Final Report on the Design and Construction of a Beam-Based Cardboard Chair Adam Catrambone Zachary Hahn Dimitri Petrakis Michael Szczesniak 10/8/15 Corr!ated "in!s # $ro% &
Abstract Crrent dormitory chairs are take % a si!ni'icant %ortion o' the s%ace o' an a(era!e dorm room and are constrcted o' material )hich is less easy to recycle* resltin! in a ne!ati(e im%act on the en(ironment+ ,he %ro-ect )as ndertaken in an attem%t to create a dormitory o''ice#style chair made solely o' recycled corr!ated cardboard that is still ca%able o' colla%sin! to nder 1. to 'it nder a dormitory bed+ A'ter collectin! data on )hat Penn State dormitory residents desire in a dorm chair and %er'ormin! research on both cardboard and chairs* (arios methods o' idea !eneration )ere sed to create mlti%le di''erent inter%retations o' )ays o' addressin! the desi desi!n !n %robl %roblem em++ ,h ,hes esee idea ideass )ere )ere then then cons consid ider ered ed and and cons consol olid idat ated ed into into 'or 'or di'' di''er erent ent %reliminary desi!ns+ ach o' the 'or desi!ns had a scale %rototy%e % rototy%e o' them constrcted* co nstrcted* )hich aided in the %rocess o' %arin! do)n ideas+ rom these* one 'inal conce%t )as chosen to 'rther %rse+ ,he 'inal desi!n consisted o' t)o 'lat side side strctres* consistin! o' mlti%le sheets* sheets* )hich 'ormed the sides o' the chair+ A'ter bein! modeled in Solid2orks* a 'll#scale %rototy%e )as constrcted+ ,rian!lar beams )ere strn! bet)een the sides in order to both s%%ort the chair and 'orm the strctre o' the seat+ A'ter this chair )as bilt* in %ro(ed to be relati(ely sccess'l at addressin! the (arios needs* incldin! com'ortability co m'ortability and sa'ety* )hich s%rred its creation+
1. Introduction As %eo%le se increasin!ly more natral resorces* the concern o' sstainability !ro)s %ro%ortionally lar!er+ Many belie(e that )e need to se earth3s resorces more e''ecti(ely by redcin! the se o' non rene)able resorces+ 4ne s%eci'ic )ay this can be accom%lished is by constrctin! 'rnitre ot o' recyclable material+ Crrently* dormitory chairs at Penn State are made o' )ood or a combination o' metal and %lastic+ n order to im%ro(e sstainability* the desi!ned chair )as entirely %rodced ot o' recyclable cardboard* )ithot any adhesi(e or other connectin! materials+ ,he chair also had to accommodate the relati(ely small size o' dorm rooms and their limited stora!e s%ace+ ,hs* the chairs )ere desi!ned to meet the constraint o' bein! able to colla%se to nder 1. in order to 'it nder a ty%ical ty%ical dormitory bed+ ,his allo)ed 'or more e''icient s%ace mana!ement at times )hen the chair is not in se+ ,he (ale o' this 'eatre )as later hi!hli!hted drin! inter(ie)s )ith colle!e stdents* )hich re(ealed that most stdents s%end little time in their dorm room chairs+ ,he cardboard chair )as created sin! methods consistent )ith the !eneral %rinci%les o' en!ineerin! desi!n+ ,asks and schedles )ere mana!ed thro!h a PM2 created at the be!innin! o' the %ro-ect and modi'ied thro!hot+ n the %roblem statement %ortion o' the acti(ity* t)o se%arate methods )ere sed in order to more clearly de'ine the ma-or isses that mst be addressed addressed )ith the cardboard chair6 the 75 2s 2s 9and 1 H: method and 7(ision#isse#m 7(ision#isse#method+ ethod+ ;esearch o' cardboard %ro%erties and cardboard chair desi!ns )as condcted to establish %ro%er back!rond kno)led!e and better de'ine the %ro%er <alities o' a cardboard chair+ n order to !ain a better nderstandin! o' cstomer needs* both sr(eys and inter(ie)s )ere condcted+ A'ter all ob-ecti(es* 'eatres* and constraints )ere established and %rioritized* idea !eneration commen commenced ced++ ,hree ,hree di''er di''erent ent strate!i strate!ies es )ere )ere sed sed to !enera !enerate te ideas6 ideas6 the =>#?#? =>#?#? Method* Method* brainstormin!* and a mor%holo!ical chart+ ,he 'or leadin! ideas )ere %rototy%ed at ⅙ scale+ P!h charts )ere )ere sed to select the 'inal* best idea+ idea+ Constrcti Constrction on o' the 'inal %rototy%e %rototy%e be!an sin! S4@D24;"S to 'inalize the desi!n desi!n and dimension the chair+ A'ter)ord the chair )as %hysically bilt in 'll scale sin! cardboard and a combination o' hand and %o)er tools+ 2ithin this re%ort* sections )ill 'ocs on each ste% o' the en!ineerin! desi!n %rocess+ Section one be!ins )ith this introdction and also incldes an initial %roblem statement that de'ines the cardboard chairs %r%ose as a %rodct+ Section t)o otlines cstomer needs and the relati relati(e (e im%ort im%ortance ance o' those those needs+ Sectio Section n three three re(ise re(isess the %roblem %roblem statem statement ent based on cstomer cstomer needs+ Section Section 'or details details eternal search search in'ormation in'ormation incldin! literatre literatre search* search* %atent search* and benchmarkin!+ Section 'i(e sho)s the techni<es and reslts o' conce%t !eneration+ !eneration+ Section Section si 'ocses on the do)nselection do)nselection %rocess %rocess and the scale models o' the 'or leadin! chair desi!ns+ Section se(en details the 'inal desi!n+ @astly* section ei!ht concldes the re%ort+
