具体实施方式：
[0052]The following detailed description contains, for the purposes of explanation, numerous specific embodiments, implementations, examples and details in order to provide a thorough understanding of the invention. It is apparent, however, that the embodiments may be practiced without these specific details or with an equivalent arrangement. In other instances, some well-known structures and devices are shown in block diagram form in order to avoid unnecessarily obscuring the embodiments of the invention. The description should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, including the exemplary designs and implementations illustrated and described herein, but may be modified within the scope of the appended claims along with their full scope of equivalents.
100s, 300s, 400s (Basics, Parts, Assembly)
Basic Description
[0053]Some embodiments of the present invention relate to a user-stabilized chair built from a folded paper substrate, and customized for each individual user for ergonomic alignment and activity. Further embodiments relate to an ergonomically correct, tailored active seating device, for example, a chair. The components of a chair according to an example embodiment of the invention is shown in FIGS. 1-8. In the embodiment depicted in FIGS. 1-8, the chair 100 comprises a base 101, three leg portions 102 defining a seat-supporting structure, and a seat or seat portion 103. The base 101 comprises a counterweight mass 134 (also referred to herein simply as a “counterweight”) which operates to bias the chair in an upright position by default, as the centre of mass of the chair would be located very close to the bottom of the base. The chair optionally further comprises a seat top cushion 131 containing, for example, a high-density foam. The chair may also include express printed graphics on the folded paper elements 150.
Paper and Counterweight
[0054]According to some embodiments, the use of paper substrates for a counterweight design is important because the entire chair or product becomes lighter than comparable products. Moreover, in the embodiment depicted in FIGS. 1-8, the pulp mass 133 in the legs may be distributed to the periphery, which may allow the central volume to be more or less free of material. Similar to an I-beam, where most of the mass would be expressed on the outer perimeter, a similar result may be achieved by setting up the folded formwork 135 to build mass away from the center. This arrangement can improve or even maximize the moment of inertia, which means that less material is required for vertical support. Due to this lowered structural demand, in some embodiments the paper substrates are more easily accommodated. Other designs which support a user's weight directly underneath the middle of the seat or chair would not be as effective or conducive to using paper substrates as the building material.
No Moving Parts
[0055]By using fixed and rigid construction, it is possible in some embodiments to achieve improved durability of materials, reliability of movement and aesthetic simplicity.
Pressure
[0056]In some embodiments, as shown for example in FIGS. 1-8, the triangular shape of the seat 103 in plan view will cause the user's coccyx to be free of encountering any abrupt pressure. Further, the pressure points in the seat cushion 131 may be limited by the use of high density foam and maximized surface area contact between the seat and the user's body. The open space underneath the seat 103 provides additional pressure relief for the user.
Ventilation & Foam
[0057]In some embodiments, the seat cushion 131 of the seat 103 is made of high density foam, which facilitates maximizing the surface area contact between the seat and the body contour for healthier pressure distribution and comfort. Fabrics which retain allergens and dust may be avoided in some embodiments. Materials such as vinyl, which cause the user to sweat, may also be avoided in some embodiments. In FIGS. 1-9 seat 103 may be made of a tensile material that spans between the foam seat edges, connected at the corners 136 and contains a few holes 130 centrally located above the paper tube void 410 for both ventilation and a lifting function.
Sustainable
[0058]As noted above, in some embodiments, the components of the chair 100 are made from paper substrate materials. Paper substrates may offer a number of advantages over other building materials, namely: carbon sequestration, recyclability, and a reduction in the overall material weight of the chair. This reduced overall weight reduces the mass required in the base 101 to act as a counterweight 134 for the chair 100. More broadly, the use of paper substrates also supports the cultivation of medium growth forests, which leads to a more sustainable harvesting strategy. Furthermore, waste from various processes may be embedded in the counterweight mass 134 in or on the base 101 of the chair 100, which mitigates harmful environmental effects while also reducing the need for consumption of additional material for the counterweight mass 134. The reduced weight would also result in lower transportation costs per unit compared to heavier materials.
Flat to 3D
[0059]According to one aspect of the present invention, the individual components of the chair 100 may be produced as flat paper stock or substrate, which are subsequently folded at precise points 336 to assume a three-dimensional shape. FIGS. 13-16 illustrate overhead views of the initially produced flat forms, including fold lines, of the seat 301, leg 302, base 303, and cushion 304.
