Production process of electric sofa bed with memory function

Abstract

The invention relates to a production process of an electric sofa bed with a memory function. The production process comprises the following steps: S1, frame pretreatment and functional element integrated installation; s2, directional tapping and function fitting of the memory sponge; s3, performing temperature control fitting and memory function calibration; and S4, carrying out antibacterial treatment and self-adaptive coating on the composite fabric. The invention has the following advantage: the product can still keep the comprehensive performance of stable structure, accurate action, comfort, health, durability and reliability in long-term use.

Description

Technical fields:

[0001] This invention belongs to the field of sofa bed manufacturing, specifically relating to a manufacturing process for an electric sofa bed with memory function. Background technology:

[0002] As people's living standards improve, their demands for the comfort, functionality, and health aspects of home furnishings are increasing. Electric sofa beds, as furniture that integrates the functions of a sofa and a bed, are favored by the market due to their strong spatial adaptability and flexible and convenient use. In particular, electric sofa beds with memory function can automatically adjust the backrest angle according to user habits and provide personalized support, making them a current research and development hotspot in the mid-to-high-end furniture market.

[0003] Currently, the manufacturing processes of electric sofa beds on the market generally suffer from the following technical defects: First, in terms of frame processing, most products only use simple welding followed by surface treatment without systematic stress-relieving annealing. This makes the frame prone to deformation under long-term use or changes in temperature and humidity, affecting structural stability and motor transmission accuracy, and shortening the product's lifespan. Second, the memory function is implemented in a rather crude way, usually only preset at the motor and control module level, lacking refined adaptation to the human body's sitting and lying pressure distribution curve. Existing foam is mostly cut into regular shapes, resulting in uneven support distribution after fitting, making it difficult to achieve true "memory" and adaptive adjustment, leading to a poor user experience. Furthermore, traditional fabric processing mainly relies on conventional weaving and surface coating, lacking long-lasting, intelligent antibacterial and deformation adaptability. After long-term use, bacteria can easily grow, and during frequent changes in the sofa bed's shape, the fabric is prone to wrinkles, tightness, or even tearing, affecting aesthetics and comfort. In addition, the various links in the production process are not tightly connected. For example, insufficient circuit protection, reliance on room temperature adhesive bonding process leading to poor bonding strength and durability, and disconnect between functional calibration and final verification processes make it difficult to guarantee the overall reliability, functional consistency and durability of the product. Summary of the Invention:

[0004] The purpose of this invention is to overcome the above-mentioned shortcomings and provide a manufacturing process for an electric sofa bed with memory function, so that the product can maintain a stable structure, precise movement, comfort, health and durability during long-term use.

[0005] The objective of this invention is achieved through the following technical solution: a manufacturing process for an electric sofa bed with memory function, comprising the following steps:

[0006] S1. Frame pretreatment and functional component integration and installation: The welded sofa bed frame is subjected to stress-relieving annealing at a temperature of 250-300℃ and a holding time of 1-2 hours, followed by furnace cooling; then, in the pre-set wiring groove on the back of the frame, the control circuit of the drive motor and sensor with memory function is laid along the groove, and the flexible buckle is used for segmented fixation.

[0007] S2. Oriented opening and functional fit of memory foam: The memory foam block is cut using a multi-axis linkage water jet cutting machine to obtain backrest foam and seat cushion foam; Asymmetrical irregular through holes are opened on the backrest foam at the position corresponding to the drive motor in step S1, along the pressure distribution curve when the human body is sitting or lying down; A layer of hot melt pressure-sensitive adhesive is uniformly coated on the inner wall of the irregular through holes and the predetermined support area on the upper surface of the seat cushion foam.

