US3252735A

US3252735A - Basic cushion construction

Info

Publication number: US3252735A
Application number: US328431A
Authority: US
Inventors: Jr Arthur Osborne Smith
Original assignee: BENJAMIN T CRUMP CO Inc
Current assignee: BENJAMIN T CRUMP CO Inc
Priority date: 1963-12-05
Filing date: 1963-12-05
Publication date: 1966-05-24
Anticipated expiration: 1983-05-24

Description

May 24, 1966 A. 0. swam-a, JR

BASIC CUSHION CONSTRUCTION 4 Sheets-Sheet 1 Filed Dec. 5, 1963 INVENTOR AWMW' m'fiome J'mz'Z/z, (ff:

ATTORNEYJ M M M m y 1966 A. 0. SMITH, JR 3,252,735

BASIC CUSHION CONSTRUCTION Filed Dec. 5, 1963 4 Sheets-Sheet 2 INVENTOR 6 AMM" UMame Jmzi/WE ATTORNEYJ' May 24, 1966 A. 0. SMITH, JR 2 BASIC CUSHION CONSTRUCTION Filed Dec. 5, 1963 4 Sheets-Sheet 5 INVENTOR May 24, 1966 A. 0. SMITH, JR 3,252,735

BASIC CUSHION CONSTRUCTION Filed Dec. 5, 1963 4 Sheets-Sheet 4 INVENTOR Ari/m2 ommemm'mcm ATTORNEYS United States Patent 3,252,735 BASIC CUSHION CONSTRUCTION Arthur Osborne Smith, .Ir., Richmond, Va., assignor to Benjamin T. Crump Company, Incorporated, Richmond, Van, a corporation of Virginia Filed Dec. 5, 1963, Ser. No. 328,431 2 Claims. (Cl. 297-452) This is a continuation-in-part application of my now pending application entitled Ottoman, Hassock or Similar Article, Serial No. 243,238, filed December 10, 1962, now abandoned.

The present invention relates to a basic cushion construction and more particularly to such a device that has two dimensions only including a horizontal support member that could be used in combination with legs, hinges, backs or any other type of furniture construction.

It is an object of the present invention to provide a novel cushion construction or the like that has a horizontal frame with support or reinforcement means adjacent the periphery of the frame for attaching legs, hinges, backs, or other means thereto.

It is another object of the present invention to provide a novel cushion construction consisting of a horizontal frame member that may be square, rectangular, triangular or circular and which frame member is provided with brace means fixed to the frame to reinforce it at the points thereof where the leg or other members are joined.

It is another object of the present invention to provide a novel cushion construction or the like having a horizontal portion for supporting an object or a person thereon and a plurality of legs or other members for supporting the horizontal portion with resilient means extending between or across the frame portion, which frame portion and resilient members are encapsulated or embedded within plastic material so as to be completely covered thereby to form an integral unit therewith for supporting comfortably the weight of a person thereon or an object thereon.

It is another object of the present invention to provide a novel type of furniture consisting of a horizontal peripheral tubular frame with resilient spring members extending between the frame, and horizontal brace members fixed to the frame for reinforcing it adjacent the points thereof to which the vertical legs or other members are attached.

It is another object of the present invention to provide a cushion construction for supporting a weight thereon provided with novel triangular shaped or enlarged reinforcement portions adjacent the frame at the points thereof where the legs or other members are attached.

It is another object of the present invention to provide a two-dimensional furniture cushion which can be used as an ottoman or hassock in combination with leg members, which further has reinforcement means adjacent the periphery of the frame member, whether it be circular or of other configuration to reinforce the frame to avoid any permanent twisting, bending or distortion thereof and which frame and reinforcement members are completely encapsulated in a plastic material.

It is another object of the present invention to provide a novel cushion construction consisting of a tubular annular frame provided with triangular brace means which serve to reinforce the annular frame means, and which frame means and reinforcement means are encapsulated in a foam material so that the plastic material and the other portions of the cushion form an integral unit that will comfortably support the weight of a person thereon without any distortion or weakness therein when the legs or other members are attached to the cushion and the weight of a person is supported thereon.

