Manufacturing method for sofa having sinuous springs, and sofa having sinuous springs

Abstract

The present invention provides a manufacturing method for a sofa having sinuous springs, and a sofa having sinuous springs. The sofa having sinuous springs comprises a sofa cushion and a backrest, wherein the sofa cushion comprises sinuous springs, a base frame and / or a cushion bottom plate therein, and the backrest comprises sinuous springs, a backrest frame and / or a backrest bottom plate therein, characterized in that a sofa cushion manufacturing method comprises the following steps: manufacturing a sinuous spring assembly on the base frame or the cushion bottom plate, covering the sinuous spring assembly with a lower covering layer, a filling material pad and an upper covering layer in sequence, and connecting and fixing same by using needles and threads or connectors. An edge between the filling material pad and the upper covering layer is filled with a straw bundle, and is then sewn on the sinuous spring assembly by using needles and threads, and a hemming curved needle and a straw-poking needle are used in combination to create the hemming shape of the sofa cushion; and a sofa cushion cover is tailor-made according to the hemming shape of the sofa cushion. The rational selection of lining materials and a sewing technique ensures that the cushion of the sofa having sinuous springs is flat and has an aesthetically pleasing shape, the processing quality is stable and reliable, and the sofa is durable.

Description

Method for manufacturing bow-shaped spring sofa and bow-shaped spring sofa Technical Field

[0001] The invention belongs to the technical field of sofa manufacturing, in particular to a manufacturing method of a bow-shaped spring sofa and the bow-shaped spring sofa. Background Art

[0002] In the early days of sofa development, cylindrical springs were used to make cushions. These cushions offered excellent elasticity, resistance to deformation, good breathability, environmental friendliness, and a long service life. However, the shapes of cylindrical spring sofas and seats were fixed entirely with hemp rope, which easily frayed. Production was also time-consuming and labor-intensive, requiring a high level of technical expertise. To accommodate the changing shapes of cushions, cylindrical springs in a variety of sizes and shapes were required. Furthermore, cylindrical springs were unsuitable for armrests. Due to the complex manufacturing process, high costs, and susceptibility to damage, cylindrical spring sofas were gradually replaced by foam sofas. Foam sofas, with their ease of processing and low price, dominated the market, squeezing out the cylindrical spring sofas, which offered many advantages. This marked the second period of development for the sofa industry.

[0003] Foam sofas are gradually gaining recognition and understanding as they become more commonplace. However, their elasticity relies on the foam itself, which is insufficient, breathable, odorous, easily deformed, and rapidly aged, making them unhealthy. Their filling material, polyurethane foam, is toxic and difficult to degrade naturally. Therefore, foam sofas come at the expense of the environment and human health. This flaw is fatal and must be addressed quickly and thoroughly. As we all know, 90% of the world's soft furniture still uses polyurethane foam. In my country alone, approximately 70 million pairs of foam sofas are discarded annually, a staggering number that creates significant harm and poses significant challenges to environmental protection.

[0004] To address the current market dominance of plastic foam sofas and the problems of columnar spring sofas and foam sofas, a Chinese patent publication discloses a method for manufacturing bow spring sofa cushions and armrests. Patent number ZL20061004505.4 addresses the aforementioned problems of columnar spring sofas and foam sofas. Because it aligns with green environmental protection concepts and development trends, it has promising development prospects. However, the patent has long been largely unpopularized and has failed to achieve the expected economic benefits. After extensive practice, research, and analysis, the applicant has discovered that the patent's product structure and manufacturing process still have many shortcomings that require improvement and supplementation. The sofa manufacturing process described in the patent does not disclose a specific sewing process. Because bow spring sofas have multiple layers of lining material and irregular shapes, conventional sewing techniques often result in uneven edges on the backrest, seat cushion, and armrests of the sofa, which is both aesthetically pleasing and fails to reflect the structural characteristics of the bow spring sofa. Therefore, in order to reflect the unique and beautiful shape of the bow spring sofa, it is necessary to provide a method for manufacturing the bow spring sofa. By selecting suitable lining materials and reasonable sewing technology, the seat cushion and backrest surfaces of the bow spring sofa can be made smooth and beautifully curved, which can better highlight the characteristics of the bow spring and achieve stable and reliable processing quality. This is the problem to be solved by the present invention. Summary of the Invention

[0005] In order to solve the above-mentioned problems and shortcomings of the prior art, the present invention provides a method for manufacturing a bow-shaped spring sofa and a bow-shaped spring sofa. By adopting suitable lining materials and reasonable sewing technology, the seat cushion and backrest surfaces of the manufactured bow-shaped spring sofa are smooth, and beautiful curved shapes can be formed, which can better highlight the characteristics of the bow spring, and the processing quality is stable, reliable and durable.