[0008] S3. Temperature-controlled bonding and memory function calibration: Place the frame with the functional components installed in step S1 on a constant temperature assembly table and heat it to 40-45℃; align the backrest sponge and seat cushion sponge prepared in step S2, and use the residual heat of the sponge itself to activate the hot melt pressure-sensitive adhesive, and accurately bond it to the corresponding parts of the frame; after bonding, power the drive motor through the control circuit built into the frame to drive the backrest to multiple preset memory angles and maintain them, while using pressure sensors to record the pressure distribution data at each angle to complete the initial calibration of the memory function;

[0009] S4. Antibacterial treatment and adaptive coating of composite fabric: The fabric used to make the bed cover is impregnated and dried in sequence; the impregnation liquid is an antibacterial gel liquid with temperature-sensitive deformation characteristics, and after drying, it forms a micro-gel layer on the surface of the fabric fibers; the treated fabric is cut and sewn into a bed cover.

[0010] S5. Overall Assembly and Functional Verification: Cover the sofa bed frame that has been fitted in step S3 with the bed cover made in step S4, and fix it with a hidden zipper; finally, install the legs, let it stand at room temperature for 24 hours, and drive the sofa bed to repeat the multiple memory angle transformation cycles calibrated in step S4 to verify the smoothness of the movement, the accuracy of the memory position, and the adaptive stretching performance of the fabric.

[0011] A further improvement of the present invention is that the stress-relieving annealing process described in step S1 is specifically as follows: the welded frame is placed in a heat treatment furnace and heated to 280°C at a rate not exceeding 80°C / hour, held at that temperature for 1.5 hours, and then cooled to below 100°C in the furnace before being removed from the furnace.

[0012] A further improvement of the present invention is that: the cutting water pressure of the multi-axis linkage waterjet cutting machine in step S2 is 300-400MPa, the cutting path is driven by three-dimensional ergonomic model data, and the irregular through hole is a teardrop shape or a waist drum shape with a larger top and a smaller bottom.

[0013] A further improvement of the present invention is that the softening point of the hot melt pressure-sensitive adhesive in step S2 is 50-60℃, and the coating amount is 15-25g / m². 2 .

[0014] A further improvement of the present invention is that the antibacterial gel solution in step S4 comprises the following components by weight percentage:

[0015] Carboxymethyl chitosan 3-5%,

[0016] Nano silver antibacterial agent 0.5-1.5%,

[0017] Thermosensitive hydrogel polymer 8-12%,

[0018] 1-2% fabric softener

[0019] The remainder is deionized water.

[0020] A further improvement of the present invention is that the initial calibration of the memory function in step S3 includes at least three angular positions: a sitting upright position, a sitting semi-reclining position, and a fully supine position.

[0021] A further improvement of the present invention is that: when laying the control line in step S1, a high-temperature resistant insulating silicone hose is used for protection at the parts where the wire may come into contact with the metal pipe of the frame.

[0022] A further improvement of the present invention is that the ambient temperature for standing for 24 hours in step S5 is 20-25°C and the relative humidity is 45-65%.

[0023] A further improvement of the present invention is that: during the functional verification in step S5, each memory angle is repeated three times, the motor current value, arrival time, and sensor feedback pressure value are recorded, and compared with the initial calibration data. If the deviation exceeds the set threshold, the recalibration process is triggered.

[0024] A further improvement of the present invention is that: in sofa beds produced by this process, the memory foam provides deformation space through the irregular through-holes and achieves slip-free overall movement through the hot melt pressure-sensitive adhesive when the drive mechanism is activated; the gel layer on the surface of the fabric undergoes microscopic softening under the action of body temperature and pressure, reducing the constraint on the deformation of the foam.

[0025] Compared with the prior art, the present invention has the following advantages:

[0026] 1. This invention introduces stress-relief annealing treatment for the frame, controlled by specific process parameters (such as a heating rate not exceeding 80℃ / hour and holding at 280℃ for 1.5 hours). This effectively eliminates residual stress inside the frame after welding, preventing slow deformation caused by stress release and ensuring the long-term dimensional stability of the entire sofa bed base. This stability is the fundamental guarantee for the long-term precise operation of all subsequent electric adjustment functions.

