U.S. patent application number 09/829154 was filed with the patent office on 2002-10-10 for futon furniture frame having a single panel of elastomeric support fabric.
Invention is credited to Cantrell, Ralph Allen, Waldrop, Anthony R., Zeiler, Bernhard.
Application Number | 20020145320 09/829154 |
Document ID | / |
Family ID | 25253678 |
Filed Date | 2002-10-10 |
United States Patent
Application |
20020145320 |
Kind Code |
A1 |
Zeiler, Bernhard ; et
al. |
October 10, 2002 |
Futon furniture frame having a single panel of elastomeric support
fabric
Abstract
A futon style sofa bed, preferably made from a metal frame, and
having an elastomeric material stretched to cover the frame. The
elastomeric material obviates the need for support slats, as well
as cushions or a mattress. In a preferred embodiment, the frame
members are made from steel tubing, and the fabric is oriented
within the frame so that the warp direction (the direction of
primary stretch) runs from front to back or from side to side in
the seat frame, and also in the seat back. Adjusting means is
disclosed, for adjusting the length and/or width of the frame, thus
adjusting the tension of the fabric stretched about the frame.
Inventors: |
Zeiler, Bernhard;
(Spartanburg, SC) ; Cantrell, Ralph Allen;
(Chesnee, SC) ; Waldrop, Anthony R.; (Easley,
SC) |
Correspondence
Address: |
Terry T. Moyer
P.O. Box 1927
Spartanburg
SC
29304
US
|
Family ID: |
25253678 |
Appl. No.: |
09/829154 |
Filed: |
April 9, 2001 |
Current U.S.
Class: |
297/284.2 |
Current CPC
Class: |
A47C 17/16 20130101;
A47C 23/12 20130101; A47C 23/005 20130101 |
Class at
Publication: |
297/284.2 |
International
Class: |
A47C 003/025 |
Claims
What is claimed is:
1. An adjustable seating apparatus comprising: a substantially
rectangular first frame having a pair of longitudinal members and a
pair of transverse members; a substantially rectangular second
frame having a pair of longitudinal members and a pair of
transverse members, said second frame pivotally attached to said
first frame along a longitudinal side thereof so that said second
frame may be positioned between a substantially horizontal and a
substantially vertical position; a fabric stretched across both
said first and second frames; and a base frame attached to said
first frame for disposing said first frame in a generally
horizontal orientation.
2. The structure set forth in claim 1, wherein said fabric has
elastomeric qualities.
3. The structure set forth in claim 1, wherein said fabric includes
a hem along each longitudinal side thereof, and wherein each said
longitudinal frame member is disposed within a corresponding
longitudinally disposed fabric hem.
4. The structure set forth in claim 3, wherein said fabric also
includes a hem along each transverse side thereof, and wherein each
said transverse frame member is disposed within a corresponding
transversely disposed fabric hem.
5. The structure set forth in claim 1, further including securing
means for locking said second frame member into either a
substantially horizontal position, or a position substantially
perpendicular to said first frame.
6. The structure set forth in claim 1, wherein said first and
second frame members are adjustable in a transverse direction,
allowing tension on said fabric to be adjusted in a transverse
direction.
7. The structure set forth in claim 4, wherein said first and
second frame members are adjustable in the longitudinal direction,
allowing tension on said fabric to be adjusted in a longitudinal
direction.
8. An adjustable seating apparatus comprising: a generally
rectangular, horizontally oriented first frame member having a pair
of longitudinal portions connected to a pair of transverse
portions; a U-shaped frame member pivotally connected to each end
of one of said longitudinal portions of said first frame member; a
continuous fabric attached to both longitudinal portions of said
first frame member, and also attached to a longitudinal portion of
said U-shaped frame member; and a base member attached to said
first frame for supporting said first frame in an elevated,
generally horizontal position.
9. The structure set forth in claim 8, wherein said fabric has
elastomeric qualities.
10. The structure set forth in claim 8, wherein said fabric
includes a hem along each longitudinal side thereof, and a
centrally positioned, longitudinally disposed hem on an underside
thereof, wherein said longitudinal frame portions of said first
frame and said U-shaped frame are disposed within said
longitudinally disposed fabric hems.
11. The structure set forth in claim 10, wherein said fabric also
includes a hem along each transverse side thereof, and wherein said
transverse portions of said first frame member and said U-shaped
frame member are disposed within said transversely disposed fabric
hems.
