US3802005A

US3802005A - Furniture spring deck and cushion assembly incorporating same

Info

Publication number: US3802005A
Application number: US00197904A
Authority: US
Inventors: H Arnold; L Tieman
Original assignee: Flex O Lators Inc
Current assignee: Flex O Lators Inc
Priority date: 1971-11-11
Filing date: 1971-11-11
Publication date: 1974-04-09
Anticipated expiration: 1991-04-09

Abstract

A spring deck for upholstered furniture consisting of a series of generally parallel configurated spring wires extending between and attached at their ends to a pair of generally parallel side strands, said side strands being adapted to be attached to opposite sides of a furniture frame with said spring wires in tension and partially straightened, and also certain novel combinations of said spring deck with other elements of a complete cushion assembly, such as the padding, cover sheet, and insulator layers thereof. The wire configurations may be disposed alternatively in the plane of the cushion for smoother, more even cushion support, or normally to the cushion plane to provide crowning of the cushion. Also, the wires may be alternatively disposed beneath the padding material of the cushion in supporting relationship thereto, or encapsulated within certain types of padding material.

Description

United States Patent 1191 Arnold et al. 1451 Apr. 9, 1974 [54] FURNITURE SPRING DECK AND CUSHION 3,142,073 7/1964 Stern 5/354 ASSEMBLY INCORPORATING SAME 3,537,752 11/1970 Kushnarov et a1 297/456 [75] Inventors: Harmon W. Arnold; Lloyd E.

Tieman, both of Carthage, Mo.

[52] US. Cl 5/354, 5/247, 5/260,

297/452, 297/456 [51] Int. Cl. A47c 23/00 [58] Field of Search 5/354, 191, 237, 247, 241, 5/26(); 297/456, 452, 457

Primary ExaminerB0bby R. Gay Assistant Examiner-Darrell Marquette [5 7] ABSTRACT A spring deck for upholstered furniture consisting of a series of generally parallel configurated spring wires extending between and attached at their ends to a pair of generally parallel side strands, said side strands being adapted to be attached to opposite sides of a furniture frame with said spring wires in tension and partially straightened, and also certain novel combinations of said spring deck with other elements of a com- [56] ,References Cit d plete cushion assembly, such as the padding, cover UNITED STATES PATENTS sheet, and insulator layers thereof. The wire configu- 3 716 271 2H9, Kurz 5/1 14 rations may be disposed alternatively in the plane of 460 712 10/1891 Bum12111IIIIIIIIIIIIII IIIII 5/231 cushm even 9 9 3,3273332 6/1967 Richardson et al... 5 354 of the cushlon Plane to Provlde cmwmhg 2,393,349 1/1946 Weingarten 5/247 of the eushleh- Also, the Wires may he alternatively 3,634,896 1/1972 Platt et al. 5/354 disposed beneath the Padding material of the Cushion 3,098,244 7/1963 Rothbauer 5/247 in supporting relationship thereto, or encapsulated 2,708,757 5/1955 Bellgrau.. 5/260 within-certain types of padding material. 2,779,036 1/1957 Platt 5/354 I 3,610,688 10/1971 Arnold et al 5/354 1 Claim, 9 Drawing Figures PATENIEDAPR 91914 SHEET 2 [IF 3 FURNITURE SPRING DECK AND CUSHION ASSEMBLY INCORPORATING SAME SPECIFICATION This invention relates to new and useful improvements in spring decks for upholstered seating, such as are used in automotive vehicles and furniture, and has' as its principal object the provision of a deck assembly wherein a single set of wires extending in generally parallel relation across a seating frame serve the double function both of supporting the padding layers of the cushion, and also of providing the yieldable spring action of the cushion.

Another object is the provision of a cushion assembly incorporating a spring deck of the character described, and involving novel relationships of the deck to other elements of the cushion, for example in that a padding layer laid over the deck, if said deck presents an irregular surface, is conformed to the deck by a tensioned cover sheet, or in that the deck wire configurations may be reinforced, permitting the use of lighter gauge and hence less expensive wire, by encapsulating the deck directly within a moldable padding material.

A further object is the provision of a spring deck of the character describedwherein alternative formations of said wires, and variations in their connections to the frame, will provide either flat cushions, or cushions with surfaces crowned in both directions, all without necessity of using crowned or otherwise specially formed padding material.

