A manufacturing method of a bow spring sofa and the bow spring sofa

Abstract

The invention provides a manufacturing method of a bow spring sofa and the bow spring sofa. The sofa cushion comprises bow springs, a base frame or / and a cushion bottom plate, and the backrest comprises bow springs, a backrest frame or / and a backrest bottom plate. The manufacturing method of the sofa cushion comprises the following steps: manufacturing a bow spring assembly on the base frame or the cushion bottom plate, covering a lower cover layer, a filling material pad and an upper cover layer on the bow spring assembly in sequence, and connecting and fixing them by using a needle thread or a connecting piece. The edge between the filling material pad and the upper cover layer is filled with straw bundles, and the straw bundles are sewn on the bow spring assembly by using a needle thread. The edge shaping of the sofa cushion is performed by using a edge-taking bending needle and a straw pushing needle. The sofa cushion cover is tailor-made according to the edge shaping of the sofa cushion. The lining material and the sewing process are reasonable, so that the sofa cushion of the bow spring sofa is flat, the shape is beautiful, and the processing quality is stable, reliable and durable.

Description

Technical Field

[0001] This invention belongs to the field of sofa manufacturing technology, specifically a method for manufacturing a bow-shaped spring sofa and a bow-shaped spring sofa. Background Technology

[0002] In the early stages of sofa development, cylindrical springs were used to make backrests, offering advantages such as good elasticity, resistance to deformation, breathability, environmental friendliness, and long lifespan. However, the shape of cylindrical spring sofas and chairs was entirely fixed with hemp rope, which was prone to breakage. Furthermore, production was time-consuming and labor-intensive, requiring a high level of skill from the makers. To accommodate varying cushion shapes, various sizes and styles of cylindrical springs were needed, and cylindrical springs were unsuitable for sofa armrests. Due to the complex manufacturing process, high cost, and susceptibility to damage, cylindrical spring sofas were gradually replaced by foam sofas. Foam sofas, with their ease of processing and low price, captured the market, squeezing out the advantageous cylindrical spring sofas. This marked the second stage of development for the sofa industry.

[0003] Foam sofas have gradually gained recognition and understanding through use. However, their elasticity relies on the foam itself, which lacks elasticity, has poor breathability, emits odors, is prone to deformation, ages quickly, and is detrimental to human health. Their filling material is polyurethane foam, which contains toxic and harmful substances that are difficult to degrade in nature. Therefore, foam sofas are products that sacrifice the environment and human health; this shortcoming is fatal and must be addressed thoroughly and quickly. It is well known that 90% of the world's upholstered furniture still uses polyurethane foam. In my country alone, approximately 70 million pairs of discarded foam sofas are generated annually—a staggering number causing immense harm and posing a significant challenge to environmental protection in my country.

[0004] To address the current market monopoly of foam sofas and the problems associated with both cylindrical spring sofas and foam sofas, a Chinese patent (patent number ZL20061004505.4) discloses a method for manufacturing backrests and armrests for arched spring sofas. This patent solves the aforementioned problems of cylindrical spring sofas and foam sofas, and because it aligns with green environmental protection principles and development trends, it has excellent development prospects. However, this patent has not been widely adopted, and its economic benefits have not met expectations. Through long-term practice, research, and analysis, the applicant has found that this patent still has many shortcomings in product structure and manufacturing processes that need improvement and refinement. The patent does not disclose specific sewing techniques for sofa manufacturing. Because arched spring sofas have multiple layers of lining material and irregular shapes, if sewn using conventional processes, the edges of the backrest, seat cushion, and armrests often appear uneven, which is neither aesthetically pleasing nor reflects the structural characteristics of the arched spring sofa. Therefore, to showcase the unique and aesthetically pleasing design of the bow-shaped spring sofa, a suitable manufacturing method is needed. By selecting appropriate lining materials and employing reasonable sewing techniques, the seat and backrest surfaces of the bow-shaped spring sofa can be made flat and feature beautiful curved shapes, thus better highlighting the characteristics of the bow-shaped springs. Furthermore, the manufacturing quality is stable and reliable. This is the problem that this invention aims to solve. Summary of the Invention

[0005] To address the aforementioned problems and shortcomings of existing technologies, this invention provides a method for manufacturing a bow-shaped spring sofa and a bow-shaped spring sofa in general. By employing suitable lining materials and reasonable sewing techniques, the surface of the seat cushion and backrest of the manufactured bow-shaped spring sofa is flat and can achieve a beautiful curved shape, which can better highlight the characteristics of the bow-shaped spring. Furthermore, the manufacturing quality is stable, reliable, and durable.