It is another object of the present invention to provide a novel cushion construction having a frame support that is made of channel members that can be readily con nected together to form an integral unit, and which channel members are provided with enlarged reinforcement means adjacent the portions thereof to which the legs or other members are fastened, and which channel members are further provided with resilient springy means extending across or between the channel members and the resilient means and channel members completely encapsulated within a foam plastic material so as to provide a comfortable piece of furniture for receiving the weight of a person thereon while permitting the cushion to have some flexibility and resiliency without causing the cushion frame to be stressed beyond its modulus of elasticity.

Various other objects and advantages of the present invention will be readily apparent from the following detailed description when considered in connection with the accompanying drawings forming a part thereof and in which:

FIGURE 1 is a perspective view of cushion being used as an ottoman partly broken away to illustrate the frame and reinforcement members and the resilient spring members that are encapsulated within the plastic material to form a rigid yet resilient structure therewith;

FIGURE 2 is a perspective view of a modified form of the reinforcement means embodied in the present invention;

FIGURE 3 is a detail view of the notch means in the tubular frame member of FIGURE 1 for attaching a resilient spring member to the frame;

FIGURE 4 is another modification of the frame and reinforcement means embodied in the present invention;

FIGURE 5 is an enlarged detailed view in plan of the reinforcement means embodied in the invention shown,

in FIGURE 4;

FIGURE 6 is a detail view of the connector member that is utilized to join two separate channel members of the frame together;

FIGURE 7 is an enlarged sectional view taken along lines 7-7 of FIGURE 4 but with the frame member shown encapsulated in plastic material;

FIGURE 8 is an elevation of an ottoman using the basic cushion construction;

FIGURE 9 is an elevation of a modified ottoman using the basic cushion construction;

FIGURE 10 is a sectional view showing a modification of the encapsulating material.

Referring to the drawings, the reference numeral 10 generally designates the basic cushion construction of a two-dimensional structure as used in this invention is meant to mean a structure which has its supporting surface substantially located in one and only one place. This type of furniture is distinguished from a threedimensional structure in which there is another portion or member formed integral with the horizontal member or portion of the furniture that extends vertically upwardly therefrom. An example of such a three-dimensional type of furinture would be a chair with either a back or a back and arms, such as chairs used in living rooms, dining rooms, kitchens, and the like.

The cushion 10 is provided with a tubular rectangular or square frame 11 that is preferably made of one piece by forming the tubular member 11 as shown in FIGURE 1 and bringing the two free ends of the member together and brazing or welding them so that it forms a single continuous horizontal frame. The tubular frame .11 is preferably solid in cross section as shown in FIGURE 3 and is provided with vertical notches 12 disposed midway between each corner 13. The corners 13 are provided with a radius so that they are rounded smoothly and there will be no sharp bends or weak points in the frame structure adjacent the corners. Resilient spring members 14 extend between the opposite sides or side walls 15 forming the tubular frame 11. Each spring member 14 consists of a vertical open-end loop 16 that is disposed in a notch 12 in the tubular frame and a plurality of U-shaped, cross sections 17. The U-shaped loops or sections 17 are disposed to face in opposite directions as is clearly shown in FIGURE 1 and the resilient spring member 14 is made of stout wire and is of sufficient length so that the end loops 16 when disposed or mounted over the tubular frame 11 in their notches will not readily be dislodged therefrom. Each spring member 14 crosses at right angles with another spring member 14 extending between the opposite sides of the frame 11 as shown in FIGURE 1. The U-shaped loops 17 of each spring member 14 extending between the oppositely disposed sides of the tubular frame 11 are in contact with each other so as to reinforce and strengthen the portion of the cushion farthest removed from the tubular frame member 11.