A still further object is the provision of a cushion assembly of the character described in which the wire deck and padding layers may be pre-fabricated and furnished to furniture manufacturers as complete units requiring only simplefasteners, and no special tools, for the mounting thereof in the frames produced by the manufacturer.

Other objects are simplicity and economy of construction, and efficiency and dependability of operation.

With these objects in view as well as other objects which will appear in the course of the specification, reference will be had to the accompanying drawing,

wherein:

FIG. I is a vertical sectional view of a spring deck and cushion assembly embodying the present invention, taken on line I-lof FIG. 2,

FIG. 2 is a top plan viewof the assemblyshown in FIG. 1, with the cover and padding layers omitted,

FIG. 3 is an enlarged, fragmentary sectional view of an edge portion of the spring. deck only, taken on line III-III of FIG. 2,

FIG. 4 is a fragmentaryview similar to FIG. 2, showing structural modifications as to the configuration of the wires, their attachment to the frame, and the frame itself,

FIG. 5 is an enlarged, fragmentary sectional view taken on line V-V of FIG. 4, partially broken away and foreshortened, a I 1 FIG. 6 is a view similar to FIG. 5, but including the padding-and cover layers, and with the wires encapsulated in the padding,

FIG. 7 is a fragmentary view similar to FIG. 2, showing further modification as to wire configuration and attachment to the frame,

FIG. 8 isan enlarged fragmentary sectional view taken on line VIII-VIII of FIG. 7, and

FIG. 9 is a view similar to FIG. 7, showing still another modification of wire configuration.

Like reference numerals apply to similar parts throughout the several views, and the numeral 2 applies generally to a cushion frame for use in furniture. Said frame is open, and generally planar. It may have many different general configurations in its plane, depending on the furniture in which it is to be used, or of which it forms an intrinsic part, but for convenience, it is illustrated as being rectangular. In FIGS. 1,2, and 7-9, the frame is wooden, including a front rail 4, rear rail 6, and side rails 8, all rigidly connected to form a unitary structure, while in FIGS. 4-6 the frame is formed of tubular metal, having front, rear, and side rails corresponding to those of FIGS. 1-2 and indicated by corresponding primed numerals.

The spring deck assembly is indicated generally by the numeral 10, and comprises a pair of side strands l2 which are generally parallel and which respectively overlie front and

rear frame rails

4 and 6, and a series of generally parallel spring steel cross wires 14 extending between said side strands in closely spaced apart relation and secured at their ends to said side strands. In

some cases, as will appear, the deck assembly may also Wires 18 are substantially heavier and stiffer than each of wires 14.

Cross wires 14 are not straight, but asshown are bent or configurated to be non-straight so that the effective length of each wire may be elastically extended by tension exerted thereon. The configurations of each wire may lie substantially in a single plane, either normal to the general cushion plane as in FIGS. 1-2, or lying in n or parallel to the general cushion plane as in FIGS. 4-6, or the configurations may take the form of helical coils, as in FIGS. 7-9,.the helical coils extending either the full distance'between side strands 12, as in FIG. 7, or along only selected portions of the lengths of wires 14, as in FIG. 9, for elective'functional reasons to be discussed below. .If normal to the deck plane, as best shown in FIG. 1, the configurations may be arranged to dispose the central portions of the cross wires somewhat above the level of the frame, in order to provide an upward bulging or crowning of the padding material 22 disposed thereover. If the configurations lie in or parallel to the cushion plane, as in FIGS. 4-6, they provide a smoother, more even support for the padding. The helical configurations of FIGS. 7-9 provide for generally easier extension of the wires, for providing a softer, more deeply yielding cushion, whenever this may be desired. Aside from these considerations, the specific formation of the wire configurations is not particularly'critical, and may take many different shapes, except of course, that they must permit the desired degree of downward yielding or saggingwhen the wires are subjected to straightening by tension" exerted thereon by the top loading of the cushion. Each end of each wire 14 is affixed to the associated side strand 12 in any suitable manner, the manner actually shown consisting of twisting said wire tightly around the sheath of said side strand, in indenting relationship to said sheath, and then twisting it about itself to form a knot 24, as best shown in FIG. 3. Intermediate strands 16, if used, may be formed of twisted paper or other soft material, and pierced by each of cross wires 14.

