US3560049A - Sofa with integral cushion - Google Patents

Abstract

AN ARTICLE OF FURNITURE WHICH MAY BE IN THE FORM OF A SOFA HAVING CUSHIONS CONSTRUCTED AS AN INTEGRAL PART THEREOF WITH EACH CUSHION INCLUDING A RIGID FRAMEWORK HAVING A PLURALITY OF ACRUATELY BOWED SEPENTINE SPRINGS WITH RESILIENT ADJUSTMENT STRAPS ATTACHED THERETO. THE END SPRINGS HAVE STABILIZING TIE CORDS AND INTERCONNECTING COIL SPRING ARE PROVIDED FOR STABILIZING THE ARCUATE SPRING MEMBERS.

Description

Feb, 2, 1971 R. E. BURTON son WITH INTEGRAL CUSHION 5 Sheets-Sheet 1 Filed April 17, 1969 Robert E Burton 1 N VEN TOR. Mm BY M m Feb. 2 1971 R. E. BURTON SOFA WITH INTEGRAL CUSHION 3 Sheets-Sheet 2 Filed A ril 17, 1969 Robert E Burton INVENTOR.

(ma M Em 2, 1971 R E, U T N SOFA WITH INTEGRAL CUSHION 3 Sheets-Sheet 5 Filed April 17, 1969 Fig. 6

Robe/'2 E. Barron INVENTOR.

United States Patent 3,560,049 SOFA WITH INTEGRAL CUSHION Robert E. Burton, Coalinga, Calif. (464 Montgomery St., Orange, Calif. 92668) Filed Apr. 17, 1969, Ser. No. 816,925 Int. Cl. A47c 7/14, 7/02 US. Cl. 297-452 8 Claims ABSTRACT OF THE DISCLOSURE The present invention generally relates to furniture construction and more particularly a sofa having integrally constructed cushion units which are fixedly secured to the frame of the sofa.

In conventional sofa structures, the seat cushions are a completely separate unit from the frame and supporting spring assembly. Usually, the frame and supporting spring assembly are constructed and completely upholstered and covered after which the cushion units which are also upholstered are placed in position. In the present invention, the spring assembly is an integral part of the cushion and the sofa frame and is not separately upholstered and is not a separate unit from the cushion. The cushion including the spring assembly slips into the framework of the sofa and is secured in place by screws or the like which construction saves a substantial quantity of material and results in a stronger and longer lasting product which can be produced at a substantial saving in cost as compared with conventional sofas while at the same time providing a structure which is attractive in appearance and capable of construction in various styles.

An object of the present invention is to provide a sofa construction employing serpentine arcuately bowed sagless spring members secured at their opposite ends to a rigid frame of the cushion together with tension adjustment straps interconnecting the spring and cushion frame for varying the firmness characteristics of the cushion unit and assuring that the arcuate bowed springs will return to their normal upwardly bowed position when weight has been removed from the cushion unit.

Another object of the present invention is to provide a sofa unit in which wrinkles in the upholstering material or cover is substantially eliminated inasmuch as the upholstering cover applies pressure on the springs and the foam resilient material placed thereover and causes the arcuate springs to be pushed down slightly by the density of the foam resilient material which in return places tension on the resilient tensioning straps all of which coact to retain the upholstering cover in a smooth wrinkle-free condition.

Still another object of the present invention is to provide a sofa construction which is long lasting and durable, attractive in appearance and requires substantially less labor and materials to construct.

These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout, and in which:

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FIG. 1 is a perspective view of a three cushion sofa unit with the central cushion unit removed;

FIG. 2 is a perspective view, with parts broken away and in section of the center cushion structure;

FIG. 3 is a transverse, sectional view of the sofa unit illustrating the cushion structure;

FIG. 4 is a longitudinal, sectional view taken substantially upon a plane passing along section line 44 of FIG. 3 illustrating further structural details of the cushion unit;

FIG. 5 is a perspective view illustrating the construction of an end cushion unit; and

FIG. 6 is a vertical sectional view of the end portion of the sofa illustrating the relationship of the cushion unit thereto.

Referring now specifically to the drawings, a sofa incorporating the significant features of the present invention is generally designated by reference numeral 10 and includes a seat cushion frame structure generally designated by the numeral 12, end structures 14 and backrest structure 16. The seat cushion frame structure or assembly 12 includes a longitudinally extending front frame member or board 18 having the ends thereof interconnected by an end frame member or end board 20. The rearward ends of the end boards 20 are interconnected by a rear frame or board 22 and another frame member 24 in the form of a wooden structural element interconnects the end members 20 in spaced relation to the rear frame member or board 22. This frame structure is supported in any suitable manner such as by rear legs 26 and front casters 28 or the like with the open lower end of the frame being closed by a fabric panel 30 in a well-known and conventional manner. The specific supporting structure and the bracing, corner blocks and the like all follow accepted practice in the construction of furniture items of this nature.