[0006] The objective of this invention is achieved through the following technical solution: a method for manufacturing a bow-shaped spring sofa, the bow-shaped spring sofa comprising a sofa cushion and a backrest, wherein the sofa cushion includes a bow-shaped spring, a base frame and / or a cushion base plate, and the backrest includes a bow-shaped spring, a backrest frame and / or a backrest base plate, wherein the bow-shaped spring has a raised arc shape in the middle and bent surfaces formed by bending downwards at both ends, characterized in that the method for manufacturing the bow-shaped spring sofa includes a method for manufacturing the sofa cushion and a method for manufacturing the backrest, wherein the method for manufacturing the sofa cushion includes the following steps:

[0007] Step 1: Fabricate the base frame and / or seat cushion base;

[0008] Step 2: The bow-shaped springs are longitudinally arranged on the base frame or the seat cushion base plate. The two ends of the bow-shaped springs are respectively fixed on the base frame or the seat cushion base plate. The four sides of the bow-shaped springs are connected to the four sides of the bow-shaped springs by a quadrilateral steel wire frame to form a whole. The middle is connected to each bow-shaped spring and the quadrilateral steel wire frame by a horizontally arranged straight steel wire to form a bow-shaped spring assembly.

[0009] Step 3: The bow-shaped spring assembly is covered layer by layer with inner lining material. The inner lining material includes a lower cover layer, a filling material pad, an upper cover layer and fiber wadding from the inside out. First, the lower cover layer, the filling material pad and the upper cover layer are covered on the bow-shaped spring assembly in sequence. Then, the inner lining material is partially connected and fixed on the bow-shaped spring assembly with needle and thread or connectors to form a preliminarily fixed sofa cushion.

[0010] Step 4: Lift up the perimeter of the upper cover layer, fill the area between the filling material pad and the upper cover layer corresponding to the front and left and right sides of the upper part of the sofa cushion with straw bundles as shaping material, then fold the upper cover layer down to cover the straw bundles, and then use fixing pins to penetrate the lower cover layer, filling material pad, straw bundles and upper cover layer to initially fix the straw bundles.

[0011] Step 5: First, use a straw-pulling needle to initially pull and gather the straw bundle towards the front edge and left and right edges of the upper part of the sofa cushion. Then, use a sewing needle and thread to sew the upper covering layer, straw bundle, filling material pad and lower covering layer onto the bow spring assembly to form the basic shape of the sofa cushion.

[0012] Step 6: Use a curved edge needle and a straw-pulling needle to shape the edge of the sofa cushion. Use the curved edge needle and thread to thread along the upper front edge and both sides of the left and right edges of the sofa cushion and tie knots. At the same time, use the straw-pulling needle to pull the straw bundle together to form a column shape, and wrap and fix the straw bundle inside the upper covering layer to complete the edge shaping of the sofa cushion.

[0013] Step 7: Based on the edge design of the sofa cushion completed in Step 6, custom-make a sofa cushion cover. The sofa cushion cover includes a top surface and three sides around the perimeter. An excess edge is left on the inner side of the seam between the top surface and the three sides, and a notch is formed on the outer side of the seam between the top surface and the three sides.

[0014] Improvements to the above technical solution include step 8: spreading fiber wadding on the upper cover of the sofa cushion completed in step 6 to make the top surface of the sofa cushion cover flat and shape it with appropriate thickness and form. Then, folding up the perimeter of the custom-made sofa cushion cover from step 7 and laying it flat on the sofa cushion. After aligning the top surface of the sofa cushion cover with the four corners of the top surface of the sofa cushion, fix it with pins. Then, using a serger and thread, stitch along the remaining edge of the inner side of the sofa cushion cover, corresponding to the front edge and the left and right edges of the upper part of the sofa cushion, and tie knots to make the serrations of the sofa cushion cover and the sofa cushion form an integrated structure. Finally, folding down the perimeter of the sofa cushion cover completes the production of the sofa cushion.

[0015] An improvement to the above technical solution: In step 3, the fixing method of the inner lining material using connectors is as follows: First, the lower cover layer is wrapped around the outside of the bow-shaped spring assembly. The lower cover layer is connected and fixed to the quadrilateral steel wire frame in the bow-shaped spring assembly using C-shaped nails fed from a C-shaped nail gun. The edge of the lower cover layer is fixed to the base frame or seat base plate using nails fired from a nail gun. Then, a filling material pad is covered on the lower cover layer. The filling material pad is connected and fixed to the quadrilateral steel wire frame in the bow-shaped spring assembly using C-shaped nails fed from a C-shaped nail gun. The edge of the filling material pad is fixed to the base frame or seat base plate using nails fired from a nail gun. Finally, the upper cover layer is covered, and the middle part of the upper cover layer is temporarily fixed with fixing pins.

[0016] Another improvement to the above technical solution: In step 3, the lining material is fixed by needle and thread as follows: First, the lower covering layer, the filling material pad, and the upper covering layer are sequentially covered on the bow-shaped spring assembly. Then, the upper covering layer is turned down, and a fixing needle is inserted into the periphery of the lower covering layer, the filling material pad, and the upper covering layer. Then, a long sewing needle with needle tips at both ends and a needle eye at one end, along with sewing thread, is used to sew the upper covering layer, the filling material pad, and the lower covering layer together and fix them to the bow-shaped spring assembly.

