Integrated Webbing Upholstery Sack for Faster Sofa Backrest 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 extensive use of fasteners and labor required for attaching webbing to the furniture frame before installing the upholstery sack, which does not efficiently provide support and comfort to users.
Innovation Solution
Incorporating a supportive material panel with integrated webbing into the upholstery sack, allowing the sack to be pre-formed to fit snugly over the furniture frame, reducing the number of fasteners needed and simplifying the assembly process by attaching the webbing and material as a single unit, thereby decreasing installation time and fastener count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If webbing is attached to the furniture frame using the staple and fold method before installing the upholstery sack, then sufficient support is provided to the user, but the installation process becomes 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 process. The webbing is stapled to the frame first, then the upholstery sack is stretched over the frame and the loose end is pulled through the webbing channel and stapled to the same staples already securing the webbing, eliminating the need for separate attachment steps and reducing total fastener count by approximately 50%
Solution Approach 2:
The webbing is pre-attached to the furniture frame using the staple and fold method before the upholstery sack is installed. This preliminary action ensures the support structure is in place and properly tensioned before the cosmetic covering is applied, allowing the webbing to serve its structural function independently while simplifying the subsequent sack installation
2Reliability
If webbing is attached to the furniture frame using the staple and fold method, then sufficient support is provided to the user, but an inordinate number of fasteners are required
Solution Approach 1:
The patent merges the fastening functions by having the upholstery sack share the same staples as the webbing attachment. The webbing is stapled to the frame, creating a channel, and the sack's loose end is pulled through this channel and stapled to the identical staples, effectively combining two fastening operations into one set of fasteners and reducing the total fastener count by approximately 50%
Solution Approach 2:
The staples serve multiple functions: they secure the webbing to the frame for structural support, create a channel for the upholstery sack's loose end, and simultaneously attach the sack to the frame. This multi-functionality eliminates the need for separate fasteners for webbing and sack attachment, reducing overall fastener complexity and quantity
3Reliability
If conventional webbing and upholstery installation methods are used, then sufficient support and comfort are provided, but labor and material costs increase
Solution Approach 1:
The patent combines the webbing attachment and upholstery sack installation into a single integrated process, where the sack's loose end is pulled through the webbing channel and stapled to the same staples securing the webbing. This merging of operations reduces labor time by approximately 50% and fastener usage by approximately 50%, directly lowering both labor and material costs while maintaining the same support and comfort quality
Data Source
AI summary
A upholstered sofa covered by a form fitting upholstery sack where the upholstery sack incorporates a supportive material panel that has integrated support webbing into the material panel. The support webbing comprising a plurality of webbing straps. With the upholstery sack properly positioned on the back rest portion, the supportive material panel is positioned on the front of the back rest portion frame. The material panel with webbing is incorporated as a component of the upholstery sack where the upholstery sack is pre-formed to snugly fit over the back rest portion of a furniture frame. The back rest portion or the frame is inserted into the sack and the material panel with integrated webbing is attached to the frame. Once the material panel is positioned and fastened, the remaining components, for example, the back panels and side panels, of the upholstery sack are attached to the frame at the back rest portion. Due to the construction of the material panel with webbing, installation time is decreased when compared to the time required for conventional webbing and upholstery installations.