[0006] The objective of the present 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, the sofa cushion comprising a bow-shaped spring, a base frame and / or a cushion bottom plate, the backrest comprising a bow-shaped spring, a backrest frame and / or a backrest bottom plate, the bow spring having a raised arc in the middle and bent surfaces formed by downward bending at both ends, characterized in that the method for manufacturing the bow-shaped spring sofa comprises a method for manufacturing the sofa cushion and a method for manufacturing the backrest, and the method for manufacturing the sofa cushion comprises the following steps:

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

[0008] Step 2: longitudinally arrange the bow spring on the base frame or the seat cushion bottom plate, fix the two ends of the bow spring to the base frame or the seat cushion bottom plate respectively, connect the four sides of the bow spring with a quadrilateral steel wire frame to form an integral body, and connect the bow springs and the quadrilateral steel wire frame with a horizontal straight steel wire in the middle to form a bow spring assembly;

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

[0010] Step 4: Lift the periphery of the upper covering layer, fill the area between the filling material pad and the upper covering layer corresponding to the front edge and left and right sides of the upper part of the sofa cushion with straw bundles as the shaping material, then fold the upper covering layer downward to cover the straw bundles, and then use a fixing needle to penetrate the lower covering layer, the filling material pad, the straw bundles and the upper covering layer to preliminarily fix the straw bundles;

[0011] Step 5: First, use a weeding needle to preliminarily move and gather the straw bundle toward the front edge and left and right edges of the upper part of the sofa cushion, then use a sewing needle and thread to obliquely thread and tie knots at a certain distance from the front edge and left and right edges of the upper part of the sofa cushion, and sew the upper covering layer, straw bundle, filling material pad and lower covering layer onto the bow-shaped spring assembly to form the basic shape of the sofa cushion edge;

[0012] Step 6: Use a sewing needle and a straw plucking needle to sew the edge of the sofa cushion. Use the sewing needle and thread to thread the needle along the upper front edge and both sides of the left and right edges of the sofa cushion and tie a knot. At the same time, use the straw plucking needle to pry the straw bundle to form a column. Wrap the straw bundle in the upper covering layer and fix it to complete the sewing shape of the sofa cushion.

[0013] Step 7: Based on the edge shape of the sofa cushion completed in step 6, a sofa cushion cover is tailored. The sofa cushion cover includes a top surface and three surrounding side surfaces. A surplus edge is left on the inner side of the seam between the top surface and the three side surfaces, and teeth are formed on the outer side of the seam between the top surface and the three side surfaces.

[0014] The improvement of the above technical solution also includes step 8: laying fiber batting on the upper covering layer of the sofa cushion completed in step 6 to make the top surface of the sofa cushion coat smooth and shape it into an appropriate thickness and shape, then turning up the periphery of the sofa cushion coat tailored in step 7 and laying it flat on the sofa cushion, aligning the top surface of the sofa cushion coat with the four corners of the top surface of the sofa cushion, fixing it with a fixing needle, and then using a sewing needle and sewing thread to thread and knot along the remaining edge of the inner side of the sofa cushion coat corresponding to the front edge and left and right edges of the upper part of the sofa cushion, so that the teeth of the sofa cushion coat and the sofa cushion form an integrated structure, finally, turning down the periphery of the sofa cushion coat to complete the production of the sofa cushion.

[0015] An improvement to the above technical solution: in step 3, the lining material is fixed using a connecting piece in the following manner: first, the lower covering layer is wrapped around the outside of the bow spring assembly, the lower covering layer is connected and fixed to the quadrilateral steel wire frame in the bow spring assembly using C-shaped nails sent out from a C-shaped nail gun, the edge of the lower covering layer is fixed to the base frame or the seat cushion bottom plate using nails shot out from a nail gun, and then the filling material pad is covered on the lower covering layer, the filling material pad is connected and fixed to the quadrilateral steel wire frame in the bow spring assembly using C-shaped nails sent out from a C-shaped nail gun, the edge of the filling material pad is fixed to the base frame or the seat cushion bottom plate using nails shot out from a nail gun, and finally, the upper covering layer is covered, and the middle part of the upper covering layer is temporarily fixed using a fixing pin.

[0016] Another improvement to the above technical solution: in step 3, the lining material is connected and fixed using needle and thread in the following manner: first, the lower covering layer, the filling material pad and the upper covering layer are sequentially covered on the bow-shaped spring assembly, the upper covering layer is turned downward, and then 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 points at both ends and a needle eye at one end and a suture are used to thread the needle and tie a knot along the middle part of the upper covering layer, and the middle part of the upper covering layer, the filling material pad and the lower covering layer are sewn together from top to bottom and fixed to the bow-shaped spring assembly.

