Multi-Function Lifestyle Chair
People's Choice Award, Retail & Consumer Products Award
Molder: Fort Wayne Plastics
Moldmaker: FGL Precision Works, LTD
Designer: Sauder Manufacturing Design Group & (Eleven)
OEM: Sauder Manufacturing Co
Description
The multi-function task and lifestyle chair reflects a two-year research and product development process in which Sauder Education returned to the college campus to explore how students engage their educational environment and more importantly, what elements remained missing in the student and university quest for creating residential atmospheres where social and educational development thrive. At first glance the multi- function task and lifestyle chair is purely task chair. Yet its sophistication (and fun!) is revealed in three quick steps transforming it from task chair to floor rocker and table/stool, enhancing the unique and alternative study positions of today’s student. With the multi-function task and lifestyle chair, studying at a desk becomes the exception and not the rule with flexibility to read, work on a computer, converse, even watch TV in the comfortable floor rocker and have a table to support a laptop, beverage, or even a friend!
Why is this Part Innovative?
This product is innovative in a number of different ways. First, the very essence of the multi-functional design is itself innovative in that it provides a bundle of features and benefits never before considered. Being purpose-designed for the student dorm room, this multi-functionality is particularly well-suited for environs where space is normally at a premium and individuals desire the ability to use their space in a multitude of ways, be it for studying, relaxing, eating, or entertaining. Moreover, there is innovation in the details of the product design, too. Examples include:
- The shape of the back which allows the occupant to sit comfortably backwards in the chair.
- The design of the interface between the seat frame and the tabletop which is error-proofed (poka-yoke) to disallow the misalignment of the components, and which provides an audible confirmation (“click”) when the components are properly engaged.
Finally, the use of the Structural Webb gas assist process represents innovation that permits the designer and the engineer to live in harmony and bring to life a design which is economical yet very structurally sound; manufacturable yet very pleasing aesthetically (see more about this below).
Process
Structural Webb Gas Assist: Structural webb gas assist molding was chosen for the mission-critical Frame and Tabletop components of the chair for several reasons. First, the process afforded the designer the opportunity to incorporate large structural rockers into the product which are central to the function of the chair. Likewise, structural web made it possible to integrate both the seat and back portion of the frame into one structural entity which passes stringent BIFMA test requirements; thus, cost was reduced through part count reduction and the elimination of assembly operations. The process also substantially reduced part weight and production cycles by hollowing thick sections of plastic, maintaining structural integrity while still yielding a very dynamic aesthetic. Finally, the process permitted the simultaneous molding of multiple parts of disparate sizes within one machine cycle thereby spreading production costs of one machine over several parts.
Design
Designed utilizing CAD (SolidWorks and ProEngineer)
Mold flow analysis (Moldflow Plastics Insight®)
Finite Element Analysis (ANSYS)
Tooling
Aluminum
H13
P20
Material
Polypropylene, ABS, Glass-filled Nylon, Nylon, TPE
Finishing
N/A
