personalization
Solution Approach 1:
The seat shell is divided into multiple functional zones, each with its own rigid support structure and padding layer. This segmentation allows different zones to be customized independently for rigidity, softness, and shape without requiring complete re-engineering of the entire shell, thus reducing preparation time while maintaining manufacturing precision.
Solution Approach 2:
Each functional zone is equipped with specific padding materials having different density and softness characteristics tailored to local ergonomic requirements. This local quality approach enables personalized seat design without the need for expensive and time-consuming custom molds for each variation.
2Adaptability or versatility
If custom molds are designed for personalized seat zones, then ergonomic consistency is improved, but industrialization costs and device complexity increase
Solution Approach 1:
The support structure is segmented into multiple independent sub-frames, each corresponding to a functional zone. This modular approach allows personalized configuration of different zones without requiring complex custom molds, as each zone can be assembled independently from standardized components.
Solution Approach 2:
The seat shell combines rigid metal sub-frames with flexible padding materials of varying densities. This composite construction enables personalized ergonomic zones through material selection and arrangement rather than through complex mold designs, reducing device complexity while maintaining adaptability.
3Shape
If multi-layer shell construction is used to achieve complex shapes, then shape versatility is improved, but shell weight increases
Solution Approach 1:
The shell is constructed as a segmented framework of metal sub-frames rather than solid multi-layer construction. This segmentation maintains shape complexity through strategic placement of support elements while minimizing material usage and overall weight.
Solution Approach 2:
The padding layers act as flexible elements that conform to the metal sub-frame structure, providing complex shapes and ergonomic contours without adding significant weight. The flexible nature of padding allows shape complexity to be achieved through form rather than mass.
Data Source
Figure 1~4
Figure 5
AI summary
Shell (10) for a seat that comprises: - at least a frame (11), conformed and consisting of one or more sub-frames (11a- 11d); at least part of said sub-frames (11a-11d) being obtained with at least a metal round piece (13) and configured to define at least one functional zone (12) of the shell (10); - at least a net (14) or a plurality of nets (14) structurally associated with at least a part of the sub-frames (11a-11d); - possibly at least a padding (18), made of expanded material, with defined density and rigidity, structurally associated with the individual nets (14) and/or with the individual sub-frames (11a-11d) to configure the functional zones (12) with personalized density and rigidity; - possibly at least a covering of enhancing material (19); - possibly at least a support base (15) configured to connect the shell (10) to a support (16). The present invention also concerns the corresponding method to obtain the shell (10).