[0017] Further improvement of the above technical solution: The specific fixing method of longitudinally setting the bow spring on the base frame or seat cushion bottom plate in the step 2 is: the base frame or seat cushion bottom plate is made of wood or plastic wood, and a U-shaped groove is set at the position where the bow spring is installed on the base frame or seat cushion bottom plate, and the two ends of the bow spring are set in the corresponding U-shaped grooves, and both ends of the bow spring are U-shaped ends, and the two ends of the bow spring are respectively fixed in the corresponding U-shaped grooves by using a bow spring fixing piece, at least one fixing hole is set in the middle of the sheet body of the bow spring fixing piece, and 4 fixing wings extend around the middle part, and the ends of at least three of the fixing wings are provided with claws bent to the same side, and the bow spring fixing piece is cross-shaped as a whole.

[0018] Further improvement to the above technical solution: the filling material pad is a palm fiber pad, coconut fiber pad, grapefruit fiber pad or bamboo fiber pad wrapped with linen, the lower covering layer and the upper covering layer are both linen or chemical fiber cloth, and the fiber batting is cotton, pearl cotton, silk cotton or chemical fiber material.

[0019] A further improvement to the above technical solution is as follows: the seat cushion bottom plate after the bow spring assembly is installed and fixed and covered with lining material is fixed on the base frame.

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

[0021] The invention discloses a bow-shaped spring sofa, comprising a sofa seat cushion and a backrest, and is characterized in that the sofa seat cushion and the backrest are manufactured by adopting the manufacturing method of the bow-shaped spring sofa.

[0022] Compared with the existing technology, the present invention has many advantages and positive effects:

[0023] 1. The present invention combines the advantages of foam sofas, which are easy to make and low in price, and the advantages of columnar spring sofas, which are good elasticity, no deformation, good air permeability, green and environmental protection, comfortable use, and long life. The bow-shaped spring used in the present invention is made of steel wire, and the lining material and the 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 being scrapped, which is in line with my country's development goals of independent innovation, green and environmental protection, and circular economy.

[0024] 2. The present invention makes the surface of the sofa cushion and backrest of the bow spring sofa smooth and can make beautiful curved shapes by selecting suitable lining materials, shaping materials and reasonable sewing technology, which can better highlight the characteristics of the bow spring, and the processing quality is stable, reliable and has a long service life.

[0025] 3. The processing method of the present invention is convenient, the product structure is simple, the cost of raw materials is low, and it is easy to promote and apply. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] FIG1 is a top view of a seat cushion base plate in Example 2 of a bow spring sofa according to the present invention;

[0027] FIG2 is a top view of the seat cushion base shown in FIG1 after the bow spring is fixed with a bow spring fixing member;

[0028] FIG3 is a top view of the base frame of a bow spring sofa in Example 1 of the present invention;

[0029] FIG4 is a perspective view of a bow spring assembly formed by mounting a bow spring and a fixing member on the base frame shown in FIG3 ;

[0030] FIG5 is a schematic diagram of the internal structure of the bow spring assembly shown in FIG4 after the outer surface is covered with a lower covering layer, a filling material pad, a straw bundle and an upper covering layer;

[0031] FIG6 is a schematic diagram showing the sofa cushion shown in FIG5 after the lining material is fixed with a fixing needle;

[0032] FIG7 is a schematic diagram showing a method of connecting the middle portion of the sofa cushion shown in FIG6 with a sewing needle and thread;

[0033] 8 is a schematic diagram of a method of threading a needle and threading a knot at a certain distance from the front edge and left and right edges of the upper portion of the sofa cushion shown in FIG. 7 ;

[0034] 9 is a schematic diagram showing a sofa cushion shown in FIG8 based on the straw needle to the upper portion of the sofa cushion front edge and left and right edges of the straw bundle to move together;

[0035] FIG10 is a schematic diagram of a method of forming an edge by threading and tying a curved needle and a thread on the front edge and left and right edges of the upper portion of the sofa cushion shown in FIG9 ;

[0036] FIG11 is a schematic diagram of sewing the teeth on the periphery of the top surface of the sofa cushion cover to the sofa cushion using a sewing needle and thread along the front edge and left and right edges of the upper portion of the sofa cushion to tie a knot on the sofa cushion shown in FIG10 ;

[0037] FIG12 is a perspective view of the overall structure of a bow spring sofa in accordance with Embodiment 1 or Embodiment 2 of the present invention;

[0038] FIG13 is a schematic diagram of the process of threading and knotting the sofa cushion shown in FIG7 using a sewing needle and thread;

[0039] Figure 14 is a schematic diagram of the process of threading a sewing needle and a thread through the sewing needle and tying a knot for the sofa cushion shown in Figure 8;

[0040] Figure 15 is a schematic diagram of the process of threading a hemming curved needle and a thread through the needle and tying a knot for the sofa cushion shown in Figure 10 or Figure 11.

