Sofa

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Solution Overview

Problem

The challenge is to reduce the manufacturing cost of sofas without compromising their functionality, particularly by optimizing the structure for easier assembly and transportation.

Innovation Solution

A modular design for sofas with a detachable backrest frame and armrest assemblies, utilizing flexible sheets to cover gaps and a receiving chamber for component storage, which reduces material usage and weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the sofa components are manufactured separately and assembled at a designated location, then the transportation and assembly efficiency is improved, but the manufacturing cost increases due to additional assembly processes and logistics

Engineering Contradiction:

Improveassembly efficiencyVSAvoidmanufacturing cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The backrest frame is integrated directly into the base structure, eliminating the need for separate assembly processes. The backrest frame forms an inherent part of the base, allowing the sofa to be manufactured as a unified structure rather than assembling separate components at the destination.

Inventive Principle:

Principle #5Merging (Combining)

2Stability of the object's composition

If the backrest frame is directly connected to the base, then the structural stability is improved, but the weight and material usage increase

Engineering Contradiction:

Improvestructural stabilityVSAvoidsofa weight

Core Design Contradiction:

Stability of the object's compositionVSWeight of moving object

Solution Approach 1:

A flexible sheet is used to cover the gap between the backrest frame and base, providing structural connection and stability while using minimal material. The flexible sheet spans the gap and maintains the structural integrity without requiring heavy reinforcement or additional support elements.

Inventive Principle:

Principle #30Flexible shells and thin films

3Ease of manufacture

If material usage is reduced to lower costs, then the manufacturing cost decreases, but the comfort and aesthetics may be compromised

Engineering Contradiction:

Improvemanufacturing costVSAvoidcomfort and aesthetics

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The flexible sheet serves multiple functions simultaneously: it covers the gap to maintain aesthetic appearance, provides structural connection to ensure stability, and can be upholstered to maintain comfort. This single element resolves the contradiction by achieving multiple goals with minimal material.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The flexible sheet performs multiple functions: structural connection, gap coverage for aesthetics, and potential upholstery for comfort. By making this single component multi-functional, the design achieves comfort and aesthetics without additional materials while maintaining structural integrity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12551015B2Sofa

Publication Date: 2026.02.17 AUGROUP TECH CO LTD

AI summary

A sofa includes: a base; a backrest assembly including a backrest frame having a front side and a rear side, and a first flexible sheet. The backrest frame is directly or indirectly connected to the base. The backrest frame has a lower end spaced a distance from the base. The first flexible sheet is connected to the front side of the backrest frame and extends from the backrest frame to and detachably connected to the base.