12. The structure set forth in claim 8, further including securing
means for locking said U-shaped frame member into either a
substantially horizontal position, or a position substantially
perpendicular to said first frame.
13. The structure set forth in claim 8, wherein said first frame
and said U-shaped frame are adjustable in a transverse direction,
allowing tension on said fabric to be adjusted in a transverse
direction.
14. The structure set forth in claim 11, wherein said first frame
and said U-shaped frame are adjustable in the longitudinal
direction, allowing tension on said fabric to be adjusted in a
longitudinal direction.
15. A method of attaching a fabric material to a rigid frame, said
method comprising the steps of: providing a pair of U-shaped frame
members in pivotal relation, each having two transverse sides and
one longitudinal portion therebetween; positioning said U-shaped
frame members perpendicularly with respect to each other; attaching
a fabric material to said longitudinal portions of each said
U-shaped frame member; positioning said U-shaped frame members in a
horizontal plane with each other; positioning a straight tube
member above said fabric in a longitudinal direction; and attaching
each end of said straight tube member to the point of attachment
between said U-shaped members, so that when said U-shaped members
are placed in a perpendicular position, said straight tube causes
said fabric to assume a similar perpendicular position.
16. A method of attaching a fabric material to a rigid futon frame,
said method comprising the steps of: providing a pair of U-shaped
frame members in pivotal relation, each having two transverse sides
and one longitudinal portion therebetween; positioning said
U-shaped frame members perpendicularly with respect to each other;
attaching a fabric material to said longitudinal portions of each
said U-shaped frame member; attaching a straight tube member to a
central portion of said fabric on an underside thereof, running
between and parallel to said longitudinal portions of said U-shaped
members; and attaching each end of said straight tube member to the
point of attachment between said U-shaped members, so that when
said U-shaped members are raised to a perpendicular position, said
straight tube causes said fabric to assume a similar perpendicular
position.
Description
BACKGROUND OF THE INVENTION
[0001] Traditionally, futon sofas have consisted of a wooden or
metal frame, with a foldable cushion mattress positioned within the
frame. The futon mattress has generally served a dual purpose in
the past, as a seat and backrest when the futon is in the upright
position, as well as being a traditional mattress when the futon is
in the horizontal sleeper position. Conventional futon frames
typically support the mattress by using slats, wooden or metal,
spanning from the front to the back in the seat bottom and from the
top to bottom in the backrest. Because these slats are rigid, they
frequently may be felt by the user in either position, and may
cause discomfort, especially if the user is trying to sleep on the
futon for extended periods. Another problem associated with
traditional style futons is that they cannot be easily disassembled
for purposes of moving the futon or for replacing broken supports.
Further, by employing rigid supports and a mattress, maneuvering
the futon between the sofa position and the bed or sleeper position
may be difficult.
[0002] Therefore, it would be desirable to provide a futon frame
that is more comfortable to a user, and is more easily maneuverable
between the sofa and bed positions. A futon having elastomeric
fabric instead of rigid slats would obviate the need for a separate
mattress, making the futon less expensive to manufacture and to
transport. It would also be desirable to provide a futon that could
be easily assembled and disassembled, so that the futon could be
more easily transported. Further, if the elastomeric support
material became soiled or torn, having a frame that is easily
disassembled would facilitate the removal for cleaning, repair, or
replacement of the support material.
OBJECTS OF THE INVENTION
[0003] Accordingly, an important object of the present invention is
to provide a futon frame structure that includes a single panel of
elastomeric support fabric instead of traditional rigid slats.
[0004] Another important object of the present invention is to
provide a futon frame structure that may be used comfortably
without a separate mattress or cushion being employed in
conjunction with the frame.
[0005] Still another important object of the present invention is
to provide a futon frame structure that is inexpensive to
manufacture, and which is easy to manipulate between the upright
and the horizontal position.
[0006] Another important object of the present invention is to
provide a method of assembling a futon frame and assembly that may
be performed by an ordinary person using a minimum amount of basic
tools or other equipment.
[0007] Yet another important object of the present invention is to
provide an adjustable futon frame structure with elastomeric
support fabric stretched over the frame, so that the tension of the
fabric may be adjusted as desired.
[0008] Still another important object of the present invention is
to provide a novel futon frame and structure that overcomes some of
the problems associated with traditional futon structures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] These and other features, aspects, and advantages of the
present invention will become better understood with regard to the
following description, appended claims, and accompanying drawings
where:
[0010] FIG. 1 is a perspective view showing an embodiment of the
present invention where a rigid, pivotal frame supports an
elastomeric fabric in a seating position;
[0011] FIG. 1A is a perspective view of an alternate embodiment of
the present invention;
[0012] FIG. 2 is a cross-sectional view along the line 2-2 of FIG.
