GB2128082A - Beds and other articles of furniture - Google Patents

Abstract

A sprung furniture unit is upholstered and comprises a base (1), a lower spring assembly (7) mounted on the base and an upper spring assembly (16) mounted above the lower spring assembly. The lower spring assembly consists of an array of interconnected upright coil springs (8) while the upper spring assembly consists of an array of pocketed upright coil springs (17). The springs in the upper assembly are more free to be compressed individually than are those in the lower assembly. A flexible diaphragm or insulator (13, 15) is interposed between the upper and lower assemblies. The unit may be used on its own as a bed or other article of furniture or it may constitute a part only of a bed or other article of furniture. For example the unit may be mounted on legs or on a box-like structure which may be provided with drawers. <IMAGE>

Description

SPECIFICATION Beds and other articles of furniture This invention relates to beds and other articles of furniture. In particular it is concerned with a sprung furniture unit which may either constitute a bed or other article of furniture or may form part of a bed or other article of furniture.

Hitherto most beds on the market have been of the kind comprising a mattress supported on a base. In many instances the mattress and the base have each contained an assembly of coil springs. While beds of that kind usually function satisfactorily, they are relatively expensive to manufacture because the mattress and the base each requires to be upholstered separately. One aim of the present invention is to provide a sprung furniture unit such as to enable the disadvantage to be overcome.

The present invention consists in a sprung furniture unit which is upholstered and which comprises a base on which is mounted a lower spring assembly, constituted by an array of interconnected upright coil springs, and an upper spring assembly, disposed above the lower assembly, constituted by an array of pocketed upright coil springs, the assemblies being such that the springs in the upper assembly are more free to be compressed individually than are the springs in the lower assembly.

A sprung furniture unit embodying the present invention may be used on its own as an article of furniture; for example it may be used as a seat for one or more people or it may be used on its own as a bed. Alternatively the unit may have another compo nent or other components associated with it, the arrangement being such that the unit together with that component or those components constitutes a complete article of furniture. For example, a sprung furniture unit embodying the present invention may constitute the seat portion of a sofa or easy chair, which also has a back portion and arm portions.

Alternatively, or in addition, a sprung furniture unit embodying the present invention may be mounted on support means. In particular, a bed may be constituted by a unit of appropriate size in combination with support means for the unit.

The support means for the furniture unit may comprise a plurality of legs, typically four or six in number, which may conveniently carry sliding feet, casters or the like; alternatively the support means may comprise a frame or a plinth or other box-like structure on which the base of the unit is mounted or can be mounted; the use of a box-like structure is particularly suitable when the unit is to form part of a bed. The frame or the plinth or other structure may itself be provided with legs. Sliding feet, casters or the like may be provided on such legs or on the frame or the plinth or other box-like structure itself.

The support means may incorporate or contain a drawer or drawers. When the unit is to form part of a bed, means for attaching a headboard may be provided on the support means or on the unit or on both the support means and the unit. When attach ment means for a headboard is provided on the unit, rather than on the support means, it would usually be necessary to mount the attachment means on a bracket or brackets attached to the base of the unit, for the thickness of the base would usually be insufficient to enable the attachment means to be attached directly to the base. The attachment means may be of the conventional form and comprise four parallel bolts extending horizontally outwards from one end of the bed, the bolts being disposed at the corners of a notional rectangle the longer sides of which are horizontal.Alternatively the sprung unit, with or without support means, may be used as a bed in combination with suitably designed bed ends.

If desired the unit may be used with a decorative surround, which may be upholstered if desired.

When the units are to form part of articles of furniture other than beds, means for attaching arms, backs and other upstanding portions may likewise be provided on the unit or (where support means is provided) on the support means or on both the unit and the support means. The means for attaching such upstanding portions may resemble those for attaching headboards to bed units or they may be of different form. In this way the units may form parts of sofas, chairs, day-beds, chaise longues etc.