1.1. Initial Problem Statement 4n accont o' concerns in(ol(in! en(ironmental sstainability* it )as desired that the )ooden and %lastic dormitory chairs in the Penn State dorms be re%laced )ith chairs made 'rom recycled recycled/re /recyc cyclabl lablee materi material+ al+ ntrod ntrodci cin! n! cardboa cardboard rd chairs chairs )old )old redce redce )aste )aste 'rom 'rom non non## recyclable chairs thereby conser(in! arths limited s%%ly o' lmber and %etrolem %rodcts+ Be) cardboard chairs cha irs cold %otentially be %hased#in as old chairs !radally need to be re%laced+
,hs* e(entally* all dorm rooms )ill be e<i%%ed )ith a cardboard chair+ Penn State stdents rely on dormitory chairs to %ro(ide seatin! 'or the dration o' the school year )ithot breakin!+ Stdents Stdents also need to be able to store their dorm chairs chairs as s%ace in dorm rooms is limited+ limited+ n order to balance the !oals o' Penn State administration )ith the needs o' stdents* )e desi!ned* %rototy%ed* and tested a chair made entirely o' cardboard that )as ca%able o' s%%ortin! the )ei!ht o' a %erson 150 %onds or hea(ier and cold be broken do)n 'or 'or stora!e+ Conse<ently* the chair )old be both en(ironmentally sstainable and %ractical 'or se by stdents in their dorms+
2. Customer eeds !ssessment Ha(in! created a startin! %roblem statement* )hich allo)ed the nderstandin! o' )hat basic !oals mst be met drin! the %ro-ect* a collection o' cstomer needs and desires 'or the %rodct is necessary so as to determine )hat other* more s%eci'ic* !oals cstomers )old )ish 'or the desi!ned %rodct to 'l'ill and ho) to %rioritize these desires by com%arin! the res%onses o' many indi(idals indi(idals++ Cstomer Cstomer needs data )as collected thro!h sr(eys and %artially %artially scri%ted scri%ted inter(ie)s desi!n to collect data on di''erent %re'erences and )ays that %eo%le sit in their crrent dorm chairs+ ,hese t)o methods )ere selected in order to !ather a broader ran!e o' data+ Sr(eys )ere chosen as they allo) the collection o' lar!e <antities o' data )ith relati(e ease+ Ho)e(er* sr(eys can only collect in'ormation their creators can antici%ate* )hich necessitated the se o' inter(ie)s as a com%lement* )hich allo) the %otential cstomer to 'reely res%ond )ith )hate( )hate(er er they desire desire to say+ say+ Binete Bineteen en %eo%le %eo%le )ere )ere sr(eye sr(eyed* d* incldi incldin! n! 1 males males and t)o 'emales* )ho ran!ed in a!e 'rom 1 to .1+ ,he 'i(e inter(ie)s all occrred )ith males either 18 or 1 years o' a!e+ All sr(eyed or inter(ie)ed indi(idals crrently reside in some Penn State dorm+ ,he sr(ey consisted o' t)el(e <estions 9see A%%endi A+:* ecldin! basic in'ormation !atherin! abot a!e and !ender* )hich )ere either mlti%le choice or short 'ill in the blank res%ons res%onses* es* ecld ecldin! in! a 'inal 'inal <estio <estion n )hich )hich o%en#en o%en#endedl dedly y allo)ed allo)ed res%ond res%ondees ees to %ro(id %ro(idee in'ormation 'reely+ ,he <estions on the sr(ey can be broken do)n into a 'e) key !ro%s6 a section in )hich res%ondees )old rate the im%ortance o' (arios as%ects or %otential 'eatres o' a chair* a section 'ocsed on their chair se habits* incldin! ho) lon! they ty%ically sit on the chair* and se(eral s%eci'ic <estions on %re'erences sch as %re'erred %rice+ 2hile smmaries o' nmerical data 'or the sr(ey is inclded in A%%endi E+* se(eral key trends emer!ed+ n the 'ree res%onse res%onse section o' the sr(ey* sr(ey* nine ot o' the t)el(e )hich ans)ered ans)ered this <estion mentioned the hardness o' the crrent dorm chair and the need 'or cshionin!+ Also* only t)o res%ondents named a %rice hi!her than F100 that they )old )ish to %ay 'or a dorm chair that 'l'ills their needs* indicatin! that most %otential cstomers )old %re'er chea%er chairs e(en i' all their desires are met+ ach inter(ie) )old be!in )ith the inter(ie)er ha(in! the indi(idal take a seat in their dorm chair and then askin! them to describe )hat 'eatres they 'irst noticed abot their chair+ nter(ie)s consisted o' 'i(e scri%ted <estions 9see A%%endi C+: 'rom )hich the inter(ie)er )old )old branch branch o'' de%endin! de%endin! on the indi(i indi(ida dal lss res%ons res%onses+ es+ ,his ,his allo)e allo)ed d the collec collectio tion n o' nantici%ated and ni<e res%onses incldin! the obser(ation that one indi(idal mainly sed his dorm chair as a ste% stool and )old need a chair that cold be sed as sch or an inter(ie)ee re<estin! a chair )ith remo(able armrests so that he cold sit some o' the time criss#cross# a%%lesace )hile still ha(in! armrests 'or )ork 9see A%%endi D++ ,his nicely do(etails )ith the
desi!n desi!n re<irement re<irement o' the chair bein! disassemblable disassemblable in order to 'it nder a dorm bed+ Another Another indi(idal noted that a )heeled chair )old ha(e redces se'lness in dorm rooms de to their small size+ Eased on the reslts o' the sr(eys and inter(ie)s* as )ell as the basic re<irements o' the %ro-ect* a list o' 1 cstomer needs )ere de(elo%ed 9see ,able 1+:+ Most cstomer needs )ere based on o(er)helmin! trends in the data !atheredG 'or instance* a constraint 'ond )as ha(in! the chair cost nder F100* )hich )as almost nanimos amon! the takers o' the sr(ey+ "able 1. Initial Customer eeds #ist $btained from Sur%e& and Inter%ie's.