The tubular frame 11 adjacent the corner section or portion 20 is provided with frame reinforcement means consisting of a diagonal brace or strut 21 welded at the opposite end to the tubular frame and in spaced relationship with the corner portion 20' so as to form the base 22 of a triangle with the adjacent opposite sides of the frame indicated at 23 forming the sides of the triangle. A leg or other member support member 24 consisting of a plate substantially rectangular in shape, except for its outer end 25 which has the same configuration as the corner portion 20 extends between the frame 11 and the brace member 21, and is in the same plane therewith and is welded to the corner portion 20 and the brace 21 to form a rigid stnucture therewith.

Each support plate or member 24 is provided with a circular recess or counter sink 26 therein which is offset, inclined or titled with respect to a frame plane so that the inner surface or side wall 27 of the counter sink is longer or deeper than the outer side wall thereof. The circular bottom 30 of the counter sink 26 projects below the outer surface or the underside of the plate 24 and is titled or extends at an angle or inclination toward the center of the frame to provide a circular seating surface for any type of engaging members. The center 30 of countersink 26 is provided with an upturned central nipple or boss 33 that is internally threaded to receive therein the threaded screw member 34 fixed to the engaging member.

From the foregoing description, it is apparent that the frame 11 and the triangular frame reinforcement means and the resilient spring members may be easily constructed and fabricated and requires a minimum amount of skill and labor and time in the manufacture thereof. After the frame has been constructed, it is inserted into a mold cavity, the surfaces of which are designed to define the planar portion of the two-dimensional cushion. The frame is positioned within a mold on spaced cores and the like which do not form part of this invention in order to properly position the frame 11, braces, and plates and the spring members 14 so that they will be completely encapsulated with a foam plastic material when the mold is closed and the material is introduced into the mold to fill up the entire mold cavity. If the entire plate is encapsulated, the encapsulating material must be punctured by the screw means on the engaging member; however, the bottom of the counter 26 can be left exposed driving the encapsulating process and the necessity of puncturing the foam material would be eliminated. The foam plastic material may be of any suitable well known composition, but is preferably of foam polyurethane. The mold is preferably of a configuration to give the square body shape 40 shown in FIGURE 1 upon which an object is placed or a person may comfortably seat himself thereon. After the foam material has set or hardened, the mold is opened and the molded cushion is removed therefrom.

It will be noted that the cushion is of such a configuration that the molded body 40 completely overlaps or extends beyond the tubular frame 11 and encloses the braces 21, the support plate 24 and the counter sink 26. The screw members 34 that extend into nipple are of sufiicient length so as to be readily threaded through the threaded nipple 33 and extend slightly thereabove. Preferably, the mold is also cored so that the undersurface or the bottom of circular wall 30 is just slightly covered with a thin film of the plastic. This permits engaging members to extend into recesses in body 40 in alignment with the bottom 30 and seat flush against the countersinks 26 so that said members extend diagonally outwardly instead of having a substantially vertical arrangement.

Complete encapsulation of the frame and reinforcement means, the counter sinks and the spring members provides a method of using material that may be economical in the cushion since the tubular frame and the other parts may be made of iron or steel, as they will not be exposed to the atmosphere and therefore will not corrode. Thus, it is not necessary to use a more expensive material such as aluminum or other noncorrosive material in forming the horizontal frame structure. Also, the materials that are used in the cushion frame do not have to be highly machined, and any burrs or rough surfaces left from brazing and welding do not have to be removed as it will not endanger a person coming into contact with the encapsulated cushion nor will they cause any unpleasing appearance.

Thus, from the foregoing description, it is readily apparent that the cushion structure of the present invention provides a somewhat simplified frame for furniture that has an annular skeletal frame with resilient spring means extending between or across the annular frame and with other rigid reinforcement brace and plate means rigidly attached to the periphery or corners of the frame to prevent it from being twisted or distorted upon receiving a person or a weight so that it will not exceed its modulus of elasticity or cause permanent bends and distortions therein out of alignment with its natural free state horizontal disposition.