[0041] The reference numerals in the figure are: 1, cushion bottom plate; 2, U-shaped groove; 3, bow spring fixing member; 4, fixing screw; 5, bow spring; 6, base frame; 7, C-shaped clip; 8, quadrilateral wire frame; 9, straight wire; 10, clamping code; 11, lower covering layer; 12, filling material pad; 13, upper covering layer; 14, straw bundle; 15, fixing needle; 16, long sewing needle; 17, sewing needle; 18, straw-pulling needle; 19, hemming curved needle; 20, sofa cushion outer cover; 21, sofa cushion; 22, armrest; 23, backrest. Embodiment

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

[0043] Referring to Figures 3 - 12, Embodiment 1 of the manufacturing method of a bow spring sofa according to the present invention, the bow spring sofa includes a sofa cushion 21 and a backrest 23. The sofa cushion 21 includes a base frame 6 and a bow spring 5 inside, and the backrest 23 includes a backrest frame and a bow spring 5 inside. The middle of the bow spring 5 is a raised arc, and both ends are respectively bent downward to form a bent surface. The manufacturing method of the bow spring sofa includes the manufacturing method of the sofa cushion 21 and the manufacturing method of the backrest 23. The manufacturing method of the sofa cushion 21 includes the following steps:

[0044] Step 1: Process and manufacture the base frame 6. The base frame 6 includes a quadrilateral frame and a fixed cross beam arranged in the middle. Preferably, the above base frame 6 can be made of wood or wood-plastic to form a mu-shaped frame (as shown in Figure 3), a ri-shaped frame or a square frame, etc.

[0045] Step 2: Vertically arrange the bow spring 5 on the base frame 6, fix both ends of the bow spring 5 on the base frame 6 respectively, connect the four sides of the bow spring 5 with a quadrilateral wire frame 8 into an integrated body, and connect each bow spring 5 and the quadrilateral wire frame 8 with a horizontally arranged straight wire 9 in the middle to form a bow spring combination. Preferably, the connection method between the quadrilateral wire frame 8 and the bow spring 5 can be fixed by using a C-type nail 7 in a C-type nail gun, and the connection method between the straight wire 9 and each bow spring 5 and the quadrilateral wire frame 8 can be fixed by using a clamping code 10 in a clamping code gun, as shown in Figure 4.

[0046] Step 3: The bow-shaped spring assembly is covered layer by layer with lining materials. The lining materials include a lower covering layer 11, a filling material pad 12, an upper covering layer 13 and fiber batting from the inside to the outside. The lower covering layer 11, the filling material pad 12 and the upper covering layer 13 are first covered on the bow-shaped spring assembly in sequence. The lining materials are partially connected and fixed to the bow-shaped spring assembly with needle and thread or connectors to form a sofa cushion with a preliminary fixed shape, as shown in Figure 5.

[0047] There are two specific ways to lay, connect and fix the above-mentioned lining materials:

[0048] The first method is to use connectors for connection and fixation: In step 3, the lining material is fixed using connectors as follows: first, a lower covering layer 11 is wrapped around the outside of the bow spring assembly. C-shaped nails are used from a C-shaped nail gun to connect and fix the lower covering layer 11 to the quadrilateral steel wire frame of the bow spring assembly. The edges of the lower covering layer 11 are fixed to the base frame 6 using nails shot from a nail gun. Then, a filling material pad 12 is placed over the lower covering layer 11. C-shaped nails are used from a C-shaped nail gun to connect and fix the filling material pad 12 to the quadrilateral steel wire frame of the bow spring assembly. The edges of the filling material pad 12 are fixed to the base frame 6 using nails shot from a nail gun. Finally, an upper covering layer 13 is placed, and the center portion of the upper covering layer 11 is temporarily fixed using fixing pins 15.

[0049] The second method is to use needle and thread connection and fixation: in the step 3, the lining material is fixed by needle and thread connection as follows: first, the lower covering layer 11, the filling material pad 12 and the upper covering layer 13 are sequentially covered on the bow-shaped spring assembly, the upper covering layer 13 is turned down, and then a fixing needle 15 is used to penetrate the periphery of the lower covering layer 11, the filling material pad 12 and the upper covering layer 13, and then, a long sewing needle 16 with needle points at both ends and a needle eye at one end and a suture are used to thread the needle and tie a knot along the middle part of the upper covering layer 13, and the middle part of the upper covering layer 13, the filling material pad 12 and the lower covering layer 11 are sewn together from top to bottom and fixed on the bow-shaped spring assembly. 6, 7 and 13, the fixing needle 15 penetrates the upper covering layer 13, the filling material pad 12 and the periphery of the lower covering layer 11 from the front and rear sides of the upper half of the sofa cushion in an oblique upward direction. The entry 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, and B6. After the periphery of the sofa cushion is initially fixed, a long sewing needle 16 is used to thread and knot the needle in the manner shown in Figure 13. The initial entry point of the lower end needle tip of the long sewing needle 16 is C, and the initial exit point of the upper end needle tip of the long sewing needle 16 with a needle eye is D. The needle is threaded in the middle of the sofa cushion in the direction of the arrow. The last exit point of the upper end needle tip of the long sewing needle 16 is E. The sewing process is now completed, making the surface of the upper covering layer 11 of the sofa cushion smooth and positioned to prevent displacement. As shown in FIG7 , both ends of the long sewing needle 16 have needle tips and one end has a needle eye. The length of the long sewing needle 16 is substantially consistent with the thickness of the sofa base, making it easy to thread the needle.

