Futon frame and support system

Abstract

A futon support comprises a frame member defining an outer boundary of a region and a bar positioned to lie in the region and including first and second ends coupled to the frame member and spaced apart longitudinally from one another. The bar further comprises first and second flat sections configured to contact a futon to support the futon in a selected position and a bight coupled to the first and second flat sections to reinforce the first and second flat sections when a load is applied to the futon.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application Ser. No. 60/194,131, filed Apr. 3, 2000, which is expressly incorporated by reference herein.

BACKGROUND AND SUMMARY OF THE INVENTION

[0002] The present invention relates to furniture, and particularly to a frame assembly and cushion support system for furniture. More particularly, the present invention relates to a futon support for supporting a futon.

[0003] A futon support and a futon cooperate to offer the advantages of several pieces of furniture in one. For example, a futon user may position a futon support and an associated futon for couch or chair use for general use, and then rearrange the futon support and futon into a bed when such a use is desired. Those components may also be arranged to provide for other positions.

[0004] Futon supports are constructed of either a metal or wood material. Futon support manufacturers desire to provide sufficient mattress support for various positions while simultaneously providing comfort for the user in each of the positions. When metal has been used in futon support construction, cushion support has been provided by a frame including rounded tubular members welded together. Larger tubular members typically make up the frame of the futon support, while smaller tubular members typically span between the larger members to form a support structure for the cushion.

[0005] According to the present invention, a futon support includes a frame and a bar including a first end coupled to the frame and a second end coupled to the frame and spaced apart longitudinally from the first end. The bar further includes a first flat section configured to contact a futon to support the futon in a selected position, a second flat section configured to contact the futon to support the futon in the selected position in cooperation with the first flat section, and a bight coupled to the first flat section and the second flat section to reinforce the first flat section and the second flat section so that the flat section and the second flat section can support the futon when a user of the futon applies a load to the futon.

[0006] In preferred embodiments, the first flat section and the second flat section are positioned to lie in transversely spaced-apart, co-planar relation to one another. The first flat section, the second flat section, and the bight extend from the first end of the bar to the second end of the bar. The bight is serpentine-shaped and is centrally located in the cross-section of the bar. Each flat section extends from either side of the bight.

[0007] Additional features of the present invention will become apparent to those skilled in the art upon consideration of the following detailed description of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The detailed description particularly refers to the accompanying figures in which:

[0009] FIG. 1 is a perspective view of a futon assembly having a futon or cushion, a frame, and bars spanning between members of the frame to provide support to the frame and cushion in accordance with the present invention;

[0010] FIG. 2 is a top view of a bar of FIG. 1 showing two flat zones extending the length of the bar and a serpentine zone located between the flat zones and similarly extending the length of the bar;

[0011] FIG. 3 is a cross sectional view of the bar of FIG. 2 showing the preferred embodiment of the serpentine zone to have a bight and a width, and the flat zones extending from the serpentine zone by a distance equal to a fraction of the width of the serpentine zone;

[0012] FIG. 4 is a view of the bar of FIG. 2 mounted to the tubular frame of the futon assembly of FIG. 1;

[0013] FIG. 5 is a section view of the futon assembly of FIG. 1, showing the relative placement of the bars on the futon frame and the support provided by the bar's flat zones to the futon cushion;

[0014] FIG. 6 is another top view of the bar of FIG. 2;

[0015] FIG. 7 is a front elevational view of the bar of FIG. 2;

[0016] FIG. 8 is a rear elevational view of the bar of FIG. 2;

[0017] FIG. 9 is an end view of the bar of FIG. 2;

[0018] FIG. 10 is another end view of the bar of FIG. 2 and a mirror image of the end view of FIG. 9; and

[0019] FIG. 11 is a bottom view of the bar of FIG. 2.

DETAILED DESCRIPTION OF THE DRAWINGS

[0020] A futon assembly 10 includes a futon support 11 and a futon or cushion 12, as shown, for example, in FIG. 1. Futon support 11 is configured to support cushion 12 using beams or bars 14 (shown in more detail in FIGS. 2 and 3) coupled to tubular frame members 16 in the manner shown, for example, in FIGS. 4 and 5. Each beam 14 is formed to include a cross-sectional serpentine zone 18, and two flat zones 20 extending therefrom, as shown, for example in FIG. 3. The flat zones 20 provide increased supportive surface area for the cushion 12, to provide added comfort and support for a futon user. The serpentine zone 18 provides structural support to beam 14 so that the beam does not fatigue under the force of the weight of the user.