Ad-stable Eack Armrests Attracti(e A%%earance Com'ortable Ca%able o' Eein! Sat in or @on! Periods o' ,ime Ca%able o' ittin! nder nde r a ,y%ical Dorm ;oom Eed Com%act Cshionin! ne%ensi(e @e(el Seat @i!ht 2ei!ht Made o' Cardboard Portable ;emo(able Armrests Sa'e Stable ,akes ,akes % @ittle S%ace ,hese cstomer needs )ere di(ided di(ided into ob-ecti(es ob-ecti(es 9see ,able ,able .+:* )hich ideally shold be maimized or minimized* constraints* )hich mst be met 'or the chair desi!n to be sccess'l* sccess'l* and %ossible 'eatres to be im%lemented into the chair+ 4b-ecti(es are ideal* )hile constraints ands 'nctions mst be met by the desi!n+ ,he only constraints sed )ere those re<ired by the initial desi!n* all other cstomer desires )ere treated as ob-ecti(es+ nctions )ere dra)n 'rom as%ects o' chairs s!!ested or s%%orted by indi(idals drin! the sr(eys and inter(ie)s+
"able 2. Categori(ed Customer eeds #ist $btained from Sur%e& and Inter%ie's.
4b-ecti(es6 Stable Sa'e Attracti(e A%%earance @i!ht 2ei!ht Portable Com'ortable @e(el Seat Com%act ne%ensi(e ,akes ,akes % @ittle S%ace Ca%able o' @eanin! Eack in Ca%able o' Eein! Sat in or @on! Periods o' ,ime Constraints6 Made o' Cardboard Ca%able o' ittin! nder nde r a ,y%ical Dorm ;oom Eed nctions6 Ad-stable Eack Armrests ;emo(able Armrests Cshionin! Cate!orization o' ob-ecti(es* constraints* and 'nctions allo)s the streamlinin! o' desi!n !oalsG it can also sho) ho) mlti%le needs can be met thro!h one s%eci'ic desi!n as%ect+ 4b-ecti(es )ere di(ided into si o(erall cate!ories 9see ,able+ ?:6 Com'ortable* Sa'e* Attracti(e A%%earance* Portable* ne%ensi(e* and Com%act+ Most o' the ob-ecti(es and 'nctions 'ell )ithin the com'ortable cate!ory* as that seemed to be the ma-or com%laint by those sr(eyed abot their crrent dorm chairs* in(ol(in! chan!es to the seat* back* and the armrests+ Ho)e(er* some o' the other cate!ories sch as sa'e* as the chair is constrcted 'rom a more nsal and )eaker material* and com%act* as the chair mst 'it nder a ty%ical dorm bed* are also im%ortant )hen dealin! )ith the desi!n o' this chair+ Also* the chair mst be attracti(e and %ortable* as 'or trans%ort and se )ithin the dorm room+
"able ). *ierarchal Customer eeds #ist $btained from Sur%e&s and Inter%ie's.
1+ Com'ortable 1+1 @e(el Seat 1+. Ca%able o' Eein! Sat in or @on! Periods o' ,ime ,ime 1+? Ca%able o' @eanin! Eack in F. F.1 Adjustable Back F.2 F.2 Cushioning F.3 F.3 Armrests Armres ts F.4 F.4 Removable Remova ble Armrests .+ Sa'e .+1 Stable ?+ Attracti(e A%%earance >+ Portable >+1 @i!ht 2ei!ht 2ei!ht 5+ ne%ensi(e C+1 Made o' Cardboard &+ Com%act &+1 Ca%able o' ittin! nder a ,y ,y%ical %ical Dorm ;oom Eed C+. Colla%sible
2.1. +eighting of Customer eeds Cstomer needs are )ei!hed in order to nderstand )hat shold 'ocsed on in the desi!n+ ach o' the main cate!ory labels )ere )ei!hed based on the sr(ey res%onses and inter(ie) res%onses 9see ,able >:+ ,he Analytic Hierarchy Process hel%ed determine )hat attribtes o' the chair are more im%ortant im%ortant to the cstomers than others+ A'ter A'ter )ei!hin! the cstomer cstomer needs 9see ,able 5:* it )as 'ond that the chair desi!ns shold 'ocs on com'ort most+ Sa'ety and e%ense )ere ro!hly e<al in im%ortance+ Portability and com%actness )ere also ro!hly e<al* bt o' a mch lo)er im%ortance than com'ort* sa'ety* and e%ense+ A%%earance )as re!arded as the least im%ortant im%ortant 'eatre by 'ar+ 'ar+ Com'ort* sa'ety* sa'ety* and e%ense e%ense shold shold be the main 'ocs o' or desi!n+ Determinin! these )ei!hted cstomers needs in'lences the desi!n and ho) time )ill be allocate to o%timize s%eci'ic characteristics+ ,he desi!n shold be 'ocsed on com'ort and sa'ety most* 'ollo)ed by cost* %ortability %o rtability** com%actness* and a%%earance+
"able "able ,. !nal&tic *ierarch& Process Data "able "able
(alat (alated ed
Co Com'ortable
Attracti(e Com'or Com'ortabl table e Sa'e A%%earance Portable ne%ensi(e Com%act ,otal ;ankin! 1
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5
5
5
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0+?
0+??
1
5
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? 15+??
0+..
0+1>
0+.
1
0+??
0+.
0+?? .+.1
0+0?
Portable
0+. 0+??
?
1
0+??
1 5+ 5 +8
0+0
n ne%ensi(e
0+. 0+??
5
?
1
5 1>+5?
0+.1
Com%act
0+. 0+??
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1
0+.