[0050] Step 4: Lift the perimeter of the upper cover layer 13 and fill the area between the filling material pad 12 and the upper cover layer 13, corresponding to the front edge and left and right sides of the upper portion of the sofa cushion, with straw bundles 14 as the shaping material. Fold the upper cover layer 13 downward to cover the straw bundles 14. Then, penetrate the lower cover layer 11, filling material pad 12, straw bundles 14, and upper cover layer 13 with a securing needle 15 to initially secure the straw bundles 14. The securing needle 15 has a tip at one end and a handle at the other. The handle of the securing needle 15 shown in Figure 6 is circular, but other shapes that are convenient for gripping are also possible.

[0051] Step 5: First, use a straw plucking needle 18 to initially pry and gather the straw bundle 14 toward the front edge and left and right edges of the upper part of the sofa cushion, then use a sewing needle 17 and a suture to 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, and sew the upper covering layer 13, the straw bundle 14, the filling material pad 12 and the lower covering layer 11 to the bow-shaped spring assembly to form the basic shape of the sofa cushion. Specific steps, referring to Figures 8 and 14, begin by using a weeding needle 18 to initially move and gather the straw bundle 14 toward the front edge and left and right edges of the upper portion of the sofa cushion. Then, using a sewing needle 17 and thread, thread the bundle at an angle, a predetermined distance from the front edge and left and right edges of the upper portion of the sofa cushion, to tie the knot. First, thread the needle downward from point G in Figure 8, penetrate the bundle, then thread it upward and exit at point F. Following the threading pattern shown in Figure 14, thread the bundle toward the sides and rearward, tying the knot in the directions indicated by the arrows, until reaching points H1 and H2. As shown in Figure 8, sewing needle 17 has a needlepoint at one end and an eye at the other. Compared to conventional sewing needles, it is longer, thicker in diameter, and has a larger eye. However, sewing needle 17 is shorter than the long sewing needle 16 described above.

[0052] Step 6: Use the sewing needle 19 and the plucking needle 18 to perform the sewing shape of the sofa cushion. Use the sewing needle 19 and the sewing thread to thread the needle and tie a knot along the upper front edge and both sides of the left and right edges of the sofa cushion. At the same time, use the plucking needle 18 to pry the straw bundle 14 so that the straw bundle 14 gathers into a columnar shape, and wrap the straw bundle 14 and fix it in the upper covering layer 13 to complete the sewing shape of the sofa cushion, as shown in Figure 5. Specific steps, referring to Figures 9, 10, and 14, are as follows: The weeding needle 18 is inserted from points J and K in Figure 9, moving the straw bundle 14 toward the front edge in the direction of the arrow, and gradually moving the straw bundle 14 toward the sides, ending at points L1 and L2. Simultaneously, the sewing needle 19 and thread are threaded and tied along the upper front edge and both left and right edges of the sofa cushion. The needle is first threaded upward from point M in Figure 10, penetrating the lining material and the straw bundle 14, and then exiting from point N. Following the threading pattern in Figure 14, the needle is threaded and tied toward both sides, ending at points P1 and P2, completing the sewing of the sofa cushion. As shown in Figure 9, the weeding needle 18 has a tip at one end and no eye at the other. A handle can be provided on the untipped end as needed. As shown in Figure 10, the sewing needle 19 is crescent-shaped, with a tip at one end and an eye at the other.

[0053] Step 7: Based on the edge shape of the sofa cushion completed in step 6, a sofa cushion cover 20 is tailored. The sofa cushion cover 20 includes a top surface and three surrounding side surfaces. A surplus edge is left on the inner side of the seam between the top surface and the three side surfaces, and teeth are formed on the outer side of the seam between the top surface and the three side surfaces of the sofa cushion cover 20.