The backrest 16 is formed by end members 30, a top member 32, a front frame member 34 and a lower frame member 36. Cushioning material or a cushioning assembly 38 is mounted forwardly of the front frame 34 and the cushioning material is covered by a fabric panel of upholstery material 40 which extends downwardly and partially wraps around the frame member 36 and is secured thereto by a fastener 42 and extends upwardly along the front of the cushioning material 38, across the top panel 30 and then downwardly to close the rear of the backrest with the lower edge thereof being attached to the board 22. This specific construction also may be varied depending upon the appearance characteristics to be incorporated into the backrest.

The end structures 14 include a hollow frame including a bottom member 44, an inner rigid panel 46, a top panel 48 and an interconnecting fabric panel 50 forming the outer surface of the hollow frame. A cushioning material is disposed against the inner, top and outer surface of the hollow frame as designated by the numeral 52 and an upholstery fabric covering 54 is provided around the end frame structure as illustrated in FIG. 6 with the supporting legs 26 and the casters 28 being in supporting engagement with the end frame members and if desired or necessary, additional supporting legs and casters may be provided intermediate the ends of the sofa depending upon the over-all length thereof.

The front board or frame member 18 is provided with cushioning material 56 on the exterior surface thereof and the cushioning material is covered with a fabric upholstery covering 58 which extends under the front edge of the board 18 and is secured thereto in any suitable manner and the upper edge of the fabric cover 58 extends over the rounded upper end of the front board 18 and is secured to the inner surface thereof in any suitable manner with suitable fasteners. The front fabric cover 58 may be provided with a horizontal ribbing 60 or the like or 3 other structural features enhancing the decorative appearance thereof. Thus, an open framework is provided for receiving the seat cushion unit with one of the seat cushion units being omitted in FIG. 1 to show the relationship thereof to the sofa.

The center cushion unit is generally designated by the numeral 62 and is best illustrated in FIGS. 2-4 and includes a rigid wood frame consisting of a pair of end members 64 and 66 interconnected by a lower front member 68 and an upper front member 70 as well as a rear lower member 72 and an upper rear member 74 all of which may be wood frame members with the members being interconnected by any suitable fastening construction, the details of which are not shown.

Extending between the front member 68 and the rear member 72 is a plurality of longitudinally spaced sagless spring members 76 of generally serpentine construction with the front end of each spring 76 being connected to a clip 78 which in turn is secured to the recessed forward surface 80 of the front frame member 68. The rear end of each frame 76 is connected with a similar clip 82 secured in the recessed rear edge 84 of the rear frame member 72 with the clips 78 and 82 being that type of clip normally employed for securing the sagless spring members in position with suitable fastening devices employed for securely mounting the springs so that they will be retained in upwardly bowed arcuate position as illustrated in FIG. 3.

Each forward end portion of each spring 76 has a tension strap 86 connected to one of the loops thereof with the end of the resilient strap 86 being secured to the top surface of the front top frame member 70 by suitable fasteners 88. Similar resilient tensioning straps 90 are connected to the rear end portion of each of the springs 76 and the terminal end thereof is anchored to the upper rear frame member 74 as by fasteners 92. Each end spring 76 is provided with a tie cOrd or twine 94 which extends in a zig-zag manner between the loops of the end spring 76 and the top surface of a recess 96 formed in the end frame members 64 with the cord being secured thereto at spaced points by fasteners 98. For retaining the springs 76 in properly longitudinally spaced relation, a plurality of tension coil springs 100 are interconnected between the adjacent springs 76. Thus, the frame and spring assembly form a stable structural assembly and overlying the springs is a resilient pad 102 of foam plastic or rubber having a fabric upholstery cover 104 thereon. Welting cords or ribs 106 may be provided for the pad or cushion and depending upholstery panels 108 integral with the fabric cover 104 extend downwardly along the end panels 64 and 66 andare secured to the upper surface of the cut-out area 96 or along the exterior surface of the end panels. Similar panels extend down from the front and rear with the rear extension panel 110' extending under and being attached to the front upper frame member 70. Thus, a unitary structure is formed which is self-contained and thus may be inserted into the sofa framework 12 with the front and rear frame members 68 and 72 being secured to the front member 18 and the frame member 24 respectively by suitable fasteners 110 thus forming a rigid integral unit. As illustrated in FIG. 4, the end members 64 and 66 are supported on front to rear support members 112 extending between the front board member 18 and the frame member 24 thereby forming a rigid supporting unit with the central cushion 62 integrally and fixed central portion fixed thereto.