The provision of the triangular shaped reinforcement means adjacent the corners readily enables the fabrication of a cushion having the same strength as the normal three-dimensional piece of furniture. In the threedimensional chair there is no need for overcoming this problem of distortion or bending of the annular frame due to the fact that the arms and back of the chair are attached to the horizontal portion of a chair and thus reinforce it or make it an integral unit. In accordance with the present invention, since some pieces of furniture require only a horizontal dimension and the vertical dimension, which comprises the vertical legs that support the horizontal portion, the present invention readily adapts to this requirement of reinforcing by providing the triangular reinforcement section in the same horizontal plane as the annular frame to give the necessary reinforcement while not interfering at all with the provision of the horizontal weight receiving portion. Since the cushion is constructed for maximum strength, a threedimensional piece of furniture can be made to incorporate two such cushions mounted at substantially right angles and each acting independently with no cross support needed between the back and seat. This arrangement will be described below.

Thus, the present invention provides a novel cushion that consists primarily of a frame with its reinforcement means completely hidden from view and forming an integral unit with the plastic horizontal body and the engaging members. The complete covering of all the metal parts as already stated further makes the furniture pleasing to the eye, and readily useable in any type atmosphere whether there be high humidity or other moisture conditions that cause corrosion since all of these parts are sealed off from contact with the atmosphere.

While the embodiment of the invention shown in FIG- URE 1 has been described for purposes of illustration with respect to a cushion having a rectangular or square type of annular frame, it is readily apparent that, if desired, the frame may also be circular, a figure eight configuration or other conventional types.

Referring to the modification of the invention shown in FIGURE 2 this is substantially the same as that of FIGURE 1, except that the reinforcement and support means generally designated 50 consists of a triangular plate member 51 disposed or mounted adjacent each corner section of the tubular frame 11 with identical sleeve members 52 extending along each side of the triangular plate 51 rolled over the adjacent portion 23 of the tubular frame so that the reinforcement member is rigidly connected to the tubular frame. The plate 51 has its bottom face 53 extending diagonally between the two adjacent portions 23 forming the corner section 20 of the tubular frame with the apex of the triangle 54 rounded so as to conform to the round configuration of the corner. Since the sleeves 52 are rolled or bent over the frame 11 on opposite sides of the corner 20', there is no chance of linear slippage of the reinforcement plate 51 along the tubular frame.

The plate 51 is provided with a countersink or projection 55 extending below the plate with the bottom 56 thereof diagonally inclined so that an engaging member, such as a leg, affixed thereto will extend at a slight inclination beyond the outer perimeter or boundary of the horizontal body 10 of the cushion. The countersink 55 is also provided with the upturned threaded nipple 57 disposed centrally thereof for receiving a screw member. The plate 51 is disposed in the same plane as the horizontal plane of the tubular member 11.

Referring to the embodiment of the invention shown in FIGURES 4 to 7, the frame generally designated as 60 consists of a plurality of U-shaped channel members 61 in cross section, each channel member having a bottom 62 and upstanding ribs 63. The channel members 61 are substantially L-shaped in a horizontal plane and have two identical straight leg portions 64 at its opposite ends.

The channel members 61 are rigidly connected together by means of a U-shaped connector brace or strip 65 which is disposed in the U-shaped channel of 61 as best seen in FIGURES 4 and 7. The connector member 65 is spot welded to adjacent abutting ends 64 of the channel members. The connector or reinforcement member 65 has upstanding ribs 66 on either side thereof and a fiatcentral portion 67 provided with a longitudinal arcuate rib 68 for giving it additional strength. In the preferred embodiment, the channel member 60 is made up into a square with two channel members 61 forming each side of the square. The straight end sections 64 of the channel member 61 are provided with apertures 70 therein in certain channel members disposed opposite one another to receive a member 71 therein. The member 71 comprises a flat spring having a series of alternate U-shaped configurations 72 disposed in the frame plane with a bend 73 normal to the central portion and adjacent the 0pposite ends thereof that extend through the apertures 70 and are thereafter bent inwardly as at 74 and about the underside of the channel members so that the resilient spring members 71 are attached to the frame and will not come loose therefrom.

Each channel member 61 is provided with a counter sink 75 therein that is circular in cross section and similar to thee ountershinks already described in connection with FIGURES 1 and 2.