Side strands 12 are attached respectively to front and

rear frame rails

4 and 6 by any suitable means. For example, as shown, if the frame is wooden as in FIGS. 1 and 2, there may be provided a series of fasteners 26 affixed to each frame rail, as by nails 28 or otherwise, each including a hook member 30 opening away from deck assembly 10, and adapted to be engaged about the associated side strand 12. Alternatively, side strands 12 can be very simply secured to the frame rails by ordinary staples 31, as shown in FIGS. 7-9. If the frame is of tubular metal, as in FIGS. 4-6, each fastener 26 may consist of a metal strap ha fing one end airah'tfiasr rebent to form a hook 32 corresponding to hook 30, and its opposite end portion bent into generally semicylindrical form to partially encircle the frame rail, at the outer side thereof,the extreme freeend portion of the latter semi-cylindrical portion being bent sharply inwardly to form a tooth 34 engaged in a slot 36 formed thereforin the wall of the frametube. The use o f sheaths 20 on the side strands, and of intermediate strands 16, of soft, non-metallic material, eliminates all metal-tometal contact in the assembly, and thereby prevents any rubbing or grating wire noises which otherwise would occur. It will-be understood that the configurations of spring cross wires 14 are such that when said wires are completely relaxed and free of tension, they position side strands l2 closer together than they will be when attached to by the opposite frame rails. Thus, in mounting the deck assembly in the frame, side strands 12 must be pulled farther apart, thereby tensioning and partially straightening cross wires 14. This pretensions the deck so that it provides a degree of stiffness or resistance to downward deflection of the deck. By proper selection of the initial width of the deck as compared to the width to which it must be extended to mount it in the frame, and of the number, spacing and weight of cross wires 14, any desired degree of pre-tensioning can be provided. Core wires 18 of the side strands permit

hooks

30 or 32 to be spaced widely apart, and hence require fewer hooks, since the stiffness of the side strands supplied thereby transfers the stresses of several adjacent cross wires 14 to a single hook, without appreciable flexure of the side strands.

In FIG. I, there is shown an insulator sheet 38, which may be of cloth or other flexible material, applied directly over deck assembly 10, the edges of said sheet being brought down around frame 2 and secured thereto by nails 40, or by staples or any other suitable fasteners. The padding 22 may consist of a thick planar slab of foamed resilient material. such as rubber, polyeurethane, or the like, applied over insulator sheet 38. The cushion is then finished by applying a cover sheet 42 over padding 22, pulling said cover sheet down around the edges of the padding and frame, and securing it to said frame by nails 44, or by staples or any other suitable fasteners. The cover sheet shapes the top surface of the padding into a smooth even appearance, while the lower surface of the padding is forced into conformity with the deck surface defined by cross wires 14. While in FIG. 1 this deck surface is uneven, as a result of the configurating of wires 14 normally to the cushion plane, it has been found that so long as the wire configurations are rather gentle, as shown, and not too sharp, they will not cause any unevenness of the top padding surface which cannot be controlled by top cover sheet 42, and therefore that no special shaping of the lower padding surface to conform to the deck contour is required, although the padding could of course be so shaped if desired. If wires 14 are configurated in the plane of the cushion, as in FIGS. 4-6, this problem does not occur. Wires 14 are spaced sufficiently close together to form an adequately smooth and continuous support for the padding, to prevent it from working down into the spaces between the wires, and from being cut by the wires with most types of foam padding. However, with padding materials of less strength, and particularly when the wires are configurated normally to the cushion plane as in FIG. 1, so as to form upwardly projecting humps," there may still be a ten- 20 dency for the wires to cut into or damage the padding. Insulator sheet 38 largely prevents any such damage. Most foam type padding materials presently in use do not require the use of an insulator sheet. In such cases, the insulator sheet could be dispensed with. Intermediate strands 16 serve to maintain a uniform spacing between wires 14 along their entire lengths. Again, these strands are particularly important when the wires are configurated normally to the cushion plane, since without these strands, the upward humps of the wires would tend to tilt or twist laterally.