When a sprung unit is to be used as a bed or as part of a bed, the height or thickness of the unit would usually be greater than that of a conventional mattress. In one convenient method of use, a removable, fitted sheet is fitted over the unit, its marginal parts extending a short way beneath the unit. For this reason it is preferred to mount the unit on support means such that at least the sides and foot of the unit project beyond the support means and provide space for the marginal parts of a fitted sheet to extend beneath the projecting or overhanging part of the unit. The bed may also be used in conjunction with a quilt, duvet or similar padded covering.When a bed unit embodying the present invention is used in either of the ways outlined above, there is of course no gap resembling the gap between the mattress and the base in a conventional bed and into which the marginal parts of an upper sheet, blanket or other bed-covering can be tucked.

The absence of such a gap is no disadvantage, however, when a fitted lower sheet is employed together with a duvet or the like.

The base of the unit is preferably rigid and preferably comprises a horizontal frame, for supporting marginal parts of the lower spring assembly, and at least one transverse rail, for supporting intermediate parts of the lower spring assembly. The frame may be rectangular. Where more than one transverse rail is provided the transverse rails are preferably mutually spaced apart.

The lower spring assembly preferably comprises an array of individually formed coil, springs, such as Bonnell springs, which are interconnected at both their upper and lower ends by helical wires lying substantially in the planes of the upper and lower surfaces of the array. The helical wires are preferably disposed with their axes horizontal and mutually parallel, and the wires preferably extend between parallel edges of the array. An array of this preferred kind may thus resemble a spring interior of the kind customarily incorporated in mattresses and in divan bases.

A flexible diaphragm or insulator is preferably disposed between the upper and lower arrays of springs so as to prevent direct contact between the upper and lower arrays while permiting loads applied to areas of the upper array to be transmitted to those areas of the lower array immediately beneath them. The diaphragm or insulator may be such as to spread the load from individual coil springs of the upper array over a greater area of the top surface of the lower array. The diaphragm or insulator preferably comprises one or more sheets of bonded plastics fibres.

The upper spring assembly preferably comprises a plurality of individual coil springs each of which is disposed in a flexible fabric pocket, adjacent pockets being joined together. Preferably the pockets are arranged in parallel rows, each pocket in any one row (other than the pockets at the ends of the row) being joined only to the pockets on each side of it in that row. The coil springs are preferably arranged in parallel rows, the springs in each row being uniformly spaced apart, alternate rows being offset longitudinally relative to the intervening rows by a distance equal to half the distance between adjacent springs and the springs being packed together, like the cells of a honeycomb.At least some of the springs of the upper assembly that are adjacent to at least one of the side edges of the unit may be stiffer than springs spaced away from the edges of the unit, so that increased support is given to anyone sitting on the edge of the unit. This arrangement is particularly applicable to units which are to be used as beds or are to be incorporated in beds; it is generally less applicable to units which are to be used as seats or to be incorporated in seats, where it may be preferable for all the springs of the upper assembly to be of the same stiffness.

An embodiment of the present invention will now be described in more detail, by way of example, with reference to the accompanying drawings, in which Figure lisa diagrammatic section through part of a spring furniture unit embodying the present invention and intended for use or for incorporation in a bed, the section being along the line 1-1 of Figure 3, Figure 2 is a perspective view of one corner portion of a frame constituting part of said unit, Figure 3 is a plan view of the portion of the frame shown in Figure 2, together with part of a lower spring assembly, Figure 4 is a plan view of a portion of an upper spring assembly that overlies the portion of the lower spring assembly shown in Figure 3, the tops of pockets being omitted to reveal springs inside the pockets, and Figure 5 is a perspective view of another portion of the unit, with parts omitted and broken away to reveal the structure of the unit.

The sprung unit illustrated is intended for use as part of a single bed; it may be mounted on a box-like support (not shown), in which case the unit and the support together constitute the bed.