1
0+08
Sa Sa'e Attracti(e A%%earance
Com%arison Criteria
5+? 5+
"able "able . +eighted *ierarchal Customer eeds #ist $btained from Sur%e&s and Indi%idual Inter%ie's
1+ Com'ortable 90+?: 1+1 @e(el Seat 1+. Ca%able o' Eein! Sat in or @on! Periods o' ,ime ,ime 1+? Ca%able o' @eanin! Eack in F. F.1 Adjustable Back F.2 F.2 Cushioning F.3 F.3 Armrests Armres ts F.4 F.4 Removable Remova ble Armrests .+ Sa'e 90+..: .+1 Stable ?+ ne%ensi(e 90+.1: C+1 Made o' Cardboard >+ Portable 90+0: >+1 @i!ht 2ei!ht 2ei!ht 5+ Com%act 90+08: 5+1 Ca%able o' ittin! nder a ,y ,y%ical %ical Dorm ;oom Eed C+. Colla%sible 9colla%ses to nder 1.: &+ Attracti(e A%%earance 90+0?:
). Re%ised Problem Statement ,he colle!e administration and sta'' o' Penn State are concerned abot en(ironmental sstainability and )ish to re%lace the )ooden and %lastic dormitory chairs in the Penn State dorms )ith chairs made 'rom recycled/recyclable material+ ntrodcin! cardboard chairs )old redce )aste 'rom non#recyclable chairs thereby conser(in! arths limited s%%ly o' lmber
and %etrolem %rodcts+ Be) cardboard chairs )ill be %hased#in as old chairs !radally need to be re%laced+ (entally* all dorm rooms rooms )ill be e<i%%ed )ith a cardboard chair+ Penn State stdents rely on dormitory chairs to %ro(ide seatin! 'or the dration o' the school year )ithot breakin!+ Stdents also need to be able to store their dorm chairs chairs as s%ace in dorm rooms is limited+ n order to balance the !oals o' Penn State administration administration )ith the needs o' stdents* )e %lan to desi!n* %rototy%e* and test a chair made entirely o' cardboard that is ca%able o' s%%ortin! the )ei!ht o' a %erson 150 %onds or hea(ier and can be broken do)n 'or stora!e+ stora!e+ Eased on 'eedback 'eedback 'rom sr(eys and inter(ie)s inter(ie)s** )e aim to kee% the cost o' the chair nder F5* %ro(ide reclinin! o%tions 'or the chair* and maimize the com'ort o' the chair+ 4r desi!n shold allo) or chair to be both en(ironmentally sstainable and %ractical 'or se by stdents in their dorms+
,. /ternal Search Ha(in! %er'ormed %er'ormed cstomer cstomer needs* )hich 'rther de'ined the %roblems %roblems the desi!n mst address* the eternal search allo)s the s%eci'ics o' these isses to be 'rther researched+ ,he eternal search is %er'ormed 'or three %r%oses6 as a )ay o' seein! inherent %roblems or other related in'ormation* as a )ay o' seein! ho) similar desi!n %roblems )ere sol(ed by others in order to 'rther this desi!n* and to %re(ent accidental in'rin!ement on the intellectal %ro%erty o' others+ istant literatre )as re(ie)ed in order to address the need 'or im%ortant back!rond in'ormation abot chairs* cardboard and other 'actors* )hile research in(ol(in! %atents )as %er'ormed to re(ie) cardboard strctres and eistent chairs+
,.1. .1.
#ite #iterratur aturee Re%ie e%ie' '
,he er!onomics o' a %iece o' 'rnitre are one o' the most im%ortant 'eatres+ Colle!e stdents se their dorm chairs 'or a (ariety o' acti(ities* sch as stdyin!* bro)sin! the )eb* or sim%ly lon!in! arond+ Eecase the chair has so many ses* it is (ital that it %ro(ides s%%ort is is sa'e to sit in 'or lon! drations+ Pro%erly sized chairs redce stress on the lmber and allo) 'or more com'ortable and less distracted )ork+ ,he best ty%es o' chairs are those that are easily ad-stable to 'it the s%eci'ic dimensions o' the consmer 9,heresa* n+d+ :+ Ho)e(er* becase o' the desi!n limitations that cardboard !i(es s* )e mst look at 'ied chair desi!ns* those that are not ad- ad-st stab able le++ Eeca Eecase se hm hmans ans !reat !reatly ly ran!e ran!e in hei! hei!ht ht and and size* size* )e m mst st look look at ran! ran!es es measrements 'or di''erent %arts o' the chairs+ ,he seat %an de%th and )idth shold be no !reater than >? cm and no less than >5 cm res%ecti(ely+ ,he accommodate most %eo%le* the backrest shold rise % at least >5 cm abo(e the seat %an and be set at an an!le minimm 0 de!rees to the seat+ ,he lar!er the an!le* the more relaed a %osition the sitter is in* so 'or a stdent )e )ill )ant to kee% the an!le )ith 15 de!rees o' 0 de!rees+ ,he )idth o' the backrest shold be more than ?& cm+ ,he armrest are the most (ariable %art o' the chair becase arm len!th is so di''erent amon!st indi(idals+ t is recommended that a 'ied armrest be bet)een 1#. cm and s%an >& cm across the seat 9Hed!e* .01?:+ Pro%er armrest %osition %re(ents %re(ents the ser 'rom e%eriencin! e%eriencin! mscle 'ati!e or soreness o(er %rolon!ed se o' the chair 9nited States De%artment o' @abor* n+d+:+ A chair that stays )ithin these restrictions )ill %ro(ide most sers )ith a com'ortable seatin! e%erience* e(en o(er lon! %eriods o' time+ ,he desi!n )ill 'ollo) these !idelines and ran!es to make a non#ad-stable chair cha ir that is er!onomic 'or the lar!est %ortion o' the %o%lation+