[0027] 2. In the initial calibration stage, this invention does not simply record the motor position, but records the pressure distribution data at each preset memory angle through a pressure sensor. The angle information is then correlated with the real-time support pressure information for calibration, forming a multi-dimensional memory storage. Secondly, water jet cutting is driven by three-dimensional ergonomic model data to create asymmetrical irregular through holes in the memory foam. This design is not random, but optimized according to the pressure distribution curve of the human body when sitting or lying down, so that the foam can produce a deformation that conforms more to the curve of the human body when subjected to force, providing non-uniform and dynamic support force.

[0028] 3. This invention endows traditional fabrics with intelligent properties of dynamic adaptation and long-lasting antibacterial effect through innovative fabric treatment process. The fabric is impregnated with a specially made temperature-sensitive deformation antibacterial gel liquid. The gel liquid forms a micro-gel layer on the fiber surface. Its temperature-sensitive deformation characteristics allow the fabric to stretch or shrink more smoothly with the deformation of the frame and sponge during the shape change of the sofa bed. This effectively avoids the damage caused by tightness, wrinkles or stress concentration due to frequent deformation, and improves the durability and aesthetics of the fabric. Detailed implementation method:

[0029] To enhance understanding of the present invention, the present invention will be further described in detail below with reference to embodiments. These embodiments are only used to explain the present invention and do not constitute a limitation on the scope of protection of the present invention.

[0030] In the description of this invention, it should be understood that the terms indicating orientation or positional relationship are used only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the structure or unit referred to must have a specific orientation, and therefore should not be construed as a limitation of this invention.

[0031] A manufacturing process for an electric sofa bed with memory function includes the following steps:

[0032] S1. Frame pretreatment and functional component integration and installation: The welded sofa bed frame is subjected to stress-relieving annealing at a temperature of 250-300℃ and a holding time of 1-2 hours, followed by furnace cooling; then, in the pre-set wiring groove on the back of the frame, the control circuit of the drive motor and sensor with memory function is laid along the groove, and the flexible buckle is used for segmented fixation.

[0033] S2. Oriented opening and functional fit of memory foam: The memory foam block is cut using a multi-axis linkage water jet cutting machine to obtain backrest foam and seat cushion foam; Asymmetrical irregular through holes are opened on the backrest foam at the position corresponding to the drive motor in step S1, along the pressure distribution curve when the human body is sitting or lying down; A layer of hot melt pressure-sensitive adhesive is uniformly coated on the inner wall of the irregular through holes and the predetermined support area on the upper surface of the seat cushion foam.

[0034] S3. Temperature-controlled bonding and memory function calibration: Place the frame with the functional components installed in step S1 on a constant temperature assembly table and heat it to 40-45℃; align the backrest sponge and seat cushion sponge prepared in step S2, and use the residual heat of the sponge itself to activate the hot melt pressure-sensitive adhesive, and accurately bond it to the corresponding parts of the frame; after bonding, power the drive motor through the control circuit built into the frame to drive the backrest to multiple preset memory angles and maintain them, while using pressure sensors to record the pressure distribution data at each angle to complete the initial calibration of the memory function;

[0035] S4. Antibacterial treatment and adaptive coating of composite fabric: The fabric used to make the bed cover is impregnated and dried in sequence; the impregnation liquid is an antibacterial gel liquid with temperature-sensitive deformation characteristics, and after drying, it forms a micro-gel layer on the surface of the fabric fibers; the treated fabric is cut and sewn into a bed cover.

[0036] S5. Overall Assembly and Functional Verification: Cover the sofa bed frame that has been fitted in step S3 with the bed cover made in step S4, and fix it with a hidden zipper; finally, install the legs, let it stand at room temperature for 24 hours, and drive the sofa bed to repeat the multiple memory angle transformation cycles calibrated in step S4 to verify the smoothness of the movement, the accuracy of the memory position, and the adaptive stretching performance of the fabric.

[0037] The stress-relief annealing process in step S1 is as follows: the welded frame is placed in a heat treatment furnace and heated to 280°C at a rate not exceeding 80°C / hour, held for 1.5 hours, and then cooled to below 100°C in the furnace before being removed from the furnace.