[0021] A futon support 11 includes a top frame 15 and a bottom frame 17 coupled to top frame 15. Rails 70 of futon support 11 support bottom frame 17, as shown, for example, in FIG. 1 with respect to one of rails 70. The top and bottom frames 15, 17 include tubular members 16 and bars 14 that span between tubular members 16 to support the cushion 12, as shown in FIG. 1. The top frame 15 forms the back of the futon when in the sitting position, and cooperates with a connector or linkage 19 to recline to an alternate bed position (not shown), wherein top frame 15 is parallel to bottom frame 17. A preferred embodiment of bar 14 is shown in FIG. 2 as a modified flatstock steel bar having a length, width, and thickness, bar 14 being placed in futon support 11 such that each end of the length of bar 14 is coupled to a tubular member 16.

[0022] Tubular members 16 include a first frame member 16a and a second frame member 16b. First frame member 16a defines an outer boundary of a first region 40. Second frame member 16b defines an outer boundary of a second region 42. A first set 44 of bars 14 is positioned to lie in first region 40 and is coupled to first frame member 16a. A second set 46 of bars 14 is positioned to lie second region 42 and is coupled to second frame member 16b.

[0023] A cross-section of the width 21 of one of the bars 14 is shown in FIG. 3. The cross section of bar 14 is a modified flatstock that includes a serpentine zone 18 and a flat zone 20 extending from each end of the serpentine zone 18. The serpentine zone 18 includes a single bight 22 that extends outwardly from the flat zone approximately one third of an outside diameter 60 of a tubular member 16. As shown best in FIG. 3, bight 22 includes a “positively sloping” first quarter round section 22a having a first radius of curvature 30, an “inverted” half round middle section 22b having a radius of curvature 32 that is smaller than radius of curvature 30, and a “negatively sloping” second quarter round section 22c having a radius of curvature 34 that is equivalent to radius of curvature 30. Bight 22 defines two points of inflection 62. As shown in FIG. 3, flat zones 20 include a first flat section 20a and a second flat section 20b positioned to lie in transversely spaced-apart, co-planar relation to first flat section 20a so as to define a common plane 64. The components 20a, 22a, 22b, 22c, and 20b are arranged in series to give bar 14 its characteristic cross-sectional shape.

[0024] It is within the scope of this disclosure to vary shape of sections 22a, 22b, 22c and length of radii 30, 32, 34 to vary the appearance of bight 22. The presently preferred embodiment of bar 14 is manufactured to have the following approximate dimensions: a width 21 of ⅞ inch, a height 23 of {fraction (7/16)}, a thickness 25 of {fraction (1/16)}, a width of serpentine zone 18 of {fraction (11/16)}, and a width of each flat zone 20 of {fraction (3/32)}. For example, it is possible to form serpentine zone 18 with a plurality of bights, with a differently proportioned bight, or with any other construction that provides sufficient support to the bar 14, all of which are within the scope of this disclosure.

[0025] A flat zone 20 extends from either side of serpentine zone 18, as shown by FIG. 3. The flat zone 20 has an inside surface 24 facing away from the bight 22, the inside surface contacting and supporting cushion 12, as shown in FIG. 5. Each flat zone 20 need only extend a fraction of the width of serpentine zone 18 from either side of serpentine zone 18 to provide adequate comfort to a futon user. However, greater widths of each flat zone 20 are possible, and are within the scope of this disclosure.

[0026] First flat section 20a includes a first outer edge 52 and a first inner portion 54 coupled to first quarter round section 22a. First inner portion 54 is positioned to lie transversely inwardly of first outer edge 52.

[0027] Second flat section 20b includes a second outer edge 56 and a second inner portion 58 coupled to second quarter round section 22c. Second inner portion 58 is positioned to lie transversely inwardly of second outer edge 56.

[0028] Each bar 14 includes a first end 48 and a second end 50. Each end 48, 50 of bar 14 is coupled to one of first frame member 16a and second frame member 16b, preferably by welding, as shown in FIG. 4. Welding allows for greater tolerances and therefore promotes improved productivity and quality in the futon. In the preferred embodiment, as shown in FIG. 5, the bars 14 are spaced apart by a distance 26 that is approximately equal to four times the width 21 of the bar 14, or 3½ inches. This spacing distance, improves the comfort and support of the futon.

[0029] Another top view of the bar of FIG. 2 is shown in FIG. 6 and shows the flat zones extending the length of the bar and the serpentine zone disposed between the flat zones and similarly extending the length of the bar. FIGS. 7 and 8 show front elevational and rear elevational views of the bar of FIG. 2, respectively. FIGS. 9 and 10 show end views of the bar of FIG. 2, and FIG. 11 is a bottom view of the bar of FIG. 2.