[0017] Further improvement to the above technical solution: The specific fixing method for longitudinally setting the bow-shaped spring on the base frame or seat cushion base plate in step 2 is as follows: The base frame or seat cushion base plate is made of wood or plastic wood. A U-shaped groove is set at the position where the bow-shaped spring is installed on the base frame or seat cushion base plate. The two ends of the bow-shaped spring are set in the corresponding U-shaped grooves. Both ends of the bow-shaped spring are U-shaped ends. The two ends of the bow-shaped spring are fixed in the corresponding U-shaped grooves by the bow-shaped spring fixing component. The plate-shaped body of the bow-shaped spring fixing component is provided with at least one fixing hole in the middle. Four fixing wings extend from the middle around the perimeter. At least three of the fixing wings are provided with claws bent to the same side at their ends. The bow-shaped spring fixing component is cross-shaped as a whole.

[0018] Further improvements to the above technical solution: the filling material pad is a palm fiber pad, coconut fiber pad, teak fiber pad, or bamboo fiber pad with an outer burlap covering, the lower covering layer and the upper covering layer are both burlap or chemical fiber cloth, and the fiber wadding is cotton, pearl cotton, silk floss, or chemical fiber material.

[0019] A further improvement to the above technical solution: the seat base plate, after the bow-shaped spring assembly is installed and covered with inner lining material, is fixed to the base frame.

[0020] Further improvements to the above technical solution: The manufacturing steps of the backrest manufacturing method are basically the same as those of the sofa cushion manufacturing method in terms of the materials used.

[0021] The present invention discloses a bow-shaped spring sofa, comprising a sofa cushion and a backrest, characterized in that the sofa cushion and backrest are manufactured using the aforementioned bow-shaped spring sofa manufacturing method.

[0022] This invention has many advantages and positive effects compared with existing technologies:

[0023] 1. This invention combines the advantages of foam sofas, such as ease of manufacture and low price, with the advantages of cylindrical spring sofas, such as good elasticity, non-deformation, good breathability, environmental friendliness, comfort, and long lifespan. The bow-shaped springs used in this invention are made of steel wire, and the inner lining materials and straw used for shaping are basically natural materials. Therefore, there is no pollution, and most of the raw materials can be recycled or reused after disposal. This is in line with my country's development goals of independent innovation, green environmental protection, and circular economy.

[0024] 2. By selecting appropriate lining materials, shaping materials, and reasonable sewing techniques, this invention makes the surface of the seat cushion and backrest of the bow-shaped spring sofa flat and can create a beautiful curved shape, which can better highlight the characteristics of the bow-shaped spring. Moreover, the processing quality is stable and reliable, and the service life is long.

[0025] 3. The processing method of this invention is convenient, the product structure is simple, the raw material cost is low, and it is easy to promote and apply. Attached Figure Description

[0026] Figure 1 This is a top view of the seat cushion base plate in Embodiment 2 of the bow-shaped spring sofa of the present invention;

[0027] Figure 2 exist Figure 1 The top view shown is of the seat cushion base plate after the bow spring is fixed with a bow spring fastener.

[0028] Figure 3 This is a top view of the base frame in Embodiment 1 of the bow-shaped spring sofa of the present invention;

[0029] Figure 4 Is Figure 3 A perspective view of the bow-shaped spring assembly formed by mounting the bow-shaped spring and fixing components on the base frame shown;

[0030] Figure 5 Is Figure 4 The diagram shows the internal structure of the bow-shaped spring assembly after it is covered with a lower covering layer, a padding material, a bundle of straw, and an upper covering layer.

[0031] Figure 6 Is Figure 5 The diagram shows the sofa cushion base after the inner lining material has been secured with pins.

[0032] Figure 7 Is Figure 6 The diagram shows how a long sewing needle and thread are used to connect the middle part of a sofa cushion to the base of the sofa cushion.

[0033] Figure 8 Is Figure 7 The diagram shows how a sewing needle and thread are used to stitch and tie the sofa cushion at a certain distance from the front edge and the left and right edges of the upper part of the sofa cushion.

[0034] Figure 9 Is Figure 8 The diagram shows how a bundle of straw is gathered and pushed towards the front edge and the left and right edges of the upper part of the sofa cushion using a straw-pulling needle.

[0035] Figure 10 exist Figure 9 The diagram shows how, based on the sofa cushion, a stitching needle and thread are used to stitch and knot the front and left and right edges of the upper part of the sofa cushion to create a stitched edging effect.

[0036] Figure 11 exist Figure 10The diagram shows how the edging on the top edge of the sofa cushion cover is sewn onto the sofa cushion using a curved needle and thread along the front and left and right edges of the upper part of the sofa cushion.

[0037] Figure 12 This is a perspective view of the overall structure of an arched spring sofa according to Embodiment 1 or Embodiment 2 of the present invention;

[0038] Figure 13 for Figure 7 The diagram shows the process of using a long sewing needle and thread to thread and tie the fabric for a sofa cushion.

[0039] Figure 14 for Figure 8 The diagram shows the process of sewing a sofa cushion using a sewing needle and thread, stitching and knotting.

[0040] Figure 15 for Figure 10 or Figure 11 The diagram shows the process of using a beveled needle and thread to stitch and knot the fabric on a sofa cushion.