[0038] This invention introduces a stress-relief annealing treatment for the frame, controlled by specific process parameters (such as a heating rate not exceeding 80℃ / hour and a holding time at 280℃ for 1.5 hours). This effectively eliminates residual stress within the frame after welding, preventing slow deformation caused by stress release and ensuring the long-term dimensional stability of the entire sofa bed base. This stability is the fundamental guarantee for the long-term precise operation of all subsequent electric adjustment functions.

[0039] In step S2, the cutting water pressure of the multi-axis linkage waterjet cutting machine is 300-400MPa, the cutting path is driven by three-dimensional ergonomic model data, and the irregular through hole is a teardrop shape or a waist drum shape with a larger top and a smaller bottom.

[0040] In step S2, the softening point of the hot melt pressure-sensitive adhesive is 50-60℃, and the coating amount is 15-25g / m². 2 .

[0041] In the initial calibration stage, this invention does not simply record the motor position, but records the pressure distribution data at each preset memory angle through a pressure sensor. The angle information is then correlated with the real-time support pressure information for calibration, forming a multi-dimensional memory storage. Secondly, water jet cutting is driven by three-dimensional ergonomic model data to create asymmetrical irregular through holes in the memory foam. This design is not random, but optimized according to the pressure distribution curve of the human body when sitting or lying down, so that the foam can produce a deformation that conforms more to the curve of the human body when subjected to force, providing non-uniform and dynamic support force.

[0042] The antibacterial gel solution described in step S4 comprises the following components by weight percentage:

[0043] Carboxymethyl chitosan 3-5%,

[0044] Nano silver antibacterial agent 0.5-1.5%,

[0045] Thermosensitive hydrogel polymer 8-12%,

[0046] 1-2% fabric softener

[0047] The remainder is deionized water.

[0048] This invention endows traditional fabrics with intelligent properties of dynamic adaptation and long-lasting antibacterial effects through an innovative fabric treatment process. The fabric is impregnated with a specially formulated temperature-sensitive deformation antibacterial gel liquid, which forms a micro-gel layer on the fiber surface. Its temperature-sensitive deformation properties allow the fabric to stretch or contract more smoothly with the deformation of the frame and foam during the shape changes of the sofa bed, effectively avoiding the damage caused by tightness, wrinkles or stress concentration due to frequent deformation, and improving the durability and aesthetics of the fabric.

[0049] The initial calibration of the memory function in step S3 includes at least three angular positions: sitting upright, sitting semi-reclining, and fully supine.

[0050] When laying the control lines in step S1, high-temperature resistant insulating silicone tubing is used to protect the parts where the conductors may come into contact with the metal pipes of the frame.

[0051] During the installation of control lines, high-temperature resistant insulating silicone tubing is used on areas that may come into contact with the metal frame, providing dual protection: firstly, to prevent short circuits due to wire wear; and secondly, to withstand localized temperature rises that may occur in the frame during operation, greatly enhancing the safety and durability of the electrical system. Through systematic reliability design from the structural foundation to core functional components, this invention fundamentally reduces the risk of product failure due to structural deformation or electrical faults, extends service life, and improves overall reliability.

[0052] The ambient temperature for the 24-hour standing period in step S5 is 20-25℃ and the relative humidity is 45-65%.

[0053] During the functional verification described in step S5, each memory angle is run three times repeatedly, and the motor current value, arrival time, and sensor feedback pressure value are recorded. These are then compared with the initial calibration data. If the deviation exceeds the set threshold, the recalibration process is triggered.