1, showing a connection between a straight tube and a U-shaped
frame member;
[0013] FIG. 3 is a cross-sectional side view along the line 3-3 of
FIG. 1, showing the longitudinal frame members disposed within the
hems of the fabric;
[0014] FIG. 3A is a cross-sectional side view along the line 3-3 of
FIG. 1A, where the fabric is attached to the outer frame members by
means of a hem, and where the central portion of the fabric is
disposed beneath the straight tube member;
[0015] FIG. 4 is a cross-sectional side view along the line 3-3 of
FIG. 1, showing one step in the method of attaching the elastomeric
fabric to the longitudinal portions of the frame, where the outer
longitudinal members are attached first, and the middle
longitudinal member is then attached while the fabric bears no
tension;
[0016] FIG. 4A is a cross-sectional view showing the next step in
the process illustrated in FIG. 4, wherein the upper U-shaped frame
is pivoted to the horizontal position, thereby creating tension on
the fabric;
[0017] FIG. 4B is a cross sectional view showing an alternate next
step to be used in lieu of the next step shown in FIG. 4A, wherein
the middle longitudinal member is pulled into position with a
jacking screw on each end thereof;
[0018] FIG. 5 is a cross-sectional view showing an alternate method
of attaching the fabric where the fabric is only attached to the
two outer longitudinal frame members, and the fabric bears no
tension;
[0019] FIG. 5A is a cross-sectional view showing the next step in
the process illustrated in FIG. 5, where the upper U-shaped frame
is positioned in the horizontal position, and the center
longitudinal frame member is disposed directly above and adjacent
the fabric;
[0020] FIG. 5B is a cross sectional view showing an alternate next
step to be used in lieu of the next step shown in FIG. 5A, wherein
the middle longitudinal member is pulled into position with a
jacking screw on each end thereof;
[0021] FIG. 6 is a cross-sectional close-up view of a mechanism (in
a non-extended position) for making the frame members adjustable in
either a longitudinal or transverse direction, in order to adjust
tension of the fabric;
[0022] FIG. 6A is a cross-sectional view of the embodiment of the
frame shown in FIG. 6, showing the adjustment means in the extended
position;
[0023] FIG. 7 is a perspective view of a base member in accordance
with the embodiment shown in FIGS. 5, 5A and 5B;
[0024] FIG. 8 is a side view along the lines 8-8 on FIG. 7, showing
a ledge and crossbar attached to a leg of an armrest member;
[0025] FIG. 9 is a complete perspective view of the embodiment of
the present invention shown in FIGS. 1, 3, 4, 4A and 4B, which
further includes the base member; and
[0026] FIG. 9A is a perspective view of the embodiment of the
present invention shown in FIGS. 1A, 3A, 5, 5A and 5B, which
further includes the base member.
DETAILED DESCRIPTION
[0027] Generally, the apparatus disclosed herein is a futon style
sofa bed, preferably made from a rigid metal frame, and having an
elastomeric fabric material stretched to cover the frame. This
elastomeric material, which is 100% polyester in a preferred
embodiment, obviates the need for support slats, as well as
cushions or a mattress. It is anticipated that a non-elastic
material may be used in an alternate embodiment of the present
apparatus. The material may be easily installed on the frame by
using a minimum amount of tools, and conversely, the material is
easily removed for cleaning or replacement. In a preferred
embodiment, the frame members are made from steel tubing, and the
fabric is oriented within the frame so that the warp direction (the
direction of primary stretch) runs longitudinally or transversely
in the seat frame, and similarly in the seat back. As used herein,
the term "longitudinal" shall mean the direction from one armrest
to the other, and the term "transverse" shall mean the direction
from the upper portion of the backrest to the lower portion
thereof, and also from the front of the seat portion to the rear
thereof.
[0028] Referring to FIG. 1, a first frame 4 is formed by a straight
tube 6 and a fixed U-shaped frame member 8. A movable U-shaped
frame member 10 is pivotally attached to the first frame 4 on both
ends of the straight tube 6. The first frame 4 forms the seat of
the futon, and the movable U-shaped frame member 10 forms the
backrest that pivots downwardly to a horizontal position, forming a
bed. A fabric 12, preferably having elastomeric qualities, is
attached to the straight tube 6 and the long portions of each of
the U-shaped frame members (herein, collectively called the
longitudinal portions of the frame members).