[0041] The following are the labels in the diagram: 1. Seat cushion base; 2. U-shaped groove; 3. Bow-shaped spring fixing piece; 4. Fixing screw; 5. Bow-shaped spring; 6. Base frame; 7. C-shaped clip; 8. Quadrilateral steel wire frame; 9. Straight steel wire; 10. Clip; 11. Lower covering layer; 12. Filling material pad; 13. Upper covering layer; 14. Straw bundle; 15. Fixing pin; 16. Sewing needle; 17. Sewing needle; 18. Straw-pulling needle; 19. Edge stitch; 20. Sofa seat cushion cover; 21. Sofa seat cushion; 22. Armrest; 23. Backrest. Detailed Implementation

[0042] The present invention will now be described in further detail with reference to the accompanying drawings:

[0043] See Figures 3-12 This invention discloses a method for manufacturing a bow-shaped spring sofa, embodiment 1. The bow-shaped spring sofa includes a sofa cushion 21 and a backrest 23. The sofa cushion 21 includes a base frame 6 and bow-shaped springs 5, and the backrest 23 includes a backrest frame and bow-shaped springs 5. The bow-shaped springs 5 ​​have a raised arc shape in the middle, and the two ends are bent downwards to form bending surfaces. The method for manufacturing the bow-shaped spring sofa includes a method for manufacturing the sofa cushion 21 and a method for manufacturing the backrest 23. The method for manufacturing the sofa cushion 21 includes the following steps:

[0044] Step 1: Fabricate the base frame 6, which includes a quadrilateral frame and a fixed crossbeam in the middle. Preferably, the base frame 6 can be made of wood or wood-plastic composite in a U-shape (e.g., Figure 3 (as shown), a sun-shaped frame or a square frame, etc.

[0045] Step 2: The bow-shaped springs 5 ​​are longitudinally positioned on the base frame 6. Both ends of the bow-shaped springs 5 ​​are fixed to the base frame 6. A quadrilateral steel wire frame 8 is used to connect the four perimeters of the bow-shaped springs 5 ​​to form a single unit. A horizontally arranged straight steel wire 9 connects each bow-shaped spring 5 and the quadrilateral steel wire frame 8 to form a bow-shaped spring assembly. Preferably, the quadrilateral steel wire frame 8 and the bow-shaped springs 5 ​​can be connected and fixed using C-shaped nails 7 from a C-shaped nail gun. The straight steel wire 9 can be connected and fixed using clamps 10 from a clamping gun. Figure 4 As shown.

[0046] Step 3: The aforementioned bow-shaped spring assembly is covered layer by layer with an inner lining material. This inner lining material includes, from the inside out, a lower covering layer 11, a filling material pad 12, an upper covering layer 13, and fiber wadding. First, the lower covering layer 11, the filling material pad 12, and the upper covering layer 13 are sequentially placed over the bow-shaped spring assembly. Then, the inner lining material is partially connected and fixed to the bow-shaped spring assembly using needle and thread or connectors, forming a preliminary, fixed sofa cushion shape. Figure 5 As shown.

[0047] The specific methods for laying and fixing the aforementioned lining materials are as follows:

[0048] The first method is to use connectors for fixation: In step 3, the inner lining material is fixed using connectors as follows: First, the lower cover layer 11 is wrapped around the outside of the bow-shaped spring assembly. C-shaped nails from a C-shaped nail gun are used to connect and fix the lower cover layer 11 to the quadrilateral wire frame in the bow-shaped spring assembly. Nails from a nail gun are used to fix the edge of the lower cover layer 11 to the base frame 6. Next, a filling material pad 12 is placed on top of the lower cover layer 11. C-shaped nails from a C-shaped nail gun are used to connect and fix the filling material pad 12 to the quadrilateral wire frame in the bow-shaped spring assembly. Nails from a nail gun are used to fix the edge of the filling material pad 12 to the base frame 6. Finally, the upper cover layer 13 is placed on top, and the middle part of the upper cover layer 11 is temporarily fixed using fixing pins 15.

[0049] The second method is to use needle and thread for connection and fixation: In step 3, the lining material is connected and fixed using needle and thread as follows: First, the lower covering layer 11, the filling material pad 12, and the upper covering layer 13 are sequentially placed on the bow-shaped spring assembly. Then, the upper covering layer 13 is folded down, and a fixing needle 15 is inserted into the periphery of the lower covering layer 11, the filling material pad 12, and the upper covering layer 13. Then, a long sewing needle 16 with needle tips at both ends and a needle eye at one end, along with sewing thread, is used to sew along the middle part of the upper covering layer 13, tying a knot to sew the middle part of the upper covering layer 13, the filling material pad 12, and the lower covering layer 11 together as one piece, and then fixed to the bow-shaped spring assembly. For specific steps, please refer to... Figure 6 , Figure 7 and Figure 13 The fixing needle 15 penetrates the upper covering layer 13, the filling material pad 12, and the perimeter of the lower covering layer 11 from the front and back sides of the upper half of the sofa cushion at an upward angle. The insertion points of the fixing needle 15 are A1, A2, A3, ..., and the exit points of the fixing needle 15 are B1, B2, B3, B4, B5, B6. After initially fixing the perimeter of the sofa cushion, a long sewing needle 16 is used to press... Figure 13 The stitching and knotting are as shown. The initial insertion point of the lower tip of the long sewing needle 16 is C, and the initial exit point of the upper tip with the eye of the long sewing needle 16 is D. Following the direction of the arrow, stitch along the center of the sofa cushion. The final exit point of the upper tip of the long sewing needle 16 is E. This completes the sewing process, ensuring the surface of the upper covering layer 11 of the sofa cushion is flat and properly positioned to prevent displacement. Figure 7 As shown, the long sewing needle 16 has needle tips at both ends and a needle eye at one end. The length of the long sewing needle 16 is basically the same as the thickness of the sofa base, which makes it easy to thread the needle.