[0054] Furthermore, it also includes step 8: laying fiber batting on the sofa cushion completed in step 7, covering the stitching parts and uneven parts, making the top surface of the sofa cushion flat, and shaping it into an appropriate thickness and shape, then turning up the periphery of the sofa cushion cover 20 tailored in 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, fixing it with a fixing needle 15, and then using a sewing needle 19 and a sewing thread to thread and knot along the remaining edge of the inner side of the sofa cushion cover 20 corresponding to the front edge and left and right edges of the upper part of the sofa cushion, so that the teeth of the sofa cushion cover 20 and the sofa cushion form an integrated structure, finally, turning down the periphery of the sofa cushion cover 20 to complete the production of the sofa cushion. Specific sewing steps are as follows: with reference to FIG11 and FIG15 , the periphery of the sofa cushion cover 20 tailored in step 8 is turned up and laid flat on the sofa cushion. The top surface of the sofa cushion cover 20 is aligned with the four corners of the top surface of the sofa cushion and fixed with four fixing needles 15 at points S1, S2, S3 and S4, respectively. This is to lay the foundation for the stitch distance during the sewing process of the sewing needle 19. The sewing needle 19 and thread are then inserted from point Q and exited from point R, penetrating the lining material and the straw bundle 14. The thread is then pulled back from point R to point Q and knotted. The thread is then tied from both sides of the sofa cushion according to the threading route shown in FIG15 . The above method is repeated to points S3 and S4, and the thread on the top surface of the sofa cushion cover 20 is sewn to the sofa cushion into an integrated structure, completing the thread sewing process. Finally, the periphery of the sofa cushion cover 20 is turned down to complete the production of the sofa cushion.

[0055] Furthermore, in step 2 above, the specific fixing method for longitudinally setting the bow spring 5 on the base frame 6 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 spring 5 is installed on the base frame 6, the two ends of the bow spring 5 are set in the corresponding U-shaped groove 2, and both ends of the bow spring 5 are U-shaped ends. The two ends of the bow spring 5 are respectively fixed in the corresponding U-shaped grooves using a bow spring fixing member 3, a fixing hole is provided in the middle of the sheet-like body of the bow spring fixing member 3, and the bow spring fixing member 3 is fixed to the base frame 6 through the fixing hole using a fixing screw 4. Four fixing fins extend from the middle of the bow spring fixing member 3. The ends of at least three of the fixing fins are provided with claws bent toward the same side. The claws can fix the two U-shaped ends of the bow spring 5. The bow spring fixing member 3 is cross-shaped as a whole.

[0056] The bow spring fixing member 3 described above can be the bow spring fixing member described in the Chinese patent application titled "A Bow Spring Fixing Member and Bow Spring Sofa" (Patent No.: CN201920330710.9), and the installation and fixing methods are the same or similar. It can also be fixed with reference to the method shown in FIG2 , so a detailed description thereof will not be given here. The bow spring 5 described above can be the bow spring described in the Chinese patent application titled "Method for Making a Sofa Backrest, Seat Cushion, and Armrest Using a Bow Spring" (Patent No.: CN200610045054.5), and the installation and fixing methods are the same or similar, so a detailed description thereof will not be given here.

[0057] To facilitate securing the lining material and enhance the aesthetics of the sofa cushion, a long wooden strip 6.1 is placed on each side of the base frame 6, forming a stepped shape with an outer bottom and an inner height. Nails are fired from a nail gun to secure the edges of the lower covering layer 11, the filling material pad 12, and the upper covering layer 13 to the outer sides of the long wooden strips. Finally, after covering with fiber batting, the sides of the entire lining material are substantially 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 filling material pad 12 is a palm fiber pad, coconut fiber pad, grapefruit fiber pad or bamboo fiber pad wrapped with linen, the lower covering layer 11 and the upper covering layer 13 are both linen or chemical fiber cloth, and the fiber batting is cotton, pearl cotton, silk cotton or chemical fiber and other materials.

[0059] Furthermore, the steps and materials used in the aforementioned backrest manufacturing method are essentially the same as those used in the aforementioned sofa cushion manufacturing method, and therefore will not be further described. If the bow-shaped spring sofa also includes armrests 22, the steps and materials used in manufacturing the armrests 22 can also refer to the aforementioned backrest manufacturing method, or to the armrest manufacturing method disclosed in Chinese Patent No. CN200610045054.5. Finally, the fabricated sofa cushion 21, backrest 23, and armrest 22 are assembled into a single unit, completing the bow-shaped spring sofa.

[0060] As shown in FIG12 , Embodiment 1 of a bow-spring sofa according to the present invention includes a sofa seat cushion 21, a backrest 23, and armrests 22. The sofa seat cushion 21, backrest 23, and armrests 22 are manufactured using the aforementioned Embodiment 1 method for manufacturing a bow-spring sofa. Embodiment 1 of the bow-spring sofa according to the present invention may also be a bow-spring sofa without the armrests 22 (not shown).