The countersinks 75 extend below the bottom of the channel members, as best shown in FIGURE 7, and have their inner end 76 extending below the outer end 77 thereof so that the bottom of the countersink or projection 75 is inclined at an angle with the plane of the frame structure. The countersink is also provided with a threaded upstanding nipple 78 centrally disposed therein to receive the screw member of any engaging memher.

The embodiment of the invention shown in FIGURE 4 is shown without the plastic foam material covering and encapsulating the frame for purposes of clarity. However, in FIGURE 7 a detail view is shown of the frame embedded and encapsulated within the plastic foam material 80 after it has been properly molded. It will be noted that the plastic foam 80 covers and encloses the entire frame so that there is nothing that can be seen I of the frame after the molding operation.

In order to provide reinforcement means for the channel members 61 adjacent the portion thereof to which the engaging members are attached, the channel members 61 are provided with an enlarged or widened flat section generally designated 81. The enlarged section 81 generally follows the configuration of a triangular member and is disposed adjacent the corner 82 of the frame. However, the triangular configuration is somewhat muted to form an outer radius 83 and an inner radius 84 instead of the more sharp triangular plate as already described for FIGURE 2.

With the enlarged reinforcement section 81 formed integral with the frame and in the same plane therewith, the engaging members can be affixed to the frame and the cushion will not be distorted out of its original shape when a weight is supported thereby. That is, the frame member will not be bent or permanently twisted but the cushion will provide two-dimensional support on which a weight or a person may be seated which will still give the resilience and springiness generally desired for such an object to provide a comfortable seating thereon, while at the same time enabling it to maintain its original rigidity. The reinforcement means are necessary in the two-dimensional furniture because of the independent support capability and since them are no arms or backs associated therewith to give the necessary reinforcement, as is the case in a three-dimensional piece of furniture such as a chair having arms and a back. Thus, the present invention solves the problem of providing a readily fabricated cushion structure that provides an annular skeletal horizontal frame therearound with reinforoement means formed therein adjacent the points where the engaging members are attached, that has fiat spring members extending between opposite sides of the frame with these parts completely encapsulated within a foam plastic material to give the cushion the necessary resiliency and springiness without sacrificing its required strength.

Referring to the embodiment of the invention shown in FIGURE 10, this is substantially the same as that shown in FIGURES 4 to 7, except that the channel members 61 which have enlarged apertures 104 therein adjacent the corners permit the fabrication of a cushion with a premolded core of ecelsior or paper batting 106 disposed within the plastic foam material 107. The paper batting 106 illustrated comprises three distinct and separate laminations of batting completely encapsulated on opposite ends, sides, and top and bottom by the plastic foam material. The holes 104 widely dispersed around the channel members 61, permit the plastic material, before it is curved and set to penetrate around the batting core so as to 'be dispersed all around the batting and not be blocked in one side thereof in the fabrication of it. This embodiment of the invention has the advantage of utilizing a minimum amount of foam plastic material and substituting paper wadding or other inexpensive material as a filler to reduce the expense of manufacturing the cushion.

The different combinations and uses of the basic cushion construction will now be described.

FIGURE 1 shows the basic cushion construction being used as an ottoman, hassock, or other similar type of article. The engaging members consist of legs 32 which are preferably made of polished wood, though they may also be made of plastic or metal material desired and tapered from an enlarged portion 36 adjacent the upper end to a narrower portion 37 adjacent the lower end, which narrower section has metal casters 38 of an ornamental nature mounted thereon. Screw members 34 are integrally mounted on the tops of the leg 32 so that when the screws 34 are rotatably threaded into nipples 33 the top surfaces of legs 32 are fully seated and flush with the underside of countersinks 26. Due to the angular relationship between the center 30 of countersinks 26 with the plane of frame 11, legs 32 assume the optimum angular position with respect to said frame 11. When fully assembled, there results an ottoman of extremely sturdy construction and rigidity that can withstand great weights and yet afford optimum comfort.