[0050] Step 4: Lift up the perimeter of the upper cover layer 13. Fill the area between the filling material pad 12 and the upper cover layer 13, corresponding to the front and left / right areas of the upper part of the sofa cushion, with straw bundles 14 as shaping material. Then fold the upper cover layer 13 down to cover the straw bundles 14. Next, use a fixing pin 15 to penetrate the lower cover layer 11, the filling material pad 12, the straw bundles 14, and the upper cover layer 13 to initially secure the straw bundles 14. The fixing pin 15 has a needle tip at one end and a handle at the other end. Figure 6 The handle of the fixing pin 15 shown is circular, but the handle can also be other shapes that are easy to grip.

[0051] Step 5: First, use the straw-pulling needle 18 to initially gather the straw bundle 14 towards the front edge and left and right edges of the upper part of the sofa cushion. Then, use the sewing needle 17 and thread to sew the upper covering layer 13, straw bundle 14, filling material pad 12, and lower covering layer 11 onto the bow-shaped spring assembly, forming the basic edge design of the sofa cushion. For detailed steps, refer to... Figure 8 and Figure 14 First, use the straw-pulling needle 18 to initially gather the straw bundle 14 towards the front edge and left and right edges of the upper part of the sofa cushion. Then, use the sewing needle 17 and thread to diagonally thread the needle and tie a knot at a certain distance from the front edge and left and right edges of the upper part of the sofa cushion. Figure 8 Thread the needle downwards from point G, pass it through, then thread it upwards again, and exit from point F, following... Figure 14 Following the needle-threading method, thread the needle and tie knots to both sides and back in the direction shown by the arrows, ending at points H1 and H2. For example... Figure 8As shown, the sewing needle 17 has a needle tip at one end and a needle eye at the other end. Compared with ordinary sewing needles, it is longer, has a thicker diameter, and a larger needle eye. However, the sewing needle 17 is shorter than the long sewing needle 16 mentioned above.

[0052] Step 6: Use the edging hook 19 and the straw-pulling needle 18 to shape the edging of the sofa cushion. Use the edging hook 19 and thread to stitch along the upper front edge and both sides of the left and right edges of the sofa cushion, tying knots along the lines. Simultaneously, use the straw-pulling needle 18 to pull the straw bundle 14 together, forming a column shape. Then, wrap and secure the straw bundle 14 within the upper covering layer 13, completing the edging of the sofa cushion. Figure 5 As shown. Refer to the detailed steps. Figure 9 , Figure 10 and Figure 14 18 grass-removing needles were respectively from Figure 9 Starting at points J and K, pluck the straw bundle 14 forward along the arrow-directed edge, then gradually pluck it towards both edges, ending at points L1 and L2. Simultaneously, thread the curved stitch 19 and the sewing thread along the upper front edge and both sides of the left and right edges of the sofa cushion, tying knots along these points. Figure 10 Thread the needle upwards from point M, passing through the lining material and straw bundle 14, then exit from point N, following... Figure 14 Using the needlework method, thread the needle and tie knots on both sides, ending at points P1 and P2, thus completing the edging design of the sofa cushion. (Example:) Figure 9 As shown, the weed-removing needle 18 has a needle tip at only one end and no needle eye at the other end. A handle can be added to the end without the needle tip if needed; for example... Figure 10 As shown, the edge-curved needle 19 is a crescent-shaped arc, with a needle tip at one end and a needle eye at the other end.

[0053] Step 7: Based on the edge design of the sofa cushion completed in Step 6, custom-make the sofa cushion cover 20. The sofa cushion cover 20 includes a top surface and three sides around the perimeter. An excess edge is left on the inner side of the seam between the top surface and the three sides. A tooth is formed on the outer side of the seam between the top surface and the three sides of the sofa cushion cover 20.