Another im%ortant 'eatre o' the chair is the material material sed to assemble it+ it+ ,here are many di''erent kinds o' corr!ated cardboard characterized by 'lte size )hich is the size o' the corr!ation+ ,he C 'lte is the a(era!e size )hile the A 'lte is mch bi!!er and the 'lte is mch smaller 9Po%il* n+d+:+ ,he 'lte is the most most com%act so it )old be the stron!est stron!est material 'or the chair+ chair+ ltes ltes can also be combined so that there are mlti%le mlti%le layers o' corr!ation* corr!ation* so com%ondin! 'ltes )old yield the stron!est stron!est bildin! material 9Po%il* n+d+:+ A .. sheet o' C 'lte cardboard can hold ?8+5lbs at %eak load )hile a .. sheet o' 'lte cardboard can hold 85+?lbs 9Po%il* n+d+:+ Com%ondin! 'ltes make the material stron!er bt also more e%ensi(e+ t cost F?+.5 'or a sin!le )alled corr!ated C 'lte in a >> by & size sheet )hile 'or the same size o' a doble )alled corr!ated corr!ated C 'lte it costs costs F&+00 %er sheet 9Eo'orless* .015:+ ,he hi!her cost makes the doble )alled corr!ated corr!ated cardboard cardboard less economical+ economical+ Also* Also* the most common 'lte size is the C 'lte and since the bildin! material can only consist o' sed cardboard* it )old be too di''iclt to 'ind any other ty%e o' 'lte sized corr!ated cardboard 9Po%ol* n+d+:+ Eecase o' economic e''iciency* and bildin! constraints the C 'lte corr!ated cardboard )ill be the bildin! material o' the cardboard chair e(en tho!h it is not as stron!+ 2hile cardboard is recyclable* there are se(eral restrictions on )hat can be recycled+ 2et cardboard cannot be recycled as most machines cannot handle it* )hile cardboard contaminated )ith !rease* )a* or other similar sbstances is not seableG ho)e(er* some added materials sch as ta%e or sta%les can remain as they are 'iltered ot drin! the recyclin! %rocess 92aste ndstries SA* .015:+ Some research s!!ests that the recyclin! o' cardboard may not be better en(iro en(ironmen nmental tally ly than than sim%ly sim%ly inciner incinerate ated d it* it* de%endi de%endin! n! on som somee s%eci' s%eci'ic ic condit condition ionss o' the incineration %lantG this )old render a chair o' recycled cardboard in'erior in relation to one made 'rom recycled %lastic* another %ossible material 'or dorm chairs 9Merrild* .011:+ Ho)e(er* %lastic re<ires the se o' 'ossil 'els 'e ls in its %rodction nlike cardboard and sch research has been <estioned* as (aryin! assm%tions made by researchers !reatly alter the reslts 9Iillane(a 9Iillane(a and a nd 2enzel* .00:+ ,hee colle ,h collect cted ed rese resear arch ch tends tends to s%% s%%or ortt the the decis decisio ion n to cons constr trct ct a chai chairr made made o' cardboard and o''ers more s%eci'ic in'ormation on some o' the bene'its* constraints* and %ossible dra)backs that cardboard has as a material+ Similarly* some o' the research illminates %ro%er desi!n dimensions 'or a relati(ely er!onomic chair* )hich )ere closely 'ollo)ed in the desi!n o' the 'inal %ro-ect+ Ha(in! collected this !eneral data* more s%eci'ic data on eistin! desi!ns )ere so!ht+
,.2.
Patent Se Search
2hile the literatre re(ie) %ro(ides !eneral in'ormation on im%ortant to%ics sch as chairs and cardboard* it does not s%%ly the s%eci'ic technical details o' a %atent search+ Patent searches searches ser(e t)o %r%oses6 %r%oses6 they allo) one to see ho) %re(ios %re(ios desi!ners ha(e sol(ed certain %roblems* and* i' e%ired* can be 'ashioned into a soltion in a later %ro-ect* and %re(ent accidental intellectal %ro%erty (iolations 'rom occrrin! drin! the desi!n %rocess+ ,he %atents described belo) mainly )ere 'or chair desi!ns* tho!h one instead 'ocsed on a lode bearin! strctre made o' cardboard+ Patent C! 2"2"14#$% & 'Chair made o( corrugated boards) *ao) +ue) 1",2-,2"11 1",2-,2"116 ,his %atent otlines a cardboard chair com%osed o' mlti%le interlockin! boards+ ach board consists o' 'or to 'i(e cardboard sheets layered on to% o' one another+ ,he boards interlock (ia a system o' tabs and sockets+ Constrction o' the lar!er lar!er cardboard boards may re<ires some 'orm
o' adhesi(e material* material* )hich is %rohibited %rohibited by or desi!n constraints+ constraints+ ,he chair )old need to be entirely disassembled 'or stora!e nder a bed 9$ao* .011:+ Patent CA 2%411-" 2%411-" A1 'Chair (rom (olded cardboard /anel) 0ourue) 0ikael 0. 0.) tra//aon) alome . .) an,15,2"126 ,he chair described described and claimed as intellectal intellectal %ro%erty %ro%erty by this %atent %atent is constrcted constrcted 'rom a sin!le* continos sheet o' cardboard+ t has mlti%le handles* )hich enhance %ortability+ %ortability+ ,he sheet o' cardboard 'rom )hich the chair is constrcted )old need to be 'airly thick/ri!id in order to s%%ort a %ersons )ei!ht+ ,he seat o' the chair is only s%%orted at the ed!es and may ca(e in drin! se 9Mor<e* et al+* .01.:+ Patent & 3--4%"$ A 'Cardboard 'Cardboard chairs) Brod6) Brod6) Bruce .) Brod6) 7r8in 9.) $,23,15%26 ,he %atent is intended to make a cardboard chair that doesnt re<ire s%%ort beams+ ,he desi!n also a(oids the ty%ical cardboard bo strctres )hich it claims to be )eaker+ Ho)e(er* this %atented cardboard chair is intended to be sed only by b y and 'or yon! children* )hich )oldnt likely ha(e the stren!th to meet the re<isite )ei!ht 'or a chair ment 'or colle!e dorm rooms 9Erody* et al+* 1.:+ Patent & 4-4#-$# A 'Colla/sible chair) chair) Calco) Calco) :a6ne) :a6ne) 3,1",15#%6 ,he chairs %atented desi!n is constrcted by 'oldin! t)o s%eci'ically ct %ieces o' cardboard+ ,his desi!n makes the chair easy to assemble* colla%se* and trans%ort+ ,here are se(eral %roblems )hich make this desi!n im%ractical 'or the %r%ose o' this %ro-ect+ ,he chair re<ires a lar!e* sin!le %iece o' cardboard* )hich )old likely not be a(ailable+ Additionally* this sheet )old ha(e to be 'olded and ct in (ery s%eci'ic %laces+ ;ecie(ed 'rom6 htt%s6//)))+!oo!le+com/%atents/S>&>8&58 Patent & &4$-33%% A ';igh