[0061] Referring to Figures 1 and 2, Example 2 of a method for manufacturing a bow-spring sofa according to the present invention comprises a sofa seat cushion and a backrest. The sofa seat cushion comprises a base frame, a seat cushion base plate 1, and a bow-shaped spring 5. The backrest comprises a backrest frame, a backrest base plate, and a bow-shaped spring 5. The bow spring 5 has a raised arc in the middle, with downwardly bent ends forming curved surfaces. Both ends of the bow spring 5 have U-shaped ends. The method for manufacturing the bow-spring sofa includes methods for manufacturing the sofa seat cushion and the backrest. The sofa cushion manufacturing method and steps of Example 2 are substantially the same as those of Example 1, except that, in Example 2, instead of providing a U-shaped groove 2 on the base frame, a U-shaped groove 2 is provided on the seat cushion base plate 1. The two U-shaped ends of the bow spring 5 are fixedly mounted within the U-shaped groove 2 on the seat cushion base plate 1. The bow spring assembly is then assembled on the seat cushion base plate 1 to form a bow spring assembly. The bow spring assembly is then covered with a lining material and fixed in shape. Finally, the seat cushion base plate 1, after the bow spring assembly is fixed and covered with the lining material, is secured to the base frame. The ends of the bow spring 5 are secured using bow spring fixing members 3, as shown in FIG. The specific fixing method described in Chinese Patent No. CN201920330710.9 can be used. Alternatively, the fixing method described in Chinese Patent No. CN200610045054.5 for bow springs can be used, and thus will not be further described.

[0062] The sofa cushion manufacturing method and steps of Example 2 are basically the same as those of Example 1, so they will not be repeated. Similarly, the manufacturing steps of the backrest manufacturing method in Example 2 are basically the same as the backrest manufacturing method and materials used in the sofa cushion manufacturing method in Example 1, so they will not be repeated.

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

[0064] When the seat cushion base plate 1 is made of a thicker wooden board into a square frame, a mesh shape or a sun shape, in Example 2, the seat cushion base plate 1 after the bow spring assembly is installed and fixed and covered with lining material does not need to be fixed to the base frame, but the seat cushion base plate 1 is directly used as the base frame to assemble the bow spring sofa.

[0065] As shown in FIG12 , Embodiment 2 of a bow-spring sofa according to the present invention includes a sofa seat cushion 21, a backrest 23, and armrests 22. These sofa seat cushion 21, backrest 23, and armrests 22 are manufactured using Embodiment 2 of the bow-spring sofa manufacturing method described above. Embodiment 2 of the bow-spring sofa according to the present invention may also be a bow-spring sofa without armrests 22 (not shown).

[0066] Of course, the above description is not a limitation of the present invention, and the present invention is not limited to the above examples. Any changes, modifications, additions or substitutions made by ordinary technicians in this technical field within the essential scope of the present invention should fall within the scope of protection of the present invention.

Claims

1. A method for manufacturing a bow spring sofa, the bow spring sofa comprising a sofa cushion and a backrest, the sofa cushion comprising a bow spring, a base frame and / or a cushion bottom plate, the backrest comprising a bow spring, a backrest frame and / or a backrest bottom plate, the middle portion of the bow spring is a raised arc, and the two ends are respectively bent downward to form a bending surface, characterized in that: The method for making the bow-shaped spring sofa includes a method for making a sofa cushion and a method for making a backrest, and the method for making the sofa cushion includes the following steps: Step 1: Process and manufacture the base frame and / or the seat cushion base plate; Step 2: longitudinally arrange the bow spring on the base frame or the cushion bottom plate, respectively fix the two ends of the bow spring on the base frame or the cushion bottom plate, connect the four sides of the bow spring with a quadrilateral steel wire frame, and connect the bow springs and the quadrilateral steel wire frame with a horizontally arranged straight steel wire in the middle to form a bow spring assembly; Step 3: The bow-shaped spring assembly is coated layer by layer with lining materials, wherein the lining materials include a lower covering layer, a filling material pad, an upper covering layer and fiber batts from the inside to the outside. The lower covering layer, the filling material pad and the upper covering layer are sequentially covered on the bow-shaped spring assembly, and the lining materials are partially connected and fixed on the bow-shaped spring assembly with needle and thread or a connector to form a preliminarily fixed sofa cushion; Step 4: lift up the periphery of the upper covering layer, fill straw bundles as modeling materials in the front and left and right areas of the upper part of the sofa cushion between the filling material pad and the upper covering layer, then fold the upper covering layer downward to cover the straw bundles, and then use a fixing needle to penetrate the lower covering layer, the filling material pad, the straw bundles and the upper covering layer to preliminarily fix the straw bundles; Step 5: First, use a weeding needle to initially move and gather the straw bundle toward the front edge and left and right edges of the upper part of the sofa cushion, then use a sewing needle and a sewing thread to obliquely thread and knot at a certain distance from the front edge and left and right edges of the upper part of the sofa cushion, and sew the upper covering layer, the straw bundle, the filling material pad and the lower covering layer onto the bow-shaped spring assembly to form the basic shape of the sofa cushion; Step 6: Use a sewing needle and a grass-pulling needle to perform sewing shaping of the sofa cushion. Use the sewing needle and the sewing thread to thread and tie a knot along the front edge of the upper part of the sofa cushion and both sides of the left and right edges. At the same time, use the grass-pulling needle to pull the straw bundle to gather the straw bundle into a columnar shape, and wrap the straw bundle in the upper covering layer to complete the sewing shaping of the sofa cushion. Step 7: Based on the edge shape of the sofa cushion completed in step 6, a sofa cushion cover is tailored, and the sofa cushion cover includes a top surface and three peripheral sides. A surplus edge is left on the inner side of the seam between the top surface and the three side surfaces, and teeth are formed on the outer side of the seam between the top surface and the three side surfaces.