[0054] Furthermore, the process includes step 8: spreading fiber wadding on the sofa cushion completed in step 7 to cover the stitching and uneven areas, making the top surface of the sofa cushion smooth and shaping it to an appropriate thickness and form. Then, folding up the edges of the custom-made sofa cushion cover 20 from step 8 and laying it flat on the sofa cushion, aligning the top surface of the sofa cushion cover 20 with the four corners of the top surface of the sofa cushion, and securing it with fixing pins 15. Next, using a serger hook 19 and sewing thread, stitch along the inner edge of the sofa cushion cover 20, corresponding to the front edge and the left and right edges of the upper part of the sofa cushion, and tying knots to form a unified structure between the sofa cushion cover 20 and the sofa cushion. Finally, folding down the edges of the sofa cushion cover 20 completes the production of the sofa cushion. For specific sewing steps, refer to... Figure 11 and Figure 15 Fold up the edges of the custom-made sofa cushion cover 20 from step 8 and lay it flat on the sofa cushion. Place the top of the sofa cushion cover 20 against the four corners of the top surface of the sofa cushion. Secure it at points S1, S2, S3, and S4 with four fixing pins 15. This serves to establish the stitch spacing for the edge looper 19 during sewing. Then, insert the edge looper 19 and thread from point Q and out from point R, passing through the lining material and straw bundle 14. Pull it back from point R to point Q and tie a knot. Seal the looper 19 from both sides of the sofa cushion... Figure 15 As shown, thread the needle and tie the knot. Repeat the above method to points S3 and S4 to sew the tabs on the top surface of the sofa cushion cover 20 to the sofa cushion into a single structure, completing the tab sewing process. Finally, fold down the edges of the sofa cushion cover 20 to complete the sofa cushion making.

[0055] Furthermore, the specific method for fixing the bow-shaped spring 5 longitudinally on the base frame 6 in step 2 above is as follows: The base frame 6 is made of wood or plastic wood. A U-shaped groove 2 is provided at the position where the bow-shaped spring 5 is installed on the base frame 6. Both ends of the bow-shaped spring 5 are placed in the corresponding U-shaped grooves 2, and both ends of the bow-shaped spring 5 are U-shaped ends. The bow-shaped spring fixing member 3 is used to fix the two ends of the bow-shaped spring 5 into the corresponding U-shaped grooves respectively. A fixing hole is provided in the middle of the sheet-like body of the bow-shaped spring fixing member 3. The fixing screw 4 is used to fix the bow-shaped spring fixing member 3 to the base frame 6 through the fixing hole. Four fixing wings extend from the middle of the bow-shaped spring fixing member 3. At least three of the fixing wings have claws bent to the same side at their ends. The claws can fix the two U-shaped ends of the bow-shaped spring 5. The bow-shaped spring fixing member 3 is cross-shaped as a whole.

[0056] The aforementioned bow-shaped spring fastener 3 can be the same as the bow-shaped spring fastener described in Chinese Patent No. CN201920330710.9, entitled "A Bow-shaped Spring Fastener and a Bow-shaped Spring Sofa," and the installation and fixing methods are the same or similar. Figure 2 The method shown is fixed, so it will not be described again. The bow spring 5 mentioned above can be the bow spring in Chinese patent (patent number: CN200610045054.5) entitled "Manufacturing method of backrest, seat cushion and armrest of sofa using bow spring", and the installation and fixing method of bow spring 5 is the same or similar, so it will not be described again.

[0057] To facilitate the fixing of the inner lining material and to make the sofa cushions aesthetically pleasing, a long wooden strip 6.1 is installed on each of the left and right sides of the base frame 6, forming a stepped shape with an outer bottom and an inner top. Nails fired from a nail gun are used to fix the two sides of the lower covering layer 11, the filling material pad 12, and the upper covering layer 13 to the outer surfaces of the long wooden strips. Finally, after covering with fiber wadding, the two sides of the entire inner lining material are made basically flush with the left and right sides of the base frame 6. Preferably, the length of the wooden strip 6.1 is less than the distance between the two U-shaped ends of the bow spring 5.

[0058] Furthermore, the aforementioned filling material pad 12 is a palm fiber pad, coconut fiber pad, teak fiber pad, or bamboo fiber pad covered with burlap, the aforementioned lower covering layer 11 and upper covering layer 13 are both burlap or chemical fiber cloth, and the aforementioned fiber wadding is made of cotton, pearl cotton, silk floss, or chemical fiber materials.

[0059] Furthermore, the manufacturing steps and materials used in the aforementioned backrest manufacturing method are basically the same as those in the aforementioned sofa cushion manufacturing method, and therefore will not be repeated here. If the bow-spring sofa also includes sofa armrests 22, the manufacturing steps and materials used for the armrests 22 can also refer to the aforementioned backrest manufacturing method, or refer to the armrest manufacturing method in Chinese Patent (Patent No.: CN200610045054.5). Finally, the manufactured sofa cushions 21, backrests 23, and armrests 22 are assembled into one unit, and the entire bow-spring sofa is completed.

[0060] like Figure 12 As shown, Embodiment 1 of the bow-shaped spring sofa of the present invention includes a sofa cushion 21, a backrest 23, and armrests 22. The sofa cushion 21, backrest 23, and armrests 22 are manufactured using the manufacturing method of Embodiment 1 of the bow-shaped spring sofa described above. Embodiment 1 of the bow-shaped spring sofa of the present invention can also be a bow-shaped spring sofa without armrests 22 (not shown).