In FIG. 6, the padding material is indicated at 22, and also consists of a generally planar slab of foam padding material, but in this case the entire spring deck assembly 10, with the exception of side strands 12 and knots 24 of wires 14, is permanently embedded or encapsulated in the lower portion of the padding slab, as shown, as for example by a molding process. Said side strands and wire knots are accommodated in recesses 16 formed therefor in the bottom of the padding slab,

in order to provide access to said side strands for engaging them in hooks 32. In some cases, it may be desirable to mount spring deck 10 in frame 2 before encapsulation, and then to encapsulate or mold both the deck and the frame in the padding material. This type of construction would adapt the structure for use with self-skinning" padding materials, which when molded form a skin of sufficient toughness and durability that cover sheet 42 could be dispensed with. While the wires 14 in FIG. 6 are configurated in the plane of the cushion, the normally configurated wires of FIG. 1 may be similarly encapsulated if desired. The helically configurated wires at FIGS. 7-9 may also have padding laid thereover as in FIG. 1, or may be encapsulated in the padding asin FIG. 6. The advantages of the encapsulation as shown are that it permits pre-fabrication of a still greater proportion of the entire cushion structure, so asto require fewer operations at the time of final installation, that wires 14 are thereby protected against atmospheric corrosion, and that the bends of wires 14 are reinforced against straightening by the padding material itself when encapsulated therein. This permits the use of a lighter gauge and hence less expensive wire. Also, the padding material preserves the spacing of the wires, so that intermediate strands 16 may be dispensed with. To minimize possible internal cutting or other damage to the padding by the wires, it is preferable that side strands 12 be separated to the approximate spacing they will eventually have in frame 2, and maintained at that spacing while the padding material is molded around wires 14.

As shown in FIG. 6, the padding slab 22' may be formed with a depending skirt 48 around the edges thereof, said skirt being disposed outwardly from but in close proximity to frame 2, whereby to form a softedge" cushion. The cover sheet 42 disposed over the padding is drawn downwardly around the sides of the padding and under skirt 48 thereof, and secured to the frame in any suitable manner. When the frame is metallic, as in FIG. 6, the cover sheet may be secured thereto, for example, by engaging it on sharp barbs 50 (one shown) affixed to the inner side of said frame at spaced intervals therealong. Padding slabs with skirts 48 may also be used in combination with wooden frames as shown in FIGS. 1 and 2.

It is considered that the operation of the spring deck and cushion assembly has been fully described in con nection with the description of its construction set forth above. It will be seen to possess numerous advantages. It is extremely simple and economical in construction. When the deck is pre-fabricated without the frame, as

would usually be the case, it may be applied to pre-' existing furniture frames very rapidly and conveniently even by unskilled labor, requiring no special tools and no fitting or adjusting. Cross wires 14, in and of themselves, perform the dual functions both of providing the sole support for the padding material, and also, by reason of the transverse configurations thereof, of providing the resilient yieldability desired. There are comparative advantages of using either the in-plane" configurations of FIGS. l-2. With the in-plane configurations of FIGS. 4-6, wires 14 provide a smoother, more even support for the padding material so that there is no need for substantial tensioning of cover sheet 42 to maintain the top of the padding smooth. The in-plane configurations do not, however, lend themselves to use in crowned cushions, since deck assembly of course tends to assume a planar configuration. The crowning could still be achieved, of course, by the use of crowned slabs of padding material, but such crowned padding slabs require special molding, and would increase the cost of the structure. The normal configurations of the wires as shown in FIGS. l2, on the other hand, provide crowning of the cushion without the use of crowned padding material slabs, permitting'the padding slabs to be economically cut from continuous sheets of uniform thickness, since they can easily be made to provide a deck the central portion of which is disposed higher than its edge portions. The normal configurations are also easier to form on automatic rnachinery, though this of course is merely a manufacturing advantage. The helical configurations of FIGS. 7-9

provide operation much the same as that of the inplane configurations of FIGS. 4-6, except that as previously mentioned, they provide a generally softer, more yieldable cushion, and except that they are perhaps not as well adapted to be encapsulated in the padding, since they have a greater tendency to damage the padding internally.