Referring to FIGURE 8, there is shown another type of ottoman. Said ottoman 90 includes a wooden annulus 91 on which is secured the same rod frame 11 shown in FIGURE 1, by bolt members 92 disposed adjacent each other rather each corner of the annulus and threaded into the nipples 33 of the countersinks 26. Thus, the horizontal portion of the hassock consists of the annular wooden frame with the metal rod frame and reinforcement means disposed.thereon.

Instead of the legs described in the previous embodiment of the invention, the annulus 91 is supported by vertical wooden struts, or posts 93 disposed in spaced relationship around the perimeter of the annulus. Struts 93 are fastened or secured at their upper ends to the underside of the annulus by well-known means such as bolts, by nailing, adhesive cement and the like, and are secured at their lower ends by the lower annulus, by box-type frame 94. The wooden frame 94 is substantially square in cross-section and is much smaller than the upper annulus 91. A fiber-board cover or enclosure member 95 extends completely around the hassock, extending vertically between frame 94 and annulus 91 and being fastened by well-known means to them and also to the struts 93. A plastic covering member 96 is secured to the outer side of the fiber-board member 95 to completely cover and hide it from view and lower end of the plastic sheet material is tucked under frame 94 and then rolled over the top of it and may be secured thereto by staples hidden from view. Frame 11, as is clearly shown in FIGURE 8, in this embodiment is encapsulated as already described with plastic film 97 to completely embed, cover and hide frame 11 from view. The plastic film material 97 is covered with a sheet of plastic material 98 provided with decorative beads 99 stitched or otherwise provided herein around the border of the seat or horizontal portion of the hassock.

Referring to FIGURE 9, there is shown another type of hassock or ottoman which is substantially the same as that shown in FIGURE 8, except that the annulus 91 is not rigidly secured to the vertical strut members 93, but instead is hingedly connected thereto by hinges 100. The hinges 100 secured or disposed small wooden box member or frame 101 fastened to the upper ends of the struts 93. Instead of having a lower frame 94 as in the embodiment of FIGURE 8, the bottom of the hassock is provided with a wooden floor member 102 fastened to the lower end of the struts 93. Thus, this embodiment of the invention provides a storage chamber or compartments 103 within the interior of the hassock in addition to the other features already described.

Inasmuch as changes may be made in the form, location and relative arrangement of the several parts without departing from the essential characteristics of the invention, it will be understood that the invention is not to be limited except by the scope of the appended claims.

What is claimed is:

1. A basic cushion construction comprising a frame having L-shaped channel members having straight sections adjacent their ends, said L-shaped channel members disposed end to end with their straight sections in linear relationship to each other, U-shaped rib members disposed in said channel members and overlapping the ends of said channel members to rigidly connect said channel members together to form the frame, said channel member further comprising an enlarged reinforcement portion between said channel members and forming corner sections for said frame, a countersink in each reinforcement portion extending below the channel member, a threaded nipple extending upwardly into said countersink, spring members extending between opposite sides of the frame formed by said channel members, and a body member of plastic foam material enveloping and encapsulating said frame, spring members and reinforcement portions.

2. A cushion construction as claimed in claim 1, batting material disposed above said channel members and reinforcement portion and also being encapsulated by said body member material, and said channel members further comprising holes to allow the foam material to fully encapsulate said channel members.

References Cited by the Examiner UNITED STATES PATENTS 2,597,860 5/1952 Gerber et al 297440 2,821,243 1/ 1958 Toulmin 5351 2,838,100 6/1958 Follows 297421 2,845,997 8/1958 Waite 297458 2,899,689 8/1959 Pastl 297459 2,989,112 6/1961 Sonnleitner 156-213 3,009,739 11/1961 Hamilton 297461 3,049,730 8/1962 Wall et al. 297-455 3,069,701 12/1962 McInerney 5351 3,083,056 3/1963 Ward 297452 3,160,381 12/1964 Longbaum 248188 FOREIGN PATENTS 693.712 9/1964 Canada. 614,666 1/1961 Italy.

FRANK B. SHERRY, Primary Examiner.