2. The method for making a bow-shaped spring sofa according to claim 1, characterized in that: The method also includes step 8: laying fiber batting on the upper covering layer of the sofa cushion completed in step 6 to make the top surface of the sofa cushion coat flat and shape it into a proper thickness and shape, then turning up the periphery of the sofa cushion coat tailored in step 7 and laying it flat on the sofa cushion, aligning the top surface of the sofa cushion coat with the four corners of the top surface of the sofa cushion, fixing it with a fixing needle, and then threading and knotting along the remaining edge of the inner side of the sofa cushion coat corresponding to the front edge and left and right edges of the upper part of the sofa cushion with a sewing needle and a sewing thread, so that the teeth of the sofa cushion coat and the sofa cushion form an integrated structure, and finally, turning down the periphery of the sofa cushion coat to complete the production of the sofa cushion.

3. The method for making a bow-shaped spring sofa according to claim 1 or 2, characterized in that: In step 3, the lining material is fixed using the connecting parts in the following manner: first, the lower covering layer is wrapped around the outside of the bow spring assembly, the lower covering layer is connected and fixed to the quadrilateral steel wire frame in the bow spring assembly with C-shaped nails sent out from a C-shaped nail gun, the edge of the lower covering layer is fixed to the base frame or the seat cushion bottom plate with nails shot out from a nail gun, and then the filling material pad is covered on the lower covering layer, the filling material pad is connected and fixed to the quadrilateral steel wire frame in the bow spring assembly with C-shaped nails sent out from a C-shaped nail gun, the edge of the filling material pad is fixed to the base frame or the seat cushion bottom plate with nails shot out from a nail gun, and finally, the upper covering layer is covered, and the middle part of the upper covering layer is temporarily fixed with a fixing pin.

4. The method for making a bow-shaped spring sofa according to claim 1 or 2, characterized in that: In step 3, the lining material is connected and fixed by needle and thread in the following manner: first, the lower covering layer, the filling material pad and the upper covering layer are sequentially covered on the bow-shaped spring assembly, the upper covering layer is turned downward, and then a fixing needle is inserted into the periphery of the lower covering layer, the filling material pad and the upper covering layer, and then, a long sewing needle with needle points at both ends and a needle eye at one end and a suture are used to thread the needle and tie a knot along the middle part of the upper covering layer, and the middle part of the upper covering layer, the filling material pad and the lower covering layer are sewn together from top to bottom and fixed on the bow-shaped spring assembly.

5. The method for making a bow spring sofa according to claim 1 or 2, characterized in that: The specific fixing method for longitudinally setting the bow spring on the base frame or the seat cushion bottom plate in the step 2 is: the base frame or the seat cushion bottom plate is made of wood or plastic wood, a U-shaped groove is set at the position where the bow spring is installed on the base frame or the seat cushion bottom plate, and the two ends of the bow spring are set in the corresponding U-shaped grooves, and both ends of the bow spring are U-shaped ends. The two ends of the bow spring are respectively fixed in the corresponding U-shaped grooves by using a bow spring fixing piece, at least one fixing hole is set in the middle of the sheet body of the bow spring fixing piece, and 4 fixing wing pieces extend around the middle, and at least three of the fixing wing pieces have claws bent to the same side at the ends, and the bow spring fixing piece is cross-shaped as a whole.

6. The method for manufacturing a bow spring sofa according to claim 1 or 2, characterized in that: The filling material pad is a palm silk pad, coconut silk pad, grapefruit silk pad or bamboo silk pad wrapped with linen, the lower covering layer and the upper covering layer are both linen or chemical fiber cloth or chemical fiber cloth, and the fiber batt is cotton, pearl cotton, silk cotton or chemical fiber material.

7. The method for manufacturing a bow spring sofa according to claim 1 or 2, characterized in that: The seat cushion bottom plate after the bow spring assembly is installed and fixed and covered with lining material is fixed on 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 and the manufacturing steps and materials used in the sofa cushion manufacturing method are basically the same.

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

10. A bow spring sofa, comprising a sofa cushion and a backrest, characterized in that: The sofa seat cushion and backrest are made by the method for making a bow spring sofa according to any one of claims 1 to 9.

Images