[0061] See Figures 1-2This invention provides a second embodiment of a method for manufacturing a bow-shaped spring sofa. The bow-shaped spring sofa includes a seat cushion and a backrest. The seat cushion includes a base frame, a seat base plate 1, and bow-shaped springs 5. The backrest includes a backrest frame, a backrest base plate, and bow-shaped springs 5. The bow-shaped springs 5 ​​have a raised arc shape in the middle and bent downwards at both ends to form bending surfaces. Both ends of the bow-shaped springs 5 ​​have U-shaped ends. The manufacturing method of the bow-shaped spring sofa includes a method for manufacturing the seat cushion and a method for manufacturing the backrest. The manufacturing method and steps of the sofa cushion in Example 2 are basically the same as those in Example 1, except that in Example 2, instead of setting a U-shaped groove 2 on the base frame, a U-shaped groove 2 is set on the cushion base plate 1. The two U-shaped ends of the bow spring 5 are fixedly installed in the U-shaped groove 2 on the cushion base plate 1. A bow spring assembly is assembled on the cushion base plate 1, and then the bow spring assembly is covered with inner lining material and fixed in shape. Finally, the cushion base plate 1, after the bow spring assembly is installed and fixed and covered with inner lining material, is fixed to the base frame. The fixing method of the two ends of the bow spring 5 is as follows: Figure 2 As shown, it is fixed with bow-shaped spring fixing part 3. The fixing method can be referred to in Chinese Patent (Patent No.: CN201920330710.9) or the fixing method of bow-shaped spring in Chinese Patent (Patent No.: CN200610045054.5), so it will not be described in detail.

[0062] The manufacturing methods and steps for the sofa cushions in Example 2 are basically the same as those in Example 1, so they will not be described again. Similarly, the manufacturing steps for the backrest in Example 2 are basically the same as those for the backrest in Example 1, and the materials used will not be described again.

[0063] The seat cushion base plate 1 is made of wood, plastic wood, or steel plate stamping. A pawl (replacing the spring fixing part 3) can be set on the steel plate base plate. The pawl can fix the U-shaped end of the bow spring 5. The fixing method is simple and relatively firm.

[0064] When the seat base plate 1 is made of a thicker wooden board into a square, eye-shaped, or sun-shaped base plate, in Embodiment 2, the seat base plate 1, after being installed and fixed with the bow-shaped spring assembly and covered with inner lining material, does not need to be fixed to the base frame. Instead, the seat base plate 1 is directly used as the base frame to assemble the bow-shaped spring sofa.

[0065] like Figure 12 As shown, Embodiment 2 of the bow-shaped spring sofa of the present invention includes a sofa cushion 21, a backrest 23, and armrests 22. The sofa cushion 21, backrest 23, and armrests 22 are manufactured using the manufacturing method of Embodiment 2 of the bow-shaped spring sofa described above. Embodiment 2 of the bow-shaped spring sofa of the present invention can also be a bow-shaped spring sofa without armrests 22 (not shown).

[0066] Of course, the above description is not intended to limit the present invention. The present invention is not limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the scope of the present invention should be protected by the present invention.

Claims

1. A method for manufacturing a bow-shaped spring sofa, the bow-shaped spring sofa comprising a sofa cushion and a backrest, wherein the sofa cushion includes a bow-shaped spring, a base frame and / or a cushion base plate, and the backrest includes a bow-shaped spring, a backrest frame and / or a backrest base plate, wherein the bow-shaped spring has a raised arc shape in the middle and bent surfaces formed by bending downwards at both ends, characterized in that... The manufacturing method of the bow-shaped spring sofa includes a method for manufacturing the sofa cushion and a method for manufacturing the backrest. The method for manufacturing the sofa cushion includes the following steps: Step 1: Fabricate the base frame and / or seat cushion base; Step 2: The bow-shaped springs are longitudinally arranged on the base frame or the seat cushion base plate. The two ends of the bow-shaped springs are respectively fixed on the base frame or the seat cushion base plate. The four sides of the bow-shaped springs are connected to the four sides of the bow-shaped springs by a quadrilateral steel wire frame to form a whole. The middle is connected to each bow-shaped spring and the quadrilateral steel wire frame by a horizontally arranged straight steel wire to form a bow-shaped spring assembly. Step 3: The bow-shaped spring assembly is covered layer by layer with inner lining material. The inner lining material includes a lower cover layer, a filling material pad, an upper cover layer and fiber wadding from the inside out. First, the lower cover layer, the filling material pad and the upper cover layer are covered on the bow-shaped spring assembly in sequence. Then, the inner lining material is partially connected and fixed on the bow-shaped spring assembly with needle and thread or connectors to form a preliminarily fixed sofa cushion. Step 4: Lift up the perimeter of the upper cover layer, fill the area between the filling material pad and the upper cover layer corresponding to the front and left and right sides of the upper part of the sofa cushion with straw bundles as shaping material, then fold the upper cover layer down to cover the straw bundles, and then use fixing pins to penetrate the lower cover layer, filling material pad, straw bundles and upper cover layer to initially fix the straw bundles. Step 5: First, use a straw-pulling needle to initially pull and gather the straw bundle towards the front edge and left and right edges of the upper part of the sofa cushion. Then, use a sewing needle and thread to sew the upper covering layer, straw bundle, filling material pad and lower covering layer onto the bow spring assembly to form the basic shape of the sofa cushion. Step 6: Use a curved edge needle and a straw-pulling needle to shape the edge of the sofa cushion. Use the curved edge needle and thread to thread along the upper front edge and both sides of the left and right edges of the sofa cushion and tie knots. At the same time, use the straw-pulling needle to pull the straw bundle together to form a column shape, and wrap and fix the straw bundle inside the upper covering layer to complete the edge shaping of the sofa cushion. Step 7: Based on the edge design of the sofa cushion completed in Step 6, custom-make a sofa cushion cover. The sofa cushion cover includes a top surface and three sides around the perimeter. An excess edge is left on the inner side of the seam between the top surface and the three sides, and a notch is formed on the outer side of the seam between the top surface and the three sides.