Fold Sequence
[0060]A general overview of the assembly process is shown in FIGS. 13-16. In some embodiments, the assembly process begins with the production of the flat paper stock. The flat paper is then machine cut and scored into the foldable component 330 with graphics printed on the flat paper 334 by, for example, a digital die cutter and the leftover paper 331 can be reused. In relation to the initially flat components in FIG. 13A-13E, they show a step-by-step illustration of how an example embodiment of seat 301 begins as flat paper 330 and is wrapped onto a paper tube 333 to produce a three-dimensional component where the edges 332 mark the straight cut boundary. Likewise, FIGS. 14A-14F show a step-by-step illustration of how an example embodiment of leg 302 is folded into an assembled, three-dimensional component showing the front 330&334 and back 335 sides of the folded elements. Finally, FIGS. 15A-15G show a step-by-step illustration of how an example embodiment of base 303 is folded into an assembled, three-dimensional component. FIG. 17 shows the hatch coding of the fold sequence process.
Graphics
[0061]In some embodiments, graphics are printed onto the paper substrate 334 prior to cutting, scoring and gluing the paper substrate. In some embodiments, the creasing/folding, cutting and gluing can be done very quickly through automation on digital die cutters. FIGS. 13A, 14A, and 15A illustrate the output from a printer showing the graphic areas on the paper substrate. The customer may select predetermined graphic print options or may also request customized graphic prints.
Blunt Edges
[0062]In some embodiments, the production process uses a fold pattern which employs a hidden cut method to conceal the raw cut edges in the paper substrate material 347, thereby avoiding sharp edges, allowing soft contact between the user and the chair components when folded/assembled. This may facilitate active use of the chair without the user having to take undue precaution to avoid contact with sharp edges.
Assembled Parts
[0063]FIGS. 18A, 19A, 20A, 21A, 22A, and 23A show top views of example embodiments of the seat 301, legs 302, base 303, pulp 305, electrical module 306, and counterweight mass 307 respectively. FIGS. 18B, 19B, 20B, 21B, 22B, and 23B show side views of the seat 301, legs 302, base 303, pulp 305, electrical module 306, and counterweight mass 307 respectively. FIGS. 18C, 19C, 20C, 21C, 22C, and 23C show a different side view of the seat 301, legs 302, base 303, pulp 305, electrical module 306, and counterweight mass 307 respectively. FIGS. 18D, 19D, 20D, 21D, 22D, and 23D provide perspective views of the seat 301, legs 302, base 303, pulp 305, electrical module 306, and counterweight mass 307 respectively.
Joined Parts
[0064]After folding, the various components of the chair are joined together comprising the seat 301, legs 302 and base 303 and the next cast parts 305, 307 can be built.
Elements
[0065]In some embodiments, using separated pieces provides the opportunity to use knife plate joints. For example, the vertical leg pieces may extend past the horizontal members into the cast pulp or concrete volumes in order to strengthen their bonds. Without using this method, the joint between horizontal and vertical members would be significantly weaker and would limit the applicability of using paper substrates. According to some embodiments, the methods described herein may provide an efficient way to fold up building material (e.g. paper substrate), expose no cuts 342, 347, and build up mass on the outer edge cavity 340 in a way that is efficient for the moment of inertia of the overall product (e.g. chair). In some embodiments, the joining of folded elements together is facilitated by producing male 348&349 and female 345&346 ends on the paper (for example, the leg may serve as the female end while the base has the male ends of the joint).
Paper Tube
[0066]In some embodiments, horizontal members 132 may also include a paper tube beam condition to transfer loads to the vertical orientation. The paper tube beam can connect directly to the vertical support using for example, a pulp-glue-filamentous mixture joint. Such a configuration is possible because the vertical supports leave an opening into the horizontal tubes 341. This in turn functions to efficiently translate a horizontal member support condition into a vertical support condition.
