Sofa with flip-up spring deck

This invention is directed to a sofa with a flip-up deck. The sofa has a sofa frame with a back, a front, and a pair of opposed arms. The deck is rotatably coupled between the pair of opposed arms at a position intermediate the front and the back. Further, the deck is adapted to move between a closed position and an open position.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable.

Not Applicable.

BACKGROUND OF THE INVENTION

This invention relates generally to a sofa, and, more particularly, to a sofa with a flip-up deck that conceals a cavity.

Traditional sofas are known in the art and designed to support a user in a seated position. The sofa generally contains a fixed deck or support surface for supporting the user. The deck extends between the two sides and the front and back of the sofa. The cushions are placed on top of the support deck to provide a comfortable form and fit for the user. However, the deck of the traditional sofa is generally fixed and provides for wasted space within the sofa unit.

It would be desirable to manufacture a sofa with a deck that provides support to the user when seated. Further, it would be desirable to manufacture a sofa with a deck that is rotatable about a position intermediate the front and rear of the sofa. Still further, it would be desirable to manufacture a sofa with a deck that is upwardly rotatable to reveal a cavity. Still further, it would be desirable to manufacture a sofa with a rotatable deck positioned at an intermediate position for sufficient clearance with respect to the back of the sofa.

Thus, while sofas with fixed decks are known, there remains a need for an improved sofa with a flip-up deck that is hinged at an intermediate position that provides the same form, fit, and construction of a traditional sofa with a fixed deck.

BRIEF SUMMARY OF THE INVENTION

This invention is directed to a sofa with a spring deck. The sofa is constructed with a sofa frame, which includes a pair of arms, a back, a front, and a spring deck. The spring deck is designed to provide support when the unit is used as a sofa. The spring deck is movable from a closed position to an open position to reveal a cavity within the sofa unit. The spring deck consists of a frame, a rod, and a support surface. The frame is mounted to the sofa. Specifically, the frame is attached to the arms of the sofa at a location intermediate the front and rear of the sofa. The rod is disposed horizontally between the frame. The frame extends forwardly along both sides and across the front and back of the sofa.

The spring deck further includes a plurality of webbings and a cover. The webbings extend from a front portion of the frame to a back portion of the frame. As stated above, the rod is coupled to the frame at a location intermediate to the front and rear of the sofa. The webbings are attached to the front portion of the frame and the back portion of the frame. The webbings further contain sinuous wires that encircle each webbing in a serpentine-like manner. The wires extend from the portion of the webbing where the rod is located to the front portion of the frame thereby creating a hinge at the intermediate position and defining the support surface. Thus, the support surface extends forwardly from the rod to the front portion of the frame.

In another embodiment of the present invention, the spring deck includes a frame and a support surface. The frame is mounted to the sofa by a pair of channel mounts. The frame is slidably and rotatably coupled to the channel mounts by a pair of rollers. The spring deck also contains a cover and a plurality of webbings. The webbings extend from a rear portion of the frame to a front portion of the frame thereby defining the support surface.

In yet another embodiment the spring deck includes a frame and a support surface. The frame is mounted to the sofa by a mounting rod. Specifically, the frame is rotatably coupled to the mounting rod. The mounting rod is located at an intermediate location on the arms of the sofa. The frame extends forwardly from the intermediate location of the mounting rod to the front portion of the sofa. The spring deck also contains a cover and a plurality of webbings. The webbings extend from the mounting rod to a front portion of the frame thereby defining the support surface.

DETAILED DESCRIPTION OF THE INVENTION

With initial reference toFIGS. 1 and 2, a sofa according to the principles of the present invention is designated generally with the reference numeral10. Throughout this specification, the term sofa is also intended to encompass love seats and other smaller units. The sofa10is constructed with a sofa frame12, which includes a pair of arms14, a back16, a front18, and a spring deck20.FIG. 1shows the spring deck20in an open position whileFIGS. 2 and 4show the spring deck20in a closed position. The spring deck20provides support for the cushions and, thus, the seated user, not shown. As best seen inFIG. 1and as further described below, the spring deck20rotates upwardly to disclose a cavity22. Referring now toFIGS. 1 and 4, the cavity22includes a floor24and is formed in an interior area between the arms14, the back16, and the front18. The cavity22also contains a pair of stops26located proximate each arm14and abutting the front18of the sofa. The cavity22may be used for storage of various items, such as an inflatable mattress, not shown.