[0029] The fabric 12 includes longitudinal hems 16 on both
longitudinal sides or ends, and a centrally located hem 16 on an
underside thereof. The longitudinal portions of the frame members
are disposed within the hems 16, which act as sleeves disposed
about longitudinal portions of the frame. Because the material is
preferably elastomeric in nature, there exists a constant bending
load on the longitudinal portions of the frame member, pulling the
outer U-shaped members 8 and 10 inwardly toward the straight tube
6. The elastomeric material is stretched in the frame to between 3%
and 20%, and preferably between 3% and 5%. The stretching of the
material produces a force, preferably having a magnitude of about
five to ten pounds per inch width (measured along the weft
direction), and acting in the warp direction. Although the fabric
12 has been described as being attached to the frame members by
means of hems 16, it is to be understood that any other suitable
attachment means may be employed, such as hook and eyelet means,
adhesion, or the like.
[0030] FIG. 1A shows an alternate embodiment, where the straight
tube 6 is positioned on an upper side of the fabric, as opposed to
having the fabric attached on a backside thereof by means of a hem,
as shown in FIG. 1.
[0031] The straight tube 6 is crimped at either end, as shown in
FIG. 2. The end of the straight tube 6 overlays the fixed U-shaped
frame member 8, and a bolt 18 is passed through the assembly to
secure these members in position. The protruding threaded section
of the socket cap screw 19 in FIG. 2 and the mounting holes shown
in FIG. 1 allow the base frame to be rigidly attached to the
folding mechanism.
[0032] As seen in FIG. 3, the fabric 12 is a single layer with a
hem 16 sewn at the front edge and the back edge (the longitudinal
sides), and one hem 16 sewn on an underside of the fabric 12, near
the center, running parallel to the two longitudinal hems 16. Each
hem 16 is large enough to receive one steel tube frame member. The
tubes are preferably uniform in size, and the hems 16 are
preferably uniform in size, as well. An alternate embodiment is
shown in FIG. 3A, where the fabric 12 only includes two hems 16, at
each longitudinal side. The straight tube 6 in the center is
positioned above the fabric 12 in this embodiment, and is not
received by a central sleeve. As the backrest is placed in the
sitting position, the straight tube 6 retains the fabric 12 in the
proper position, as shown in FIG. 3A.
[0033] A method for installing the fabric 12 onto the frame
includes, in a first embodiment, first attaching both longitudinal
sides of the fabric 12 to the frame by sliding the hems 16 over the
longitudinal frame members, like sleeves. The backrest of the futon
should be in the sitting position during this step. The straight
tube 6, which is unattached to the rest of the frame, is then
placed within the central hem 16 of the fabric 12, as shown in FIG.
4. The backrest of the futon is then moved to the horizontal, or
sleeping, position. As seen in FIG. 4A, this step stretches the
fabric 12 tight, and also moves the straight tube 6 into position
for attachment to the rest of the frame. This method is used for
the embodiment shown in FIG. 3. Alternatively, referring to the
preferred embodiment shown in FIGS. 5 and 5A, when the seat back is
lowered into the sleeping position, the straight tube 6 can be
attached to the rest of the frame directly above and adjacent the
fabric 12, so that when the back is raised into the sitting
position, the fabric 12 wraps around the straight tube 6 and
maintains the prestretch. This method is used for the embodiment
shown in FIG. 3A.
[0034] The stretching method shown in FIGS. 4A and 5A is preferred
when the stretching tension of the fabric is relatively low, or
less than about 5 pounds per inch. For higher fabric stretching
tensions, greater than about 5 pounds per inch, it may be difficult
to lower the seat back, so an alternate stretching method, shown in
FIGS. 4B and 5B is preferred. The fabric is stretched by means of a
pair of jacking screws 17, one screw attached to each end of
straight tube 6, tapered washers 18, and nuts 19. The nuts 19 pull
the straight tube into a position that allows it to be connected to
the rest of the frame, thus stretching the fabric 12.
[0035] As shown in FIGS. 6 and 6A, an adjustment means may be
employed in order to adjust the length or width of the frame. An
adjustment to the length or width of the frame would necessarily
adjust the tension of the fabric 12 stretched about the frame.