Cast Elements
[0067]Horizontal spanning elements 132 at the top are then connected to legs by filling the pipe forms with, for example, a pulp-glue-filamentous mixture. A slip-resistant base (as shown, for example, in FIGS. 23A-23D at the base of each of chairs) may comprise, for example, rubber as a casting material. The counterweight base mass 134 may contain, for example, embedded slag or lead for added weight. Finally, the seat top is covered with a cushion 130 containing, for example, high-density foam. The slip-resistant base allows for better grip between the base and the floor when the chair is subjected to extreme tilting angles (otherwise horizontal translation may result).
Connect
[0068]The term “connected” or “coupled to” may include both direct coupling (in which two elements that are coupled to each other contact each other directly) and indirect coupling (in which at least one additional element is located between the two elements).
200s (Movement)
Movement
[0069]The chair is configured for dynamic seating with a capacity for rotation 236 around a central smooth point 137 and leaning around the anti-slip spherical base 134. This configuration is usable on uneven surfaces with a fluid range of motion. As shown in FIG. 12, movement of the hips 241 and head 240 are coordinated with the base of chair 243 and feet 242 to maintain a stable center of gravity.
Self-Recovery
[0070]The counterweight 134 facilitates self-recovery for the chair when not being sat on by the user. FIGS. 10 and 11 show a side and top view of an embodiment of the chair 100 in which suitable ranges for tilting relative to a horizontal axis 235 are compared to the density of the counterweight 234 required in order to allow for self-recovery 231. As can be seen, some embodiments of the chair 232 can allow for quite extreme tilting angles 231, including 45 degrees or more. The degree to which the chair 100 can tilt while still allowing for self-recovery depends on the density of the counterweight 234 relative to a point of rotation 233 in the base 134. Typically, the anticipated range of motion 230 for seated use of the chair 100 is less than 45 degrees, as shown in FIGS. 10 and 11.
Paper & Curvature
[0071]In some embodiments, the lightness in mass of the upper portion due to the use of paper substrate allows for the use of a sharper curvature in the rounded or spherical shape at the base 134. This may allow the chair to recover from more extreme tilted positions 231 with relative ease as the mass of the seat is considerably lighter relative to the base 234, as shown in FIGS. 10-11. This sharper curvature is important for providing and allowing for a greater variation in range of motion and movement for the user. Other designs known in the art have a shallower curvature which therefore limits the active variation permitted. If such designs using heavier materials and different weight distributions were to use a similar curvature to that which is capable of being supported by some embodiments of the present invention, the designs would become heavier still, as extra mass would need to be added to the base.
Directionless
[0072]In some embodiments, the chair has no directionality due to the equilateral form, so any user can sit down on the chair from any angle, with a reduced likelihood of a first-time user making a mistake when attempting to use the chair. This may in turn reduce the likelihood of injuries associated with use of the chair, particularly for first-time user movement. Further, the directionless priority of movement may cause the core muscles of the user to be activated all around the body depending on the position assumed by the user when seated in the chair. The detailed feedback provided by some embodiments may allow users to track their habits and achieve healthier sitting and movement/activity pattern results over long-time use of the chair.
Body Implications
[0073]In some embodiments, the design priority is to offer control of the body through the user's hips while sitting on the chair. This is important in order to manipulate and maintain a vertical spine during use. The saddle shape of the seat 103 (as shown, for example, in FIG. 1) may be more form fitting and may permit a wider angle in elevation between the spine and thighs of the user, which may yield a more natural spinal curvature for the user and may also alleviate hip flexor tightness associated with typical sitting patterns (i.e. 90 degree hip alignment). The saddle shape also supports the thighs at a diagonal angle, which may be less obtrusive to blood flow and facilitate the maintenance of a greater surface area of contact between the user's body and the seat 103.
Benefits
[0074]Some embodiments of the invention may strengthen the physical body as well as enhance body awareness therefore enabling the user to self-adjust as a result of internal and external sensations. This helps to prevent repetitive muscle imbalance induced by sedentary seating environment (particularly prolonged stillness), and facilitate increased muscle activity in the user's core, back and leg muscles under gravitational loads while facilitating movement.
Acclimation
[0075]Although some embodiments of the invention may require the user to acclimate to the conscious effort required to balance when using the chair, the user may gradually learn how to unconsciously maneuver the user's hips to maintain balance. Once attained, use of the chair according to some embodiments may encourage a more dynamic lifestyle and produce improved muscle tone, flexible joints, alleviate pressure points, increase blood flow and increase metabolic rate. These factors may contribute to peak mental performance and increased productivity, since cognitive performance is tied to activity and blood circulation. As such, use of the chair according to some embodiments may cause human resource productivity to improve though active ergonomics.
