Upholstered furniture with integrated back rest portion webbing support
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Solution Overview
Problem
The existing method of manufacturing upholstered furniture backrests is 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 the user.
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 backrest frame, reducing the number of fasteners needed and simplifying the assembly process by attaching 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 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 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 patent performs preliminary action by pre-attaching the webbing to the furniture frame using the staple and fold method before the upholstery sack installation. This ensures the webbing is securely positioned and tensioned in advance, allowing the subsequent sack installation to build upon this prepared foundation rather than requiring simultaneous coordination of multiple attachment operations
2Strength
If webbing is attached to the furniture frame prior to installing the upholstery sack, then proper support structure is established, but a large number of fasteners are required increasing material costs
Solution Approach 1:
The patent merges the fastening functions by having the upholstery sack loose end share the same staples as the webbing attachment. This single set of staples performs dual functions: securing the webbing to provide structural support and anchoring the upholstery sack, thereby reducing the total quantity of fasteners needed while maintaining structural integrity
Solution Approach 2:
The patent applies multi-functionality by designing the webbing channel in the upholstery sack to allow the loose end to be pulled through and stapled to the same location where webbing is already secured. This creates a universal attachment point that serves both the webbing support function and the upholstery sack anchoring function, eliminating redundant fasteners
3Ease of manufacture
If multiple separate components are assembled to construct the back rest, then flexibility in assembly is maintained, but labor costs and assembly complexity increase
Solution Approach 1:
The patent merges multiple assembly operations into a single integrated process. Instead of separately attaching webbing then separately attaching the upholstery sack, the invention combines these operations by designing the sack with a webbing channel that allows the loose end to be pulled through and stapled to the same staples securing the webbing, reducing assembly steps and simplifying the manufacturing process
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.