FIGS. 6 and 6A show the male/female engagement with a manual
tensioning mechanism built in. Inside the female section 100 is a
shoulder 102 with an engagement hole 104 in the center welded to
the inside diameter of the tube. At the end of the male tube 200, a
nut 202 is welded in and a long threaded socket set screw 204 with
an engaging point 206 is threaded into this nut 202. A bead of weld
208 or screw or limit pin is then applied to the socket set screw
through an access hole (not shown). The male and female sections
are now engaged as shown in FIG. 6. Then, an allen wrench 300, or
the like, may be inserted through the tool hole 210 to engage the
socket set screw 204. The allen wrench may be turned clockwise to
extend the screw, thus forcing the male section partially out of
the female section. When the bead of weld 208 contacts the backside
of the nut 202, it prevents further extension of the screw and the
consequent travel of the male section, as shown in FIG. 6A. Another
bead of weld 34 (or other limiting means such as a limiting screw
or limit pin) may be used to prevent the screw from being removed
from the nut 202. This limited travel mechanism allows a reasonable
amount of engagement between the male/female tube sections to offer
stability to the assembly.
[0036] A folding mechanism is used to facilitate the positioning of
the movable frame in either the vertical position or the horizontal
position. Conventional folding mechanisms are well known in the
art, and it is to be understood that any suitable folding mechanism
may be employed.
[0037] One embodiment of the base member 38 is shown in FIG. 7.
This embodiment of the base member 38 is used in conjunction with
the embodiments shown in FIGS. 3A, 5A and 5B. FIG. 8 shows a side
view along the line 8-8 in FIG. 7, illustrating a leg 40 of the
armrest 42 on the base in combination with the crossbar 44 and the
ledge 46. The ledges 46 are affixed to each leg 40 of the base
member 38 and are used to support the fixed frame of the seat at
all times, as well as the movable frame when it is placed in the
horizontal position.
[0038] FIG. 9 shows the first embodiment of the present invention,
having three longitudinal sleeves for receiving the longitudinal
tubes of the frame members. Transverse hems are also provided for
receiving transverse tubes of the frame members. This embodiment is
preferred when the intent is to eliminate the mattress or other
cushioning material. Longitudinal portions of fixed frame member 8
and movable frame member 10 are bend down and back respectively, as
shown, away from the fabric plane at a sufficient distance to
reduce the likelihood of contact with an occupant sitting or lying
on the fabric 12. The straight tube 6 is also lowered below fixed
frame member 8, and below the fabric plane at a sufficient distance
therefrom to reduce the likelihood of contact with an occupant
sitting or lying on fabric 12. In this embodiment, the fabric is
oreinted such that the direction of primary stretch is parallel to
the longitudinal portion of the frame members, and the fabric is
stretched by means of the mechanism shown in FIGS. 6, 6A &
4B.
[0039] FIG. 9A shows the second embodiment of the present
invention, having only two longitudinal hems in the fabric for
receiving the remote longitudinal frame members. The middle cross
bar 6 is positioned above the fabric 12, as shown.
[0040] The embodiments described herein allow the futon to be
shipped directly to the consumer in a disassembled or partially
disassembled state, which decreases the cost of shipping. Because
the design of the present invention obviates the need for support
slats and cushions or a mattress, the weight and volume of the
product is greatly reduced, which also decreases the cost of
manufacture and shipping. Further, assembly and disassembly
requires only a minimal amount of basic tools, allowing a consumer
to receive the disassembled apparatus and easily assemble it. If
the fabric 12 becomes soiled, frayed, cut, or otherwise mutilated,
or if the styles and personal tastes of the consumers change, the
consumer may easily remove the fabric 12 for cleaning, repair, or
replacement. Also, the frame may be quickly disassembled for
transport. If the fabric 12 becomes loose after extended use, the
adjustment means may be employed to retain the tension necessary
for comfortable use.
[0041] Although the present invention has been described in
considerable detail with reference to certain preferred versions
thereof, other versions are possible. For example, other sizes and
shapes of frame members could be used. Multiple panels of fabric
may be used, and other adjustment means could be employed to adjust
the size of the frame members and thus the tension of the fabric.
Other methods and means of attaching the fabric to the frame may be
employed. Another type of stretchable fabric may be utilized in
place of the polyester elastomeric fabric, such as a rubber
webbing. Even a non-stretchable fabric may be used. Further, the
apparatus and method disclosed and claimed herein may be used in a
variety of different furniture or seating applications, including
adjustable and non-adjustable sofas, chairs, lounge chairs, car
bench seats or car seats. Therefore, the spirit and scope of the
appended claims should not be limited to the description of the
preferred versions contained herein.
* * * * *