500s, 800s (Tailored, Broader Applications)
Counterweight
[0076]In some embodiments, the counterweight base formwork as shown in FIG. 15 is defined by using a flat paper edge 344 against a spherical form with adjustable placement of the dowel connections into the pulp leg elements 421. This strategy may permit the adjustment of the overall volume of the counterweight with relative ease by changing the paper boundary against a reusable spherical form. Through this method, the center of rotation for the counterweight and counterweight depth can be parametric relative to the required structure at the top seat. This strategy ensures that the counterweight spherical center can be modified independently from the volume.
Body Parameters
[0077]The design of the chair form is dictated by several parameters from the human body 510 shown in FIG. 24, which include for example hip width 511, seat edge curvature for thigh circulation 514, knee break height 516, inner hip width 512, conscious roll sensitivity, ventilation grip 513, and thigh length 515. Coordinating the chair design with a table height may be performed but it is preferably to prioritize for spinal alignment first. As noted above, FIG. 24 shows the values of certain parameters 511-516 and the associated body geometries. For example, a person who is taller than average may require a higher seat platform, and an individual with wider than average hips may require a wider form. FIGS. 26A-26B illustrate examples of several chairs with proportions tailored to particular users based on a variety of measurements 511-516. For example, chair 521 is based on parameters 511-516 for a user that is larger than average. Chair 522 is based on parameters 511-516 for an average user. Chair 523 is based on parameters 511-516 for a user of below average height. A person skilled in the art will appreciate that the parameter values listed in FIG. 24 are merely examples and intended to illustrate parameters that are tailored to a particular individual. Each of these parameters can also be modified independently to produce completely unique results.
Fixed Solutions
[0078]In some embodiments, the chair is tailored to the individual at the time of production, and does not provide for seat adjustability (e.g. dials or levers or the like for adjusting settings on the chair) during use, since optimal settings are already being provided. As such, the chair is ideally not tailored for individual table heights. Instead, the height of the desk or table at which the user is sitting may need to be adjusted to match the ideal seat height provided by the chair. In some embodiments, the chair does not include any seat adjustment knobs, as adjustment is provided through the tilting action of the chair itself. Further, according to the Canadian Centre for Occupational Health and Safety, adjustment knobs also introduce the risk that users will select settings which are improper and ultimately harmful to the user. Since the chair can be tailored to a particular user during manufacturing, the need to adjust the chair is minimal for the user, and thus associated undesirable body postures arising from potentially improper adjustments may be prevented through use of the tailored chair without altering its configuration. As illustrated in FIG. 25, the tailored outputs provide a comparable baseline for a consistent hip-spine-floor relationship. This feature is critical and permits the comparability of biomechanics evaluations listed below for the electronics.
Parametrics
[0079]In order to provide a customized chair which is tailored to the dimensions of an individual user, parametric design is used to generate the form of individual flat components shown in FIGS. 27A-D for various sizes 531-533, including creasing/fold lines and dimensions for the components. The various components of the chair according to some embodiments of the invention may be designed using, for example, Rhino 3D design together with the Grasshopper parametrics plugin. According to some embodiments, one or more of the various parameters are input into parametric equations, which output the definitions for outputting flat paper outlines, each with valid engineering parameters (including, for example, shape, thickness, joints, or the like). A particular advantage of this strategy is that the tailored mathematical relationships can be updated over time for tailoring precision to coordinate with the latest biomechanical research. Due to the consistent biomechanical baseline, those updates can be applied to all users.
Integrated Engineering
[0080]In some embodiments, the construction details are automatically configured to accommodate the variability in dimensions for a user. Since the parts for the chair are printed, cut, scored and glued on flat paper, the structural engineering is automatically integrated into the unique folded geometry outputs of FIGS. 27A-27D. It should also be noted that generically-sized components can also be developed for use in public settings where there will be more than one user and tailoring to a group demographic is desirable.
