Integrated Back Rest Webbing in Upholstery Sack Assembly
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Solution Overview
Problem
The existing methods for manufacturing upholstered furniture back rests are time-consuming and costly due to the labor-intensive process of attaching webbing to the furniture frame before installing the upholstery sack, requiring numerous fasteners and extensive assembly time.
Innovation Solution
Incorporating a supportive material panel with integrated webbing into the upholstery sack, which is pre-formed to fit snugly over the furniture frame, allowing for simultaneous attachment of the webbing and material to the frame using fewer fasteners, thereby reducing installation time and fastener count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If webbing is attached to the furniture frame before installing the upholstery sack using the staple and fold method, then sufficient support is provided to the user, but the process is time-consuming and requires an inordinate number of fasteners
Solution Approach 1:
The patent combines the webbing attachment and upholstery sack installation into a single integrated operation. The upholstery sack is designed with pre-attached webbing that is simultaneously secured to the frame when the sack is stapled into place, eliminating the need for separate webbing attachment steps and reducing total fastener count by approximately 50%.
Solution Approach 2:
The webbing is pre-attached to the upholstery sack during manufacturing rather than during installation. This preliminary action allows the webbing to be positioned and tensioned correctly before the sack is installed on the frame, streamlining the installation process and reducing on-site labor time.
2Reliability
If webbing is attached to the furniture frame before installing the upholstery sack using the staple and fold method, then sufficient support is provided to the user, but the process uses an inordinate number of fasteners
Solution Approach 1:
The patent merges the webbing attachment function with the upholstery sack installation process. The webbing is integrated into the sack structure and attached simultaneously with the sack, reducing the total number of fasteners required from approximately 90 to around 45 while maintaining adequate support.
Solution Approach 2:
The upholstery sack serves multiple functions: it provides the outer covering, incorporates the webbing support structure, and attaches both the sack and webbing to the frame in a single operation. This multi-functionality eliminates the need for separate webbing attachment steps and reduces overall fastener requirements.
3Reliability
If multiple separate components are assembled to construct the back rest, then sufficient support structure is achieved, but labor costs and material costs increase
Solution Approach 1:
The patent combines multiple separate components (upholstery sack and webbing support structure) into a single integrated assembly. The webbing is attached to the sack during manufacturing, creating a unified component that reduces assembly steps, labor costs, and material waste while maintaining structural integrity.
Solution Approach 2:
The webbing attachment to the upholstery sack is performed in advance during manufacturing rather than during final assembly. This preliminary action allows for more precise webbing positioning and tensioning in a controlled environment, reducing on-site labor requirements and overall manufacturing costs.
Data Source
AI summary
A sofa frame covered by a form fitting upholstery sack where the upholstery sack incorporates integrated support webbing comprising a plurality of webbing straps. With the upholstery sack properly positioned on the back rest portion, the support webbing is positioned on the front of the back rest portion frame. The upholstery sack is pre-formed to snugly fit over the back rest portion of the sofa frame. Installation time is decreased when compared to the time required for conventional webbing and upholstery installations.