[0030] Bars 14 cooperate with top frame 15 and bottom frame 15 to provide a comfortable and cost effective cushion support system for a futon frame. The modified flatstock support bars provide a large surface area for contacting and supporting the cushion, and the bars are placed in close proximity to each other, therefore yielding an adequate cushion supporting surface area. Thinner (than normal) cushions can be used on a futon frame made using bars 14, to promote reduced freight charges and reduced manufacturing charges without sacrificing the comfort of a person seated on the futon.

[0031] Although the invention has been described in detail with reference to preferred embodiments, variations and modifications exist within the scope and spirit of the invention as defined and defined in the following claims.

Claims

1. A futon support comprising

a frame including a first frame member defining an outer boundary of a first region and a second frame member defining an outer boundary of a second region,

a connector coupled to the first frame member and the second frame member so that the first frame member is movable relative to the second frame member,

a first set of bars positioned to lie in the first region, and

a second set of bars positioned to lie in the second region, each of the bars of the first set of bars and the second set of bars including a first end and a second end spaced apart longitudinally from the first end, the first end and the second end of each of the bars of the first set of bars being coupled to the first frame member, the first end and the second end of each of the bars of the second set of bars being coupled to the second frame member, each of the bars of the first set of bars and the second set of bars including a first flat section configured to contact a futon to support the futon in a selected position, a second flat section configured to contact the futon to support the futon in the selected position in cooperation with the first flat section and positioned to lie in transversely spaced-apart, co-planar relation to the first flat section, and a bight that is serpentine-shaped and coupled to the first flat section and the second flat section to reinforce the first flat section and the second flat section so that the first flat section and the second flat section can support the futon when a user of the futon applies a load to the futon.

2. The futon support of

claim 1, wherein the first flat section of each bar includes a first outer edge and a first inner portion that is positioned to lie transversely inwardly of the first outer edge, the second flat section of each bar includes a second outer edge and a second inner portion that is positioned to lie transversely inwardly of the second outer edge, and the bight of each bar extends from the respective first inner portion to the respective second inner portion.

3. The futon support of

claim 1, wherein the bight of each bar includes a positively sloping first quarter round section coupled to the respective first flat section and having a first radius of curvature.

4. The futon support of

claim 3, wherein the bight of each bar further includes an inverted half round middle section having a second radius of curvature that is smaller than the first radius of curvature.

5. The futon support of

claim 4, wherein the bight of each bar further includes a negatively sloping second quarter round section coupled to the respective second flat section and having a third radius of curvature that is equivalent to the first radius of curvature.

6. The futon support of

claim 5, wherein the bight of each bar further includes a negatively sloping second quarter round section coupled to the respective second flat section and having a third radius of curvature that is equivalent to the first radius of curvature.

7. The futon support of

claim 1, wherein the first flat section, the second flat section, and the bight of each bar cooperate to define a width of the respective bar, and adjacent bars of one of the first set of bars and the second set of bars are spaced apart about four times the width from one another.

8. A futon support comprising

a frame member defining an outer boundary of a region, and

a bar positioned to lie in the region and including a first end coupled to the frame member, a second end coupled to the frame member and spaced apart longitudinally from the first end, a flat zone configured to contact the futon and including a first outer edge and a second outer edge spaced apart transversely from the first outer edge, and a serpentine zone coupled to the flat zone at a location spaced apart from the first outer edge and the second outer edge to reinforce the flat zone so that the flat zone can support the futon when a user of the futon applies a load to the futon.

9. The futon support of

claim 8, wherein the flat zone includes a first flat section and a second flat section positioned to lie in spaced-apart, co-planar relation to one another to define a common plane.

10. The futon support of

claim 9, wherein the first flat section includes the first outer edge and a first inner portion positioned to lie transversely inwardly of the first outer edge, the second flat section includes the second outer edge and a second inner portion positioned to lie transversely inwardly of the second outer edge, and the serpentine zone extends from the first inner portion to the second inner portion.

11. The futon support of

claim 10, wherein the serpentine zone includes a bight that includes a positively sloping first quarter round section coupled to the first inner portion and having a first radius of curvature, an inverted half round middle section having a second radius of curvature that is smaller than the first radius of curvature, and a negatively sloping second quarter round section coupled to the second inner portion and having a third radius of curvature that is equivalent to the first radius of curvature.

12. The futon support of

claim 9, wherein the serpentine zone includes a bight that extends from the first flat section to the second flat section and outwardly from the common plane to support the first flat section and the second flat section.