Production Automation
[0081]Due to the intrinsically tied nature of computer designs and the digital die cutting equipment, in some embodiments, the generation of the initial design on flat paper automatically responds to variations in parameters to alter the shapes of the components during production. The single parametric algorithm for the design of the chair components can structurally analyze the engineering needs in a fluid and automated manner to meet all bodily requirements of the user. At the same time, the digital die cutting equipment can work in tandem with the algorithm to produce and execute the necessary cut/score/glue patterns for automated production. This ease in customizability may lead to a very efficient, context-driven product with inherent environmental and economic benefits, since waste tends to be reduced or minimized according to some embodiments of the invention when precisely built.
Imitated Construction
[0082]After the cutting, scoring and gluing, the paper substrate is then manually folded, jointed (as described below), coated and cast. The folded paper substrate ultimately defines the structural form of the chair. In some embodiments, the folding process varies only slightly for the builder. Thus, customization for tailored chair dimensions may be achieved with minimal impact or variation on the manufacturing process.
Fluid Sizes
[0083]In some embodiments, the paper/pulp or other cast material combination allows for the fulfilling of tailoring requirements because it facilitates a number of proportions in both shape, strength and counterweight ratios to support the anticipated loads according to output sizes 531-533. No single-size structural member would be able to efficiently accomplish this result. FIGS. 28-31 illustrate how the tube diameter, tube wall thickness, pulp mass, counterweight mass structure are coordinated with the folded form. The contour of the tensile cover maintains smooth flat surface over the rounded shape thereby facilitating the use of a flat material in such geometrical conditions. The electronic module is one of the components that is built without a fluid change 534 in dimension as tailoring it does not directly offer advantages for the body.
Y Shape
[0084]Furthermore, in some embodiments, the vertical leg pieces may branch apart at the outer edge in the shape of a ‘Y’ as illustrated in FIG. 29. This further reinforces the benefits of the moment of inertia of the chair and also provides access for joining paper tubes to cast legs with a solid form, which avoids unnecessary complexity in the construction process. In some embodiments, as shown in FIG. 47, each discrete element can by itself be folded into the shape of a product in such a way that it allows for a variety of fillers or castable materials 850 to be cast into it (e.g. pulp, concrete, insulation, or the like). In some embodiments, casting into the ‘Y’ shape was focused on, as the ‘Y’ shape is achieved by the division of legs into three sections, which is the simplest way to build up adjustable mass through adjoining flats with particulate or filamentous material, and the 3 divisions for the ‘Y’ shape are the fewest number of divisions by which this result can be obtained.
Coatings
[0085]The folded paper is then coated with a cellulose product (for example, cellulose nanocrystalline (CNC), described below) to add strength and a waterproof layer. In some embodiments, the structural coating is another paper substrate, but as FIG. 47 illustrates, this coating 851 can be varied according to the structural requirements. CNC comes from the cell walls of trees. Such a coating may increase the strength and stiffness of the other materials. Some embodiments of the chair will offer an efficient structural and economic balance between stock paper thickness in conjunction with CNC thickness in order to arrive at a high “green quotient”.
Pulp Fill
[0086]The components of the chair according to some embodiments have a paper structural form that is defined by folds. The paper is then coated with a CNC mixture to provide appropriate strength and waterproof properties. Then solid spanning elements may be produced by filling the folded forms 340&344 and paper tube end 411 with a variety of mixtures 850 including a pulp-glue mixture using cellulosic fibre-reinforced filaments (CF) to increase strength. Such a combination may facilitate the unique parametric tailored generation of forms for ergonomic needs as the formwork shape is tailored 420.
Lossless
[0087]Further, using wood framing (or concrete formwork) and milling the members down to their appropriate size or discarding the formwork generates material waste. According to some embodiments of the present invention shown in FIGS. 13A, 14A, and 15A, starting from a flat product allows the remainder of the paper 331 to be mulched and used for other steps in the process. In some embodiments, 100% of the material may be consumed in producing the chair. Furthermore, the material is renewable and recyclable, high functioning and environmentally friendly. According to some embodiments, the combination of parametric, tailored designs with the use of flat paper may result in a wasteless production method which is applicable to variable forms. Such a process may also provide additional demand for local forestry industries and prevent the closing down of mills.