The end cushion units are somewhat similar and are illustrated in FIGS. and 6 and generally designated by the numeral 114. The end cushion units 114 each have four springs 76 rather than five and the inner end of the cushion unit is provided with the same type of end frame and tie cord assembly as employed in each of the center cushion. However, on the outer end of each end cushion unit 114, there is a solid end frame member 116 having a top member 118 attached thereto to which the tension coil springs 120 are connected and these springs extend between the end frame member 116 and the sagless springs 76 which are identical to the sagless springs illustrated in the center cushion unit 62. Other than this difference, the end cushion units and the center cushion unit are the same and are secured in position in the same manner so that when completed, the cushion upholstery appears to provide three separate and independent cushions but in actuality, the cushion units are fixedly secured to the sofa frame and coact with the components of the sofa frame to further rigidify the unit.

The shape and configuration of the sofa unit may vary as may the dimensions of the various components including the strength characteristics thereof. The integral cushion unit may also be used in other furniture items such as chairs or the like with the appearance characteristics being variable as desired. While the cushion unit provides the appearance of a reversible cushion and affords the same comfort characteristics, it additionally provides the sleekness and softness of foam rubber and resists wrinkling of the upholstery with the seams being retained in a straight condition. The juncture between cushions have the same characteristics of softness and strength as the central part of each cushion. When employing this invention, wear will 'be distributed equally on the springs and polyurethane foam as the weight of a person is applied to the cushion, it starts a chain of events. First, the arc spring begins to give and little by little, tension is put on the resilient straps which may be latex rubber or the like until the latex rubber tension straps and are springs have built up even tension against the speed and weight of a person and the springs have adjusted themselves. Now, the foam begins to give at the equalization of a person's weight to conform with the surface of the person engaging the cushion. The chain of events works in reverse as a person lifts himself off the cushion with the tension straps and the springs returning to their normal position thus exerting pressure against the polyurethane foam and taking up the slack to keep wrinkles eliminated until the foam compresses itself into original density and shape.

The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.

What is claimed as new is as follows:

1. In an article of furniture, a cushion unit comprising an open peripheral frame including spaced parallel end members and spaced parallel side members, a plurality of longitudinally spaced arcuately bowed sagless serpentine springs extending between the side members with the arcuate central portion thereof extending above the upper edge of the frame, each of said springs including a tension strap having resilient characteristics attached adjacent each end thereof and extending to and being attached to the frame at an elevation above the point of attachment of the springs thereby returning the arcuate springs to their arcuate positions when no load is applied thereto, and a cushioning pad mounted in engagement with the springs and connected with the frame to form a cushion unit capable of being inserted into an article of furniture and fixedly secured thereto.

2. The structure as defined in claim 1 wherein said tension straps are in the form of rubber straps, and a plurality of interconnecting spring members extending longitudinally between the sagless springs to retain them in spaced condition.

3. The structure as defined in claim 2 wherein at least one end member has the upper edge thereof recessed with the spring disposed above the recess, and a tie cord extending between the recessed upper edge of the end memher and the spring overlying the same for stabilizing the end spring and retaining it in position.

4. The structure as defined in claim 3 in which the other end member is also recessed and provided with a tie cord associated with the spring in the same manner.

5. The structure as defined in claim 3 wherein the other end member defining the frame is provided with a straight upper edge with the end spring adjacent thereto being spaced inwardly from the end member, and relatively small coil springs extending between the end spring and the end member of the frame.

6. The structure as defined in claim 2 wherein said pad includes an upholstery covering thereon with depending panel extensions being secured to the frame thereby forming an assembled unit, said pad being in the form of a foam plastic with the ends of the pad extending slightly beyond the end members to cushion the entire surface of the cushion unit.

7. A sofa comprising a backrest, arm members and an open frame extending between the arm rest and disposed forwardly of the backrest, and a plurality of assembled cushion units inserted into the open frame and means fixedly securing the cushion units thereto, each of said cushion units including a rigid frame secured to the open frame forming part of the sofa, a plurality of springs mounted on the cushion frame and a cushioning pad engaging the springs on the cushion frame and engaged with the cushion frame for insertion into the sofa as a unit whereby the cushion units become integral with the sofa.

8. The structure as defined in claim 7 wherein each of the springs in the cushion unit is in the form of an armately bowed serpentine spring member having the ends thereof anchored to the cushion frame, and resilient tension straps connecting the spring adjacent each end thereof to the frame at a point spaced above the point of connection between the springs and frame for returning the springs to their arcuately bowed condition.

References Cited UNITED STATES PATENTS 2,788,845 4/1957 Bond et a1 267112 2,786,513 3/1957 Hoven et al. 297218 3,064,281 11/1962 Brown 5353.7 3,165,308 1/1965 Ratbun 267111 C. A. NUNBERG, Primary Examiner US. Cl. X.R.

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