Woven Support Seat Assembly for Thin, Quiet Auditorium Seating
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Solution Overview
Problem
Existing auditorium and theater seat assemblies require costly metal springs or wire mesh, which are noisy, prone to rust, and uncomfortable due to their material characteristics, and often necessitate complex mounting methods.
Innovation Solution
A seat assembly featuring a frame with flexible woven supports integrated within a molded foam cushion, allowing for reduced thickness, ease of egress, and cost-effective manufacturing, with connectors extending through holes in the foam for attachment to a frame, enabling a lightweight, durable, and versatile seating solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal springs or wire mesh are used in seat assemblies, then structural support is provided, but the seats become noisy, prone to rust, and uncomfortable
Solution Approach 1:
The patent replaces expensive, problematic metal springs with inexpensive woven fabric strips that can be easily replaced. The fabric webbing is a simple, low-cost alternative that eliminates rust and noise issues while maintaining structural support functionality.
Solution Approach 2:
The patent substitutes the mechanical spring system with a fabric-based tension system. Instead of metal coils that compress and expand, the invention uses woven fabric strips that provide support through tensile strength and flexibility, fundamentally changing the mechanical approach to seat support.
2Strength
If metal springs are used in seat assemblies, then load bearing capacity is achieved, but manufacturing costs increase due to materials and tooling
Solution Approach 1:
The patent replaces expensive metal springs with inexpensive woven fabric strips. The fabric webbing is significantly cheaper than metal springs both in material cost and manufacturing, eliminating the need for specialized spring manufacturing tooling and reducing overall production costs.
Solution Approach 2:
The patent changes the material parameter from metal to fabric, fundamentally altering the properties of the support element. This material substitution reduces cost while maintaining adequate load-bearing capacity through the fabric's tensile strength and flexibility.
3Ease of operation
If padding is placed over metal springs, then comfort is provided, but the padding wears quickly from contact with the springs
Solution Approach 1:
The patent replaces the problematic metal spring interface with smooth fabric webbing that does not abrade padding material. The fabric surface is gentler on the padding cover, extending its service life while maintaining comfort.
Solution Approach 2:
The patent converts the potential harm of rigid metal springs against padding into a benefit by using flexible fabric webbing. The fabric's softness and flexibility protect the padding from wear while still providing necessary structural support, turning a previously harmful interface into a protective one.
4Strength
If a single continuous web is used between side rails, then load distribution is improved, but mounting complexity increases requiring J-clips and flanges
Solution Approach 1:
The patent divides the continuous web concept into multiple separate fabric strips that can be independently attached to the seat frame. This segmentation simplifies mounting by allowing each strip to be attached separately using simple adhesive or stitching, eliminating the need for complex J-clip and flange assemblies.
Solution Approach 2:
The patent uses simple, inexpensive fabric strips instead of complex continuous web systems with specialized mounting hardware. The individual strips can be easily attached with basic adhesives or stitching, dramatically reducing mounting complexity and eliminating the need for specialized J-clip and flange components.
5Length of moving object
If reduced thickness is achieved in seat assemblies, then space and ease of egress are improved, but structural support may be compromised
Solution Approach 1:
The patent uses thin, flexible fabric webbing strips to provide structural support in a minimal thickness profile. The fabric strips can be arranged in multiple layers or patterns to achieve adequate support while maintaining a thin overall seat construction that improves space efficiency and egress.
Solution Approach 2:
The patent combines fabric webbing with foam padding to create a composite support system. The fabric provides tensile strength and structural definition, while the foam provides compression support and comfort, achieving adequate structural support in a reduced thickness compared to traditional spring-based designs.
Data Source
AI summary
A seat assembly including an assembly frame having at least two seat connection brackets, a seat frame, two or more connectors attached to the seat frame, the two or more connectors removably attached to the two or more seat connection brackets, two or more flexible supports extending across at least a portion of the seat frame, each support including a woven material, and a foam cushion including one or more holes, wherein the seat frame and the two or more flexible supports are molded within the foam cushion, and wherein the one or more connectors extend at least partially within the one or more holes.