Seed Scale
[0088]A person skilled in the art will appreciate that this parametric seed logic imitates the way a tree can grow into a multitude of final outputs based on contextual pressures from just a simple seed. The parametric seed logic described herein may be developed and applied to other products, even those which do not use paper substrate technology, and for applications which are larger or smaller than chairs 800 such as a table 801, frame 802 or complete enclosure 803. Such technology may be applied, for example, to building components illustrated in FIG. 42. As such, a person skilled in the art will appreciate that the seed strategy can be applied to other products including the support of heavier loads in the built environment and on an increasing scale. By having separated the horizontal and vertical elements into discrete parts that can be prepared independently, the value of the construction method may be increased substantially to larger scales than a chair. Although infinitely large paper cannot be sourced, and joints would be required for increasingly larger scale objects, a benefit derived from separating parts into discrete objects is that the production strategy does not have to be redefined for products which increase in size. If the chair were to have been made of one piece of material, the production strategy may need to be redefined for larger objects. As such, some embodiments of the construction strategy disclosed herein are highly scalable as shown in FIG. 42. The construction strategies which may make assembly easier are the tailored framework, folded joints, and simplified casting, all of which can be controlled and managed digitally, which may allow for the customizability and variations on the end product 804 and have minimal to no impact on the construction process. In particular, the cast folded Y-shape 805 scales proportionately to the scale of the built object and also integrates the single or double ended outputs. Male and female connections 806 are also alternated according to each element.
Scale Materials & Shapes
[0089]There are a number of advantages which may be realized by some embodiments of the invention over alternative methods. For example, 3D printers still suffer from limitations in terms of the size of objects that can be produced accurately, and face many problems when attempts are made to join 3D prints together to achieve larger volumes. Even at the scale of a chair, 3D printing is difficult. According to some embodiments of the present invention, using reinforced folded paper for joints allows for the joints to provide registration for proper alignment and defines the profile for the curved formwork. Further, unlike 3D printing, the production speed for some embodiments of the processes described herein can be quite fast, as the cutting, creasing and folding are processes that are amenable to use with a material with strong bonds between cellulose fibres. Contrastingly, 3D printing requires the build-up of chemical connections between each particle. While this affords potentially more flexibility in the final output shape, 3D printing tends to be limited in its capacity for speed and size relative to some embodiments of the processes described herein. As noted above, the processes described herein are scalable. For example, FIG. 43 shows an example embodiment in which additional members 810 are added for different geometrical configurations 811, and how these members can be scaled in terms of both length and the proportion of paper to pulp. FIG. 44 also illustrates how the response to moment of inertia can be tailored by increasing to double-ended masses 820 as the distance 821 between frames expands out away from a smaller center 822 where single-ended masses 823 were appropriate. FIG. 46 shows how these ends can be independently sizable ends 840, 841. This invention also permits a wider range of material variability than 3D printing as the solid forms can be cast afterwards like a typical construction process so a wider variation in the filler 850 and coating material 851 are acceptable. As shown in FIG. 45, the flat paper stock 830 can be replaced with, for example, a metallic material further increasing the applicability for the architectural scale. Both these materials are available in roll form 831, further supporting longer spanning distances.
Combinations
[0090]The preceding disclosure has provided many example embodiments. Although each embodiment represents a single combination of inventive elements, other examples may include all possible combinations of the disclosed elements. Thus, if one embodiment comprises elements A, B and C, and a second embodiment comprises elements B and D, other remaining combinations of A, B, C or D may also be used.
Variation
[0091]Although example embodiments have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing form the scope as defined by the appended claims. Mathematical relationships that define the precise geometries can also be updated over time to coordinate with tailored, structural or movement requirements.
600s, 700s (Electronics, User Interface)
Physical Description
[0092]The electronic housing is connected to the folded knife plate 343 inside the counterweight mass. This space is a void 440 that is filled with the electronics module depending on the customer. An electronic module can indicate battery life with a light visible on the exterior and charge the battery using a removable plug from the top 430. During installation of the electronic module, a triangular form with a 3 point corner balance adjustment is used to set the accelerometer correctly to a level ground surface. This module may assist in increasing the dynamic functions of the chair.
Basic Functions
[0093]In some embodiments, as shown by way of example in FIG. 9, the counterweight 134 in the base 101 of the chair 100 comprises an accelerometer 139 inside of a housing 138. In some embodiments, there is only a single accelerometer embedded in the c