,he %atents abo(e in'ormed the desi!n in %rimarily t)o di''erent )ays+ or o' the %atents )ere each desi!ns 'or chairs made o' cardboardG se(eral themes rea%%eared+ Mlti%le %atents* incldin! CA 2%411-" 9Mor<e and Salome* .01.:* & 3--4%"$ 9Erody* 1.:* and & 4-4#-$# 9Calco* 18: are made 'rom a 'e) lar!e sheets o' cardboard that are 'olded into the %ro%er sha%es+ Ho)er* desi!n is also restricted by the t)o crrent %atents C! 2"2"14#$% 9$ao* 2"2"14#$% 9$ao* .011: and CA 2%411 9lario* 2 %411-" -"+ ,hree %atents* C! 2"2"14#$% * CA 2%411-" 2%411-"* and & &4$-33%% 9lario* 18?:* each otlined a se%arate method o' creatin! a stron! strctre )ith cardboard* )hich col cold d be sed sed in orde orderr to incr increas easee the the chai chairs rs lode lode beari bearin! n! ca%ab ca%abil ilit itie ies+ s+ 4' the the thre threee C! and CA 2%411-" cold not be sed as the %atents ha(e not e%ired* bt the 'olded 2"2"14#$% and beam strctre is le!al to tilize 9lario* 18?:+ All All %atents s!!est that a bo is not a %ro%er load bearin! strctre+ 4(erall* these %atents sho) that %re(ios attem%ts at constrctin! on 'oldin! lar! lar!ee shee sheets ts o' card cardboa board rd** )hich )hich may %ose %ose a %rob %roblem lem 'or 'or this this desi! desi!n n base based d on mate materi rial al constraints and are 'aced )ith )ei!ht s%%ort %roblems+
,.).
Benchmar0ing
,.).1. Product 1
Figure 1. Staples "elford II3 #u/ura 4anagers Chair5 !ssorted Colors
,he @ra Mana!ers chair 9i!re 1: is one o' the hi!her end o''ice chairs on the market market 9com%a 9com%ared red to the crren crrentt dorm dorm chairs chairs bt is still still relati relati(ely (ely ine%en ine%ensi( si(ee com%ared to %ro'essional o''ice chairs:* chairs:* o''ered in black or bro)n+ ,he desi!n is ele!ant and hi!her end* clearly clearly 'or more bsiness bsiness oriented oriented indi(idals+ indi(idals+ ,he chair comes )ith )ith )heels 'or easy mobility bt the tradeo'' is that the )heels cold make the chair sli% and be more nsa'e+ 4ne isse )ith the @ra chair is that some assembly is re<ired+ Also the chair is in a 'ied %osition )ith no o%%ortnity 'or reclinin! and relain!+ ,he chair is o' !ood <ality so it can hold at least .50 %onds bt )ei!hs ?>+. %onds so it cant easily be %icked %+ ,he chair retails retails 'or F at Sta%les and F&0 on Amazon Amazon 9Sta%les* 9Sta%les* n+d+:+
,.).2. Product 2
Figure 2. Deco Dorm Chair
,he Deco Dorm chair 9i!re .: is a %ortable chair meant 'or a colle!e dorm+ Costin! only F.5+5* this ine%ensi(e and 'lly recyclable dorm chair doesnt take % a lot o' s%ace )ith dimensions dimensions o' only ?5J .0J .?J 9H 2 D:+ 4ne o' the setbacks o' makin! a chair entirely ot o' cardboard is that it is not (ery er!onomic* made % entirely o' strai!ht lines )ith )ith essentially zero cr(es+ ,he chair )ei!hs only 10#.0 lbs lbs 9estimated sin! density o' cardboard:* so it it can be easily ti%%ed and %otentially nsa'e+ ,he chair also has no )heels or etra 'eatres like like armrests and cant recline+ Eecase o' the basic desi!n* it is also not (ery a%%ealin! to the eye and the %lain )hite color )ill easily decay o(ertime o(ertime and look dirty+ dirty+ t has (ery 'e) %arts )ith )ith little assembly assembly re<ired re<ired and it can easily be disassembled i' s%ace is needed to be made 9Dorm Co+* n+d+:+
,.).). Product )
Figure ). Fle/iblelo%e arth-16
,he leible@o(e arth 1& chair 9i!re ?: has a collection o' nsal 'eatres )hich distin!ishes it 'rom the other chairs+ ,he e%andin! cardboard strctre allo)s it to accommodate % to siteen indi(idals o' a(era!e size and 'orm (arios sha%es in order to take the %lace o' di''erent sorts o' 'rnitreG )hen 'lly etended the chair
measres &>cm 5&cm .0cm+ Ho)e(er* the chairs cardboard natre has cased com%laints abot se(eral isses* the seat bends and has been re%orted as ncom'ortable+ Also* )hile little assembly is re<ired on the %art o' the consmer* the chair re<ires more %kee% than a traditional chair )old+ ,he chair is also relati(ely e%ensi(e* costin! F&00 in contries not a %art o' the ro%ean nion and more there+ Also* )hile the chair colla%ses easily 'or trans%ort* the chair )ei!hs abot &? %onds* mch more than the other chairs 'ond 9Pinzaan* .01>:+
,.).,. Product ,
Figure ,. 7intage $ffice Chair
,he (inta!e o''ice chair 9i!re >: most resembles crrent Penn State dorm chairs+ t is made o' a hi!h <ality hard)ood and comes in t)o colors* cherry and co!nac+ ,he desi!n is sim%le sim%le and made to a%%eal to the those that like classic looks+ ,he sim%le desi!n also means the chair is relati(ely li!ht 91lb: and can be mo(ed by sim%ly li'tin! it %+ ,he desi!n is also strdy+ 2hile no eact nmbers cold be 'ond )ith this %articlar chair* chairs o' similar desi!n and materials easily hold ?00lbs+ ,here are no a%%arent sa'ety concerns and a%%ears to match the er!onomic re<irements o' 'ied chairs 9listed in literatre re(ie):+ ,he ma-or do)n'all to the chair is the 'act that it is 'ied and cannot be ad-sted to the (arios sizes o' stdents and 'aclty+ ,he chair is also meant only 'or o''ice se and does not )arrant lon!in! or other sittin! %ositions besides those normally sed to stdy or ty%e+ ,he chair is tar!eted to)ards teens and adlts and only a(aiable online at )ay'air+com 'or F1.> 92inners 4nly nc* n+d+: n+d +:
"able 6. Benchmar0ing of Products eatre or Criteria 91#5: 5 bein! best Sta%lesK ,el'ord ,el'ord L @ raK Mana! ana!er erss Cha Chair Deco Dor Dorm m Chai hair
leible@ le@o(e a arth 1&
Iinta! ta!e 4' 4''ice ice Ch Chair
Aesthetics Aesthetics 9mlti#color* 9mlti#color* etc+: >
1
>
>
ase o' Assembly
?