The unit includes a rigid base in the form of a rectangular, horizontal frame 1 having side rails 2 and end rails 3. The frame also includes a plurality of mutually spaced transverse rails 4 extending be tween side rails 2 of the frame. The side and end rails 2 and 3 are each of composite construction, compris ing a lower lath 5 and an upper lath 6 secured together. The lower laths 5 of the side rails 2 are wider than the upper laths 6 thereof, so that the lower portions project inwards. End portions of the transverse rails 4 overlie the inwardly projecting parts of the lower laths and are secured to them.

A lower spring assembly 7 is mounted on the frame 1 and comprises an array of Bonnell springs 8 which are disposed with their axes vertical and are interconnected at their upper and lower ends by helical wires 9. Each of the springs 8 is individually formed and is of double-cone or hour-glass shape.

The helical wires 9 embrace portions of the end turns of the springs 8 and are disposed with their axes horizontal and mutually parallel. End portions of the helical wires are bent back on themselves to form 'eyes' so as to prevent the sharp ends of the wires protruding and to prevent the helical wires unwinding from the Bonnell springs 8. The helical wires 9 extend transversely of the unit, that is with their axes parallel with the end rails 3 of the frame. The lower end turns of those of the springs 8 that overlie or overlap parts of the frame are secured to the frame by means of staples 10. The upper end turns of those springs at the edges of the array are secured by means of hog rings 11 to a peripheral strengthening rod 12, which is bent into a rectangular shape.In an alternative construction, which is not illustrated, the strengthening rod 12 is replaced by other helical wires similar to the helical wires 9.

Two metal supporting rods 33 are secured to the top of the frame 1. One of them is spaced a short distance inwards from one of the side rails 2, and the other is similarly spaced from the other of the side rails. The supporting rods are secured to the end rails 3 and the transverse rails 4 by staples 34. Each of the rods extends below an associated outer row of the springs 8, outer edge parts of the lower end turns of the springs overlying the side rails 2, while inner edge parts thereof overly and are supported by the rods 33.

A sheet of flexible material 13 extends over the top of the lower spring assembly 7, and marginal parts thereof extend vertically down the outside of the assembly. The outer edges of those marginal parts are stapled securely to the side rails 2 and end rails 3 by staples 14. A second sheet of flexible material 15 overlies the first sheet 13. Both sheets are made from fibres of polyester bonded together. Together they constitute a flexible diaphragm or insulator.

In an alternative construction, which is not illustrated, the second sheet of flexible material 15 is omitted. In this case the sheet of flexible material 13 alone constitutes the flexible diaphragm.

In another alternative construction, which is not illustrated, not only is the second sheet of flexible material 15 omitted but in addition the marginal parts of the sheet 13 no longer extend down to the side and end rails of the frame. Instead the marginal parts of the sheet 13, which are less extensive than those illustrated, are folded round the strengthening rod 12 and secured immediately beneath the main portion of sheet 13. As in the alternative described above the sheet 13 alone constitutes the flexible diaphragm.

Above the flexiblèsdiaphragm or insulator is mounted an upper spring assembly 16 which comprises an array of upright coil springs 17 each of which is housed in an individual pocket 18 made of pocket cloth, that is a textile fabric such as calico. In the manufacture of the pockets, two strips of pocket cloth are disposed face to face and sewn together at uniform intervals along the strips, the lines of sewing extending transversely of the strips so that they extend vertically in the completed assembly.

Those portions of the strips between each pair of adjacent lines of sewing form the walls of a pocket. A spring 17 is inserted into each pocket and the ends of the pockets are closed. As shown in Figure 4, rows of pocketed springs extend lengthwise of the unit, that is in a direction parallel with the side rails 2. There are thus formed parallel rows of springs uniformly spaced apart. Alternate rows are offset iongitudinally relative to the intervening rows by a distance equal to half the distance between adjacent springs and the springs are packed together, as closely as possible, like the cells of a honeycomb. The rows are held together by soft twine 19 which is sewn to the ends of the pockets in a pattern resembling castellations or a so-called square wave, as indicated in Figure 4.