13. The futon support of

claim 8, wherein the serpentine zone includes a bight that includes a positively sloping first quarter round section coupled to the flat zone and having a first radius of curvature.

14. The futon support of

claim 13, wherein the bight further includes an inverted half round middle section having a second radius of curvature that is smaller than the first radius of curvature.

15. The futon support of

claim 14, wherein the bight further includes a negatively sloping second quarter round section coupled to the flat zone and having a third radius of curvature that is equivalent to the first radius of curvature.

16. The futon support of

claim 13, wherein the bight further includes a negatively sloping second quarter round section coupled to the flat zone and having a third radius of curvature that is equivalent to the first radius of curvature.

17. A futon support comprising

a frame, and

a bar including a first end coupled to the frame, a second end coupled to the frame and spaced apart longitudinally from the first end, a first flat section configured to contact a futon to support the futon in a selected position, a second flat section configured to contact the futon to support the futon in the selected position in cooperation with the first flat section and positioned to lie in transversely spaced-apart, co-planar relation to the first flat section, and a bight coupled to the first flat section and the second flat section to reinforce the first flat section and the second flat section so that the first flat section and the second flat section can support the futon when a user of the futon applies a load to the futon.

18. The futon support of

claim 17, wherein the bight is serpentine-shaped.

19. The futon support of

claim 18, wherein the bight defines two points of inflection.

20. The futon support of

claim 17, wherein the bight includes a positively sloping first quarter round section coupled to the first flat section and having a first radius of curvature.

21. The futon support of

claim 20, wherein the bight further includes an inverted half round middle section having a second radius of curvature that is smaller than the first radius of curvature.

22. The futon support of

claim 21, wherein the bight further includes a negatively sloping second quarter round section coupled to the second flat section and having a third radius of curvature that is equivalent to the first radius of curvature.

23. The futon support of

claim 20, wherein the bight further includes a negatively sloping second quarter round section coupled to the second flat section and having a third radius of curvature that is equivalent to the first radius of curvature.

24. The futon support of

claim 17, wherein the first flat section and the second flat section cooperate to define a common plane, the frame includes a tubular member that includes a diameter, and the bight extends from the first flat section and the second flat section away from the common plane a distance that is about one-third of the diameter of the tubular member.

25. The futon support of

claim 17, wherein the bight extends longitudinally from the first end to the second end.

26. The futon support of

claim 17, wherein the first flat section and the second flat section extend longitudinally from the first end to the second end.

27. A futon support comprising

a frame member defining an outer boundary of a region, and

a bar positioned to lie in the region and coupled to the frame member, the bar including first means for contacting a futon to support the futon in a selected position, second means for contacting the futon to support the futon in the selected position in cooperation with the first means, and means for reinforcing the first means and the second means so that the first means and the second means can support the futon in the selected position when a user of the futon applies a load to the futon, the first means and the second means being spaced apart transversely from one another, the reinforcing means being coupled to the first means and the second means.

28. The futon support of

claim 27, wherein the reinforcing means is serpentine-shaped and extends from the first means to the second means.

29. The futon support of

claim 27, wherein the reinforcing means includes a bight that includes a positively sloping first quarter round section coupled to the first means and having a first radius of curvature.

30. The futon support of

claim 29, wherein the bight further includes an inverted half round middle section having a second radius of curvature that is smaller than the first radius of curvature.

31. The futon support of

claim 30, wherein the bight further includes a negatively sloping second quarter round section coupled to the second means and having a third radius of curvature that is equivalent to the first radius of curvature.

32. The futon support of

claim 29, wherein the bight further includes a negatively sloping second quarter round section coupled to the second means and having a third radius of curvature that is equivalent to the first radius of curvature.

33. The futon support of

claim 27, wherein the first means includes a first outer edge and a first inner portion positioned to lie transversely inwardly of the first outer edge and the reinforcing means is coupled to the first inner portion.

34. The futon support of

claim 33, wherein the second means includes a second outer edge and a second inner portion positioned to lie transversely inwardly of the second outer edge and the reinforcing means is coupled to the second inner portion.

35. The futon support of

claim 27, wherein the reinforcing means includes a bight coupled to the first means and the second means.

36. The futon support of

claim 35, wherein the bar includes a first end and a second end spaced apart longitudinally from the first end and the bight, the first means, and the second means extend from the first end to the second end.

37. The futon support of

claim 27, wherein the first means includes a first flat section and the second means includes a second flat section positioned to lie in co-planar relation to the first flat section.