Moreover, the cushion crowning provided by the normal configurations may be provided transversely to cross wires 14, as'well as parallel to said wires, crowning in the latter direction being shown in- FIG. 1. Crowning in a direction transverse to thewires could be achieved by specially co'nfigurating the wires so that the upward offset of the central portions of the wires is greatest in a zone midway between side frame rails 8 or 8', with said upward offset being gradually reduced in wires successively closer to said siderails. Side strands 12 could then be straight as shown, when secured to the front and rear rails. However, the production of wires with such finely graduated variations of configuration would be a complicated, tedious, and expensive operation. The transverse crowning might preferably be accomplished by arranging strands 12, or the hooks in which they are engaged, in curved rather than straight lines, the hooks carried respectively by front rail 4 and rear rail 6 being arranged in lines curved convexly toward each other, so that strands 12 are closer together midway between said side rails than they are adjacent said side rails. In this manner, wires 14 may all be identically configurated, but their upward projection from the frame will be less adjacent side rails 8 than midway between said side rails, since the wires adjacent the side rails are extended to a greater length and therefore straightened to a greater degree than the wires midway between the. side rails. The curvature of side strands 12 may be achieved by curving the frame rails 4 and 6, or by nailing the fasteners 26 of FIGS. l-2 to said frame rails in curved rather than straight lines. However, probably the most effective method, whether the frame is wooden or metallic, is to provide fasteners 26 or 26' in which the

hook portions

30 or 32 thereof are of different lengths whereby to project inwardly differe'nt distances from the associated frame rails. Another means of providing 7 crowning of the cushion transversely to wires 14 is to make frame 2 non-planar, arching front and

rear rails

4 and 6 convexly upwardly toward the top of the cushion, so that the cushion surface is higher midway between side rails 8 than directly adjacent said side rails. This arching of the frame may of course be accomplished most easily when the frame is formed of tubular metal. When the cushion is used in a chair back, with wires 14 extending from side to side, this frame curvature may also be used to shape the a cushion specially to provide added support for the lumbar portion of the users back, and the like.

Finally, while frame rails 4 and 6 have for convenience been described as front and rear rails, thereby inferring that the structure shown is a seat cushion, and that wires 14 extend from front to rear across the seat, it is to be clearly understood that the cushion assembly shown is equally adapted for use either as a seat or back cushion, and that wires 14 may extendeither from front to rear. or from side to side across a seat cushion, and either from side to side or from top to bottom across a back cushion.

While we have shown and described certain specific embodiments of our invention, it will be readily apparent that many'minor changes of structure and operation could be made without departing from the spirit of the invention.

What we claim as new and desire to .protect by Letters Patent is: v Q

1. A cushion assembly for use in upholstered fumiture comprising: i

a..a generally rigid, generally planar open furniture frame including a pair of generally parallel, spaced apart opposite rails,

b. a continuous series of closely spaced, generally parallel spring wires extending across said 'frame' generally at right angles to said opposite frame rails to form a spring deck, each of said wires being transversely configurated to'be non-straight,

. fastening means connecting the opposite ends of each of said wires respectively to said opposite frame rails, said fastening means comprising a pair of resilient side strands extending generally transversely to said wires and to which the opposite ends of each of said wires are attached, each of said side strands consisting of a resilient core wire having a sheath of soft, non-metallic material, and hook members fixed to each of said frame rails at the tops thereof and engaged about the adjacent side strand, said side strand being oscillatable about its axis in said hooks whenever said wires are flexed by top loading of the spring deck, said spring wires d. padding material disposed over and supported by said spring deck.

Claims

1. A cushion assembly for use in upholstered furniture comprising: a. a generally rigid, generally planar open furniture frame including a pair of generally parallel, spaced apart opposite rails, b. a continuous series of closely spaced, generally parallel spring wires extending across said frame generally at right angles to said opposite frame rails to form a spring deck, each of said wires being transversely configurated to be nonstraight, c. fastening means connecting the opposite ends of each of said wires respectively to said opposite frame rails, said fastening means comprising a pair of resilient side strands extending generally transversely to said wires and to which the opposite ends of each of said wires are attached, each of said side strands consisting of a resilient core wire having a sheath of soft, non-metallic material, and hook members fixed to each of said frame rails at the tops thereof and engaged about the adjacent side strand, said side strand being oscillatable about its axis in said hooks whenever said wires are flexed by top loading of the spring deck, said spring wires and said hooks engaging only the sheaths of said side strands, whereby metalto-metal contact is eliminated, the distance between said side strands, when said wires are relaxed, being less than the distance between corresponding hooks carried by said opposite frame rails whereby said wires must be longitudinally tensioned and partially straightened for engagement of said side strands in said hooks, said hooks opening from said side strands in a direction opposite to the direction of extension of said wires from said side strands, and d. padding maTerial disposed over and supported by said spring deck.