Referring now toFIGS. 3 and 5, the spring deck20will be discussed. The spring deck20includes a frame30, a rod32, and a support surface34. The spring deck20is mounted to the sofa10by a pair of apertures36. Specifically, the spring deck20has a number of apertures36, shown as attachments, formed therein for facilitating attachment to the arms14. As such the spring deck20is fixably coupled to each arm14. It will be appreciated by one of ordinary skill in the art that any attachment method could be used, such as bolts, screws, nails, or the like. The spring deck20further contains a pair of apertures38, shown as attachments, formed therein for facilitating attachment to the rod32. The rod32contains a pair of apertures40, not shown, that mate with the holes38located on the spring deck. The rod32extends between the frame30of the spring deck20and is fixably coupled thereto. Coupling is achieved via a pair of bolts41. It will be appreciated by one of ordinary skill in the art that any attachment method could be used, such as screws, nails, welding, or the like. The rod32is coupled to the frame30at a position intermediate the front18and back16of the sofa10. As shown inFIG. 4, the coupling of the rod32at the intermediate position serves to provide clearance between the spring deck20and the back16. Thus, the spring deck20can be moved from the closed to the open position without interference with the back16.

Referring now toFIGS. 1,3, and5the frame30will be discussed. The frame30is constructed from steel tubing and is shaped as shown. It will be appreciated by one of ordinary skill in the art that any suitable material may be used. The frame30includes a front portion42and a rear portion44. The rear portion44of the frame20is fixably coupled to the arms via the apertures36. The front and rear portions42,44are connected with a bracket46. Specifically, the front portion42of the frame20is rotatably coupled to the rear portion44of the frame30by the bracket46. The bracket46is shaped as shown and contains a number of apertures48, shown as connections, to facilitate the coupling of the front and rear portions42,44of the frame30. The apertures48align with apertures in each frame member42,44, not shown, to attach the front portion42to the rear portion44. The frame30extends along the arms14and the front18and rear16of the sofa10. As seen inFIGS. 3 and 4, the front portion42of the frame30rests on the stops26when the spring deck20is in the closed position. Further as seen inFIGS. 3 and 5, a spring52is attached to the front and rear portions42,44of the frame30. The spring52is attached by protrusions54,56that extend outwardly from the front and rear portions42,44respectively. The spring52facilitates movement of the spring deck20from the closed position ofFIG. 4to the open position ofFIG. 1.

Referring now toFIGS. 3 and 4, the spring deck20also contains a cover58and a plurality of webbings60. The webbings60extend from the rear portion44to the front portion42of the frame30. As stated above, the rod32is coupled between the arms14of the sofa10via the frame30at a position intermediate the front18and back16of the sofa10. The webbings60are attached to the front and rear portions42,44of the frame30. It will be appreciated by one of ordinary skill in the art that any attachment method may be used.

As stated above, the webbings60of the support surface34extend from the rear portion44to the front protion42of the frame30. The webbings60of the support surface34further include sinuous wires62that encircle each webbing60in a serpentine-like manner. The webbings60are interconnected by a number of support rods64. The support rods64extend between the sides44of the frame30and attach to the webbings60via couplers66. The rods64together with the couplers66serve to align the webbings60of the support surface34to provide a smooth, uniform support surface34when combined with the cover58. The sinuous wires62are connected to the webbings60via slits68. As best seen inFIG. 5, the location of the sinuous wires62on the webbings60creates a hinge at the intermediate position proximate the location of the rod32to provide the support surface34of the spring deck20. As stated above the hinge at the intermediate position serves to allow for clearance between the spring deck20and the back16of the sofa10. The support surface34is defined by the webbings60with the sinuous wires62extending from the rod32toward the front portion42of the frame30and the cover58. The cover58extends along the frame30and is fixably coupled thereto.

Referring toFIGS. 1-3, the operation of the sofa10will now be discussed.FIG. 1illustrates the sofa10in the open position with the spring deck20flipped up to reveal the cavity22.FIGS. 2-4illustrate the sofa10in the closed position where the spring deck20is oriented generally horizontal for support of the user. In order to move the spring deck20from the closed position to the open position, the user simply lifts upwardly on the front portion42of the frame30. The upward lifting by the user causes the front portion42of the frame30to rotate about the bracket46connection between the front portion42and rear portion44of the frame30. The intermediate location of the bracket46connection between the front portion42and rear portion44allows the spring deck20to be lifted without interfering with the back16.

Referring now toFIGS. 6-8, an additional embodiment of a spring deck70will be discussed. It is understood that the additional embodiment of the spring deck70works with the components of the sofa10described above. The spring deck70includes a frame72and a support surface74. The frame72is constructed from steel tubing and is generally rectangular. It will be appreciated by one of ordinary skill in the art that any suitable material may be used. The frame72includes a front portion76, a rear portion78, and a pair of side portions80. The front76, rear78, and side portions80may be integral or separate pieces fastened together. The side portions80extend from the rear16to the front18of the sofa10. Each side portion80contains an aperture82, not shown, located proximate the rear portion78with a roller84coupled thereto and extending therefrom.