2. The method for manufacturing the bow-shaped spring sofa according to claim 1, characterized in that, The process also includes step 8: spreading fiber wadding on the upper cover of the sofa cushion completed in step 6 to make the top surface of the sofa cushion cover flat and shape it to an appropriate thickness and form. Then, fold up the edges of the custom-made sofa cushion cover from step 7 and lay it flat on the sofa cushion. Align the top surface of the sofa cushion cover with the four corners of the top surface of the sofa cushion and fix it with pins. Then, use a serger and thread to stitch along the remaining edge of the inner side of the sofa cushion cover, corresponding to the front edge and the left and right edges of the upper part of the sofa cushion, and tie knots to make the serrations of the sofa cushion cover and the sofa cushion form an integrated structure. Finally, fold down the edges of the sofa cushion cover to complete the production of the sofa cushion.

3. The method for manufacturing a bow-shaped spring sofa according to claim 1 or 2, characterized in that, In step 3, the lining material is fixed using connectors as follows: First, the lower cover layer is wrapped around the outside of the bow-shaped spring assembly. The lower cover layer is connected and fixed to the quadrilateral steel wire frame in the bow-shaped spring assembly using C-shaped nails fed from a C-shaped nail gun. The edge of the lower cover layer is fixed to the base frame or seat base plate using nails fired from a nail gun. Then, a filling material pad is covered on the lower cover layer. The filling material pad is connected and fixed to the quadrilateral steel wire frame in the bow-shaped spring assembly using C-shaped nails fed from a C-shaped nail gun. The edge of the filling material pad is fixed to the base frame or seat base plate using nails fired from a nail gun. Finally, the upper cover layer is covered, and the middle part of the upper cover layer is temporarily fixed with fixing pins.

4. The method for manufacturing a bow-shaped spring sofa according to claim 1 or 2, characterized in that, In step 3, the lining material is fixed by needle and thread as follows: First, the lower cover layer, the filling material pad, and the upper cover layer are sequentially placed on the bow-shaped spring assembly. Then, the upper cover layer is turned down, and a fixing needle is inserted into the periphery of the lower cover layer, the filling material pad, and the upper cover layer. Then, a long sewing needle with needle tips at both ends and a needle eye at one end, along with thread, is used to sew along the middle part of the upper cover layer and tie a knot, so that the middle part of the upper cover layer, the filling material pad, and the lower cover layer are sewn together as one piece and fixed to the bow-shaped spring assembly.

5. The method for manufacturing a bow-shaped spring sofa according to claim 1 or 2, characterized in that, The specific fixing method for longitudinally setting the bow-shaped spring on the base frame or seat cushion base plate in step 2 is as follows: the base frame or seat cushion base plate is made of wood or plastic wood, and a U-shaped groove is set at the position where the bow-shaped spring is installed on the base frame or seat cushion base plate. The two ends of the bow-shaped spring are set in the corresponding U-shaped grooves, and both ends of the bow-shaped spring are U-shaped ends. The two ends of the bow-shaped spring are fixed in the corresponding U-shaped grooves by the bow-shaped spring fixing component. The plate-shaped body of the bow-shaped spring fixing component has at least one fixing hole in the middle, and four fixing wings extend from the middle. At least three of the fixing wings have claws bent to the same side at their ends. The bow-shaped spring fixing component is cross-shaped as a whole.

6. The method for manufacturing a bow-shaped spring sofa according to claim 1 or 2, characterized in that, The filling material pad is a palm fiber pad, coconut fiber pad, grapefruit fiber pad, or bamboo fiber pad with an outer burlap covering. The lower and upper covering layers are both burlap or chemical fiber cloth, and the fiber wadding is cotton, pearl cotton, silk floss, or chemical fiber material.

7. The method for manufacturing a bow-shaped spring sofa according to claim 1 or 2, characterized in that, The seat base plate, after the bow-shaped spring assembly is installed and covered with lining material, is fixed to the base frame.

8. The method for manufacturing a bow-shaped spring sofa according to claim 1 or 2, characterized in that, The manufacturing steps of the backrest manufacturing method are basically the same as those of the sofa cushion manufacturing method, and the materials used are also basically the same.

9. The method for manufacturing the bow-shaped spring sofa according to claim 5, characterized in that, The manufacturing steps of the backrest manufacturing method are basically the same as those of the sofa cushion manufacturing method, and the materials used are also basically the same.

10. A curved spring sofa, comprising a seat cushion and a backrest, characterized in that, The sofa cushion and backrest are manufactured using the method for manufacturing a bow-shaped spring sofa as described in any one of claims 1-9.

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