Marginal parts of the upper sheet 15 of flexible material are folded upwards for a short distance around the sides of the upper spring assembly 16 and are secured to the pocket cloth at the edges of that assembly by hog rings 20. The remainder of the marginal parts are folded downwards and extend, as shown in Figure 1, part way down the sides of the sheet 13 around the lower spring assembly 7. Here they are secured by hog rings 21 to the sheet 13 near the upper surface of the lower spring assembly. If desired the marginal part of the sheet 15may extend to the level of the bottom of the lower spring assembly 7.

As indicated above, however, the upper sheet 15 may be omitted entirely. If it is omitted then the hog rings 20 and 21 will, of course, also be omitted.

If desired the upper spring assembly 16 may be secured to the lower spring assembly 7 by means of hog rings 35. The use of hog rings 35 is particularly suitable in units from which the upper sheet of flexible material is omitted.

It will be observed that the springs 17 of the upper spring assembly 16 are taller than the springs 8 of the lower assembly 7. Those of the upper springs 17 that are adjacent to the sides of the upper assembly 16 are preferably stiffer than the remaining springs so as to provide extra support for anyone sitting on the edge of the unit. Alternatively all of the upper springs 17 are of the same, uniform stiffness. The springs 8 of the lower spring assembly 7 are linked together by the helical wires 9 with the result that depression of any one of those springs tends to cause consequential depression of adjacent springs.

The springs 17 of the upper spring assembly 16, however, are not directly interconnected but are loosely and indirectly interconnected by the pockets 18. In consequence, depression of any one of the springs 17 tends to cause only little if any consequential depression of adjacent springs. Thus the springs in the upper assembly are more free to be compressed individually than are the springs in the lower assembly.

If desired there may be provided a stiffening or locating rod 31 (shown in Figures 4 and 5) which is somewhat similar to the rod 12 but overlies the upper spring assembly 16. Unlike the rod 12, however, the rod 31 is inset from the pripheryof the assembly beneath it, the extent to which it is inset being substantially equal to the diameter of a spring 17. The rod 31 is attached to the assembly 16 by hog rings 32 each of which embraces the rod 31 and extends through the pocket cloth of one or more adjacent pockets 18. The function of the rod 31 is in part to stiffen the peripheral areas of the upper spring assembly 16 and in part to assist in locating the peripheral springs of that assembly. The rod 31, like the rod 12, is sufficiently flexible and resilient to ensure that in normal use of the unit the wire does not become permanently deformed.In an alternative construction (not illustrated) flexible steel strip is used in place of the rod 31.

A sheet 23 of brushed polypropylene overlies the upper spring assembly 16. This is a woven, textile fabric, the upper face of which has been brushed to form a nap. Its marginal parts are secured by hog rings 24 to the pocket cloth around the upper ends of those springs 17 that are at the periphery of the upper spring assembly. On top of the sheet 23 is a layer 36 of garnetted cotton felt. On top of that is a layer 25 of polyurethane foam, and on top of that is a layer 26 of polyester batt or wadding. This layer 26 may be made of a material sold under the trade mark "DACRON". The batt or wadding 26 is preferably surface-bonded, that is the component fibres at its upper and lower surfaces are preferably bonded lightly together. If desired the layer of garnetted cotton felt 36 may be omitted.

Extending around the sides of the assemblies 7 and 16 is first a layer 27 of polyurethane foam and secondly a layer 28 of bonded polyester fibres. The layer 28 is generally similar to but thicker than the sheets of flexible material 13 and 15 constituting the diaphragm or insulator. If desired the layer 28 may be omitted entirely.

The whole assemblage of components described above is encased in a cover 29, made from a textile material such as mattress ticking, which extends over the top and sides of the assemblage. The lowermost parts of the cover are secured to the frame 1. A dust cover 30 of calico or similar textile material extends beneath the frame, its margins also being secured to the frame.