>
?
>
Portabilit y
>
?
.
?
alit y
>
.
?
>
Sa'ety
>
.
.
5
Iersat rsatili ility ty 9std 9stdyi yin! n!** lon!in!* etc+: .
1
5
.
eatres 9arm rest* 'oot ? rest* c% holder* etc+: armrest* ad-stable seat
1 no notable 'eatres
1 etendable
1 no noteable 'eatres
Cost Cost 9rec 9record ord mlti mlti%l %lee Dorm Dorm Co+6 Co+6 F.5 F.5+5 +5 leible@ le@o(e6 N5 5 (ales and sorces: Sta%les6 F* 9only 9only sold sold by Dorm Dorm 9ro%e 9ro%ean an Price: Price:** F&00 Amazon6 F&0 Co+: 9Bon 9Bon# #r ro% o%ea ean n Pric Price: e: 2ay'air 'air66 F1.> F1.> Ho) lon! has %rodct been in marketO Size o' Chair
the the Bot %ro(ided+
Bot %ro(ided+
A%%roimatel y 10 years+
Bot %ro(ided+
lly lly tende tended6 d6 &>cm ?&+81 .>+>1 5&cm .0cm* .>+>1 inches ?5J .0J .?J 9H 2 Colla%sed6 &>cm 5&cm 9H2D: D: .?+&cm 1 J 2 .0J D ?& J H
2ei!ht o' Chair ?>+. lbs
10#.0 10#.0 lbs 9estima 9estimated ted sin! density o' cardboard: .8+5 k! 9&.+8 lbs:
2ei!ht chair can hold .50 lbs
Bot %ro(ided+
1.0 k! 9>.?? lbs:
1 lbs Bot %ro(ided+ stimated at ?00 ?00lb lb by com% com%ar arin in! ! to similarly desi!n chairs+
,.).. Benchmar0ing "echnical +rite 8p Eenchmarkin! is im%ortant as it both allo)s one to see ho) )ell com%etitors %rodcts meet % the desi!n needs o' the crrent %ro-ect and to see both )hat has been im%lemented and )hat is 'easible+ Eenchmarkin! also allo)s one to see )hat has been sccess'l in the desi!n o' other %rodcts 9see ,able ,able &:+ or chairs )ere chosen to be analyzedG one ad-stable o''ice chair* t)o di''erent desi!ns o' cardboard chairs* and one )ooden chair similar to Penn States crrent dorm chairs 9see ,able 1+:+ ,he ad-stable ,el'ord had the hi!hest o(erall ratin! amon!st or !ro%* bein! better or e(en in aesthetics* %ortability* <ality* <ality* and 'eatres as sho)n in the table+ ,his chair is also %riced at F&0 on Amazon+com* only to be beaten by the Deco Dorm Chair+ ,he )ooden Iinta!e 4''ice Chair )as considered the sa'est )ith its strdy* classic desi!n+ ,his chair may s''er the same disad(anta!es as the crrent dorm chair )ith a similar desi!n* sch as bein! ncom'ortable o(er lon! %eriods o' time 'ond drin! cstomer needs assessment+ ,he cardboard leible@o(e arth 1& is by 'ar the most (ersatile* able to etend ot to hold )ell o(er ten %eo%le* bt is mch more
e%ensi(e 9F&00: than the other chairs+ ,he cardboard Deco Dorm Chairs ad(anta!es come 'rom its materials+ Eecase it is made o' cardboard* it is both chea% 9F.5+5: and recyclable+ ,o o%timize the chair desi!n* the best <alities o' all chairs shold %re'erably mimicked* tho!h tho!h not as to in'rin in'rin!e !e %on intellec intellecta tall %ro%er %ro%erty ty++ Ho)e(er Ho)e(er** becas becasee the chair chair is to be constrcted o' cardboard* the 'eatres o' the chair are se(erely limitedG 'or instance* it )old be challen!in! to constrct )heels or any other sort o' rollin! strctre+ (en tho!h the ,el'ord )as the hi!hest rated chair* many o' the 'eatres that made it so* incldin! said )heels and an ad-stable seat* )old not be 'easible in the 'tre desi!ns 'or this chair+ ,he desi!ns )ill likely be more similar to the Deco Dorm Chair and the Iinta!e Iinta!e 4''ice 4''ice Chair* one o' )hich )as made o' a cardboard#like material and the other ha(e a sim%le desi!n+ 4r desi!ns )ill ha(e be sa'e and str strdy dy** )hil )hilee at the the same same time time stil stilll bein! bein! cost cost e''e e''ect cti( i(ee and and recy recycl clabl able* e* as the the mate materi rial al re<irements necessitate+
,., Design "arget Eased on the in'ormation !athered 'rom (arios 'orms o' eternal search* a !eneral conce%t o' )hat )old be re<ired 'or an eco#'riendly dorm chair )as arri(ed at+ ,he cstomer needs search re(ealed se(eral im%ortant trends )ithin the desires Penn State dormitory residents ha(e 'or their o''ice chairs+ ,he indi(idals sr(eyed and inter(ie)ed* claimin! to s%end little time sin! their dorm chairs* %re'ered com'ortable and sa'e chairs* carin! little abot their a%%earance+ a%%earance+ Ho)e(er* tho!h the indi(idals indi(idals did not ty%ically ty%ically brin! % conce%ts conce%ts 'or additional additional 'eatres* they !enerally e%ressed enthsiasm 'or most ideas on )hich they )ere asked their o%inion+ ,he literatre re(ie) most im%ortantly !a(e the a%%roimate desi!n s%eci'ications necessary 'or an chair er!onomic to the a(era!e indi(idal+ ,he desi!ns* )hen dimensions )ere s%eci'ied* )hich )ere created in later sta!es o' the %rocess* all 'ollo)ed these measrements+ ,he %atent search 'ond 'or other desi!ns 'or a cardboard chair* )hich* )hile most cold not be sed directly on accont o' intellectal %ro%erty concerns* in'lenced !eneral thinkin! on ho) a cardboard chair cold be strctred+ Similarly* a sable %atent 'or a cardboard beam strctre* tho!h not tilized s%eci'ically* e(entally )ent on to in'lence the conce%t o' beam strctre sed in the 'inal desi!n+ Eenchmarkin!