Referring again toFIGS. 6 and 7, the spring deck70is mounted to the sofa10by a pair of channel mounts86. The channel mounts86have a number of apertures88, not shown, formed therein for facilitating attachment to the arms14. As seen inFIGS. 7 and 8, the channel mounts86extend from the back16of the sofa10to an intermediate position. The channel mounts86have a C-shaped cross-section90that extends along the length of the channel mounts86and a stop92located at the intermediate position. The C-shaped cross-section90is suitable for receipt of the rollers84on the side portions80of the frame72. As such, the frame72is slidably and rotatably coupled to the C-shaped cross-section90of the channel mounts86by the pair of rollers84.

Referring now toFIG. 6, the spring deck70also includes a cover94and a plurality of webbings96. The webbings96extend from the rear portion78to the front portion76of the frame72and are attached thereto. It will be appreciated by one of ordinary skill in the art that any attachment method may be used. The webbings96of the spring deck70further include sinuous wires98that encircle each webbing96in a serpentine manner. The webbings96are interconnected by a number of support rods100. The support rods100extend between the sides of the frame72and attach to the webbings96via couplers102. The sinuous wires98are connected to the webbings96via slits104. The rods100together with the couplers102serve to align the webbings96of the spring deck70to provide the smooth, uniform support surface74. Thus, the support surface74is defined by the webbings96extending from the rear portion78to the front portion76of the frame72and the cover94.

Referring now toFIGS. 6 and 7, the operation of the spring deck70will be discussed. In order to move the spring deck70from the closed position to the open position, the user simply lifts upwardly on the front76of the frame72. The upward lifting by the user causes the front portion76of the frame72to rotate about the rotatable and slidable connection between the frame72and the channel mounts86. The user then applies a forward pulling force on the front portion76of the frame72. The pulling force causes the rollers84to move forwardly within the channel mounts86. As the rollers84move forwardly in the channel mounts86, the rear78of the frame72nears the stop92located proximate the intermediate position, whereby the user may continue lifting upwardly as the frame72now clears the back16of the sofa10. Thus, the rotatable and slidable connection between the rear78of the frame72and the channel mount86allows the spring deck70to be lifted without interfering with the back16.

Referring now toFIGS. 9 and 10, an additional embodiment of a spring deck104will be discussed. It is understood that the additional embodiment of the spring deck104works with the components of the sofa10described above. The spring deck104includes a frame106and a support surface108and a mounting rod110. The frame is mounted to the sofa10by the mounting rod110. The mounting rod110has a plate112attached to each end. The plates112contain a plurality of apertures114, shown as connections, used to couple the rod110to the sofa arms14and the frame106to the rod110. The mounting rod110is coupled to the sofa arms14at a position intermediate the front and back of the sofa.

The frame106is shaped as shown and is constructed from steel tubing. It will be appreciated by one of ordinary skill in the art that any suitable material may be used. The frame106includes a front portion114and a pair of side portions116. The front114and side portions116may be integral or separate pieces fastened together. The side portions116extend from the mounting rod110to the front18of the sofa10. Each side portion116contains an aperture118that receives a bolt120to attach the frame106to the plate112of the mounting rod110.

The spring deck104also includes a cover122and a plurality of webbings124. The webbings124extend from the mounting rod110to the front portion114of the frame106and are attached thereto. It will be appreciated by one of ordinary skill in the art that any attachment method may be used. The webbings124of the spring deck104further include sinuous wires126that encircle each webbing124in a serpentine manner. The webbings124are interconnected by a number of support rods128. The support rods128extend between the sides portions116of the frame106and attach to the webbings124via couplers130. The sinuous wires126are connected to the webbings124via slits132. The rods128together with the couplers130serve to align the webbings124of the spring deck104to provide the smooth, uniform support surface108.

The spring deck108also contains a spring134attached to the frame106and the mounting rod110. The spring134is attached by protrusions136,138. The spring134facilitates movement of the spring deck108from the closed position to the open position.

Referring again toFIGS. 9an10, the operation of the spring deck104will be discussed. In order to move the spring deck104from the closed position to the open position, the user simply lifts upwardly on the front114of the frame106. The upward lifting by the user causes the front portion114of the frame106to rotate about the rotatable connection between the frame106and the mounting rod110. Thus, the rotatable connection between the mounting rod110and the frame106allows the spring deck104to be lifted without interfering with the back16.

The present invention has been described in relation to particular embodiments, which are intended in all respects to be illustrative rather than restrictive. Alternative embodiments will become apparent to those skilled in the art to which the present invention pertains without departing from its scope.