In use the unit is preferably mounted on a plinth, or other box-like supporting structure, which constitutes support means for the unit. The marginal parts of the base preferably project outwards beyond the supporting structure so that the marginal parts of a fitted sheet can extend beneath the overhanging marginal parts of the base as described above. In one convenient arrangement the plinth or other supporting structure is of rectangular shape in plan and is of dimensions such that it can just fit into the interior of the frame 1. The transverse rails 4 of the frame then rest on the top of the support structure, while the lower laths 5 of the frame depend below the level of the top of the support and locate the unit on the support.

As the unit is relatively thick compared with a conventional mattress or divan base, it is envisaged that it would usually be manufactued only in a width corresponding to the width of a singie bed. Two similar units can then be placed side by side for use as a double bed or for use in forming a double bed in combination with suitable support means. The units may be releasably secured together as, for example, by means of zip fasteners.

A range of different units may be provided, differing from one another in the strength of the springs incorporated in them. Units may be finished in different manners; they may have tufts or may be without tufts, as desired, and they may have side stitching or may be without side stitching, as desired.

A unit of substantially the same construction as that described above with reference to the accompanying drawings may also be used as a seat or may serve as the seat portion of an article of furniture in which the unit is incorporated. For example a unit may constitute the seat portion of an easy chair or the seat portion of a sofa. Similarly, one or more units may be incorporated in an article of furniture of the kind that is convertible so that it can be used at one time as a sofa and at another time as a bed.

Where a unit is used in any such manner, the cover 29 would be made of suitable upholstery fabric.

Claims (13)

1. A sprung furniture unit which is upholstered and which comprises a base on which is mounted a lower spring assembly, constituted by an array of interconnected upright coil springs, and an upper spring assembly, disposed above the lower assem biy, constituted by an array of pocketed upright coil springs, the assemblies being such that the springs in the upper assembly are more free to be compressed individually than are the springs in the lower assembly.

2. A sprung furniture unit according to claim 1 in combination with support means on which the unit is mounted or can be mounted.

3. A sprung furniture unit according to claim 2 in which the support means comprises a frame or a plinth or other box-like structure on which the base of the unit is mounted or can be mounted.

4. A sprung furniture unit according to claim 3 in which the support means incorporates or contains a drawer or drawers.

5. A sprung furniture unit according to any one of claims 1 to 4 in which the base of the unit comprises a horizontal frame, for supporting mar ginal parts of the lower spring assembly and at least one transverse rail, for supporting intermediate parts of the lower spring assembly.

6. A sprung furniture unit according to any one of the preceding claims in which the lower spring assembly comprises an array of individually formed coil springs, which are interconnected at both their upper and lower ends by helical wires lying substantially in the planes of the upper and lower surface of the array.

7. A sprung furniture unit according to any one of the preceding claims in which a flexible diaphragm, or insulator, is disposed between the upper and lower arrays of springs so as to prevent direct contact between the upper and lower arrays while permitting loads applied to areas of the upper array to be transmitted to those areas of the lower array immediately beneath them.

8. A sprung furniture unit according to any one of the preceding claims in which the upper spring assembly comprises a plurality of individual coil springs each of which is disposed in a flexible fabric pocket, adjacent pockets being joined together.

9. A sprung furniture unit according to any one of the preceding claims in which the coil springs of the upper spring assembly are arranged in parallel rows, the springs in each row being uniformly spaced apart, alternate rows being offset longitudinally relative to the intervening rows by a distance equal to half the distance between adjacent springs and the springs being packed together.

10. A sprung furniture unit according to any one of the preceding claims in which at least some of the springs of the upper assembly that are adjacent to at least one of the side edges of the unit are stiffer than springs spaced away from the edges of the unit.

11. A sprung furniture unit according to any one of the preceding claims constituting part of a bed, the bed also including support means for the unit, at least the sides and foot of the unit projecting beyond the support means.

12. A sprung furniture unit according to any one of the preceding claims constituting or adapted to constitute a bed or part of a bed, attachment means for a headboard being provided on the unit.

13. A sprung furniture unit substantially as hereinbefore described with reference to the accompanying drawings.