* )hich com%ared t)o eistin! cardboard and non# cardboard chairs crrently on the market* both bo th sho)ed ho) eistin! man'actrers ha(e )ei!hed (arios needs and sacri'ices )hen desi!nin! their %rodcts and the com%etition this chair desi!n )old 'ace in the market+ ,his com%arison s!!ested s!!ested that accessories* accessories* )hile they )old likely bene'it the cstomer en-oyment o' the %rodct* are not necessary 'or a ty%ical o''ice chair+ ch air+ Also* Also* the hi!h %rices o' all chairs benchmarked s!!ests that a market eists 'or a lo) %rice dormitory chair* )hich this entirely cardboard desi!n cold %ossibly 'l'ill+ ,hs* conce%t !eneration )as 'ocsed 'ocsed on de(elo%in! de(elo%in! er!onomic er!onomic chairs chairs as )ell as %ossible additional additional 'eatres )hich cold be im%lemented+
. Concept 9eneration 4nce research has been %er'ormed on some o' the %roblems that the chair desi!n mst 'ace and ho) other desi!ns may ha(e addressed these isses* this kno)led!e is a%%lied in the %rocess o' creatin! desi!ns to address this %roblem+ Conce%t !eneration %ro(ides a lar!e <antity o' desi!ns* 'eatres* 'eatres* and !eneral ideas 'or the the %rodct+ %rodct+ t is 'ocsed on %romotin! %romotin! ideas and
e%lorin! inno(ati(e soltions )ithot bein! restricted by 'easibility or s%eci'ications+ ,hree di''erent methods 'or !eneration initial conce%ts )ere sed 'or the cardboard cha ir+
.1. :,-)-); 4ethod ,hree methods )ere sed in order to de(elo% %ossible ideas 'or the chair desi!n6 the >#?# ? method )ith conce%t sketches* brainstormin!* b rainstormin!* and a mor%holo!ical chart+ ,he >#?#? method* an ada%tion o' &#?#5 method ad-sted de the nmber o' !ro% members and time constraints* and brainstormin! )ere both 'irst %er'ormed in class+ n this case* the 'or re'ers to the nmber o' %artici%ants* the 'irst three re'ers to the nmber o' desi!ns !enerated each time* and the second three re'ers to the time in mintes s%ent on each o' the 'or rotations+ Drin! the %er'ormance o' the >#?#? method* each !ro% member indi(idally %rodced three se%arate desi!ns or as%ects o' desi!ns* be'ore echan!in! %a%ers amon! themsel(es and creatin! alternate or related desi!ns 9see i!res 5#8:+ ,his allo)ed* o(er the corse o' the t)el(e mintes in(ol(ed* the creation o' >8 relati(ely ni<e desi!ns across the !ro%* tho!h some )ere similar to others and others )ere bilt o'' o' %re(ios %re(ios desi!ns desi!ns 9see i!res 1#>:+ A'ter)ards* A'ter)ards* these desi!ns desi!ns )ere re(ie)edG ideas )hich )ere decided by !ro% consenss to be %ossible or in'lential )ere ke%t in mind 'or 'rther consideration+ As the demandin! natre o' this task re<ired a set nmber o' desi!ns to be %rodced in a time limit* not all the !enerated ideas )ere se'l and some %ro(ided no ne) content+ Se(eral other %ossible 'la)s eist )ithin the >#?#? %rocess* as it allo)s no discssion o' ideas and can case some indi(idals to become )edded to certain ideas )hich they re%eat+ Ho)e(er* the >#?#? method does allo) indi(idals )ho )old tend to be less acti(e in the !ro% con(ersation to share their ideas at on an e<al standin!+ t also encora!es collaboration on ideas ideas as indi(i indi(idal dalss can bild bild o'' desi!ns desi!ns made made on the sheet be'ore them+ ollo)in ollo)in! ! the %er'ormance o' this method* ideas )hich had resonated )ith mlti%le !ro% members* sch as detachable armrests* or )ere considered si!ni'icantly ori!inal* en'orcin! a di''erent )ay o' lookin! at some %roblem* sch as the matri based s%%ort strctre* )ere discssed 'rther+
Figure . ,-)-) Chart 1.
Figure 6. ,-)-) Chart 2.
Figure <. ,-)-) Chart ).
Figure =. ,-)-) Chart ,.