[0054] Those skilled in the art should understand that this invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to this invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A production process of an electric sofa bed with memory function, characterized in that: The method comprises the following steps: S1, frame pretreatment and functional element integrated installation: the sofa bed frame formed by welding is subjected to stress relief annealing treatment, the annealing temperature is 250-300℃, the holding time is 1-2 hours, and the furnace cooling is performed; subsequently, the control line of the driving motor and the sensor with memory function is laid in the preset line groove of the backrest part of the frame along the groove body, and the flexible buckle is used for segmented fixing; S2, directional opening of memory sponge and functional lamination: a multi-axis linkage water jet cutting machine is used to cut the memory sponge block to obtain the backrest sponge and the seat cushion sponge; an asymmetric shaped through hole is formed on the backrest sponge at a position corresponding to the driving motor in step S1 along the pressure distribution curve of the human body when sitting and lying; a layer of hot melt pressure sensitive adhesive is uniformly coated on the inner wall of the shaped through hole and the upper surface of the predetermined support area of the seat cushion sponge; S3, temperature control lamination and memory function calibration: the frame with the installed functional elements in step S1 is placed on a constant temperature assembly table and heated to 40-45℃; the backrest sponge and the seat cushion sponge treated in step S2 are aligned, the hot melt pressure sensitive adhesive is activated by the self-heat of the sponge, and the backrest sponge and the seat cushion sponge are accurately laminated on the corresponding parts of the frame; After lamination, the driving motor is powered on through the control line built in the frame, the backrest part is driven to the preset multiple memory angles and is kept, the pressure distribution data at each angle is recorded by using the pressure sensor, and the initial calibration of the memory function is completed; S4, antibacterial treatment and self-adaptive covering of the composite fabric: the fabric used for making a bed sheet is subjected to immersion and drying treatment in sequence; the immersion uses an antibacterial gel liquid with temperature sensing deformation characteristics, and after drying, a micro gel layer is formed on the surface of the fabric fibers; the treated fabric is cut and sewn into a bed sheet; S5, overall assembly and function verification: the bed sheet prepared in step S4 is covered on the sofa bed body in step S3, and is fixed through a hidden zipper; finally, the supporting legs are installed, and after standing still at room temperature for 24 hours, the sofa bed is repeatedly changed among the multiple memory angles calibrated in step S4, and the smoothness of the action, the accuracy of the memory position and the self-adaptive stretching performance of the fabric are verified.

2. The production process of the electric sofa bed with memory function according to claim 1, characterized in that, The stress relief annealing treatment in step S1 is specifically as follows: the frame after welding is placed in a heat treatment furnace, heated to 280℃ at a rate of not more than 80℃ / hour, kept for 1.5 hours, and then furnace cooled to below 100℃ and discharged.

3. The production process of the electric sofa bed with memory function according to claim 2, characterized in that, The cutting water pressure of the multi-axis linkage water jet cutting machine in step S2 is 300-400MPa, the cutting path is driven by three-dimensional human engineering model data, and the shaped through hole is in the shape of water drop or waist drum with the upper part larger and the lower part smaller.

4. The production process of the electric sofa bed with memory function according to claim 3, characterized in that, The softening point of the hot-melt pressure sensitive adhesive in step S2 is 50-60°C, and the coating amount is 15-25 g / m 2 .

5. The production process of an electric sofa bed with memory function according to claim 4, characterized in that, The antibacterial gel liquid in step S4 comprises the following components by weight percentage: Carboxymethyl chitosan 3-5%, Nano-silver antibacterial agent 0.5-1.5%, Temperature-sensitive hydrogel polymer 8-12%, Softener 1-2%, The balance is deionized water.

6. The production process of an electric sofa bed with memory function according to claim 5, characterized in that, The initial calibration of the memory function in step S3 includes at least three angle positions: a sitting upright position, a sitting half-lying position and a completely lying position.

7. The production process of an electric sofa bed with memory function according to claim 6, characterized in that, In step S1, when laying the control line, high-temperature-resistant insulating silica gel hoses are sleeved at positions where the wire may contact the frame metal pipe.

8. The production process of an electric sofa bed with memory function according to claim 7, characterized in that, In step S5, the ambient temperature during the 24-hour standing is 20-25℃, and the relative humidity is 45-65%.

9. The production process of an electric sofa bed with memory function according to claim 8, characterized in that, In step S5, when verifying the function, each memory angle is repeatedly run three times, and the motor current value, the arrival time, and the sensor feedback pressure value are recorded. The recorded values are compared with the initial calibration data. If the deviation exceeds the set threshold, the re-calibration process is triggered.