Seat support assembly for furniture having leg rest extension and seat back recline

A seat support assembly supports a cushion of a furniture member. The seat support assembly may include a frame, at least two seat springs, a support spring, and a coil spring. The support spring may be positioned between two seat springs, and the seat springs and the support spring may extend across the frame. A coil spring may be positioned on and attached to the support spring. The coil spring may extend to and bias against the two seat springs positioned on either side of the support spring.

FIELD

The present disclosure relates to a seat support mechanism for furniture having a mechanism for moving a leg rest and reclining a seat back of the furniture

BACKGROUND

Furniture, such as chairs, sofas, loveseats, sectionals, and the like, can include a mechanism that allows an occupant of the furniture to move a leg rest panel and to recline a seat back of the furniture. As an example, the leg rest can be moved from a stowed or retracted position to a deployed or extended position to support the legs and/or feet of the occupant. Furthermore, the seat back can be rotatable to move the seat back from a fully upright position to a fully reclined position and/or a position between the fully upright position and the fully reclined position.

The furniture can include a cushion for supporting the occupant sitting or lying on the furniture. Due to a pressure exerted onto the cushion by the occupant, the cushion can protrude into a void between the cushion and the mechanism. In addition, as the seat back reclines and/or the leg rest extends, the cushion can move further into the void toward the mechanism. Accordingly, the cushion can interfere with the mechanism and, therefore, can affect the performance of the mechanism.

SUMMARY

The present disclosure is generally directed toward a seat support assembly for supporting a cushion of a furniture member. The seat support assembly may include a frame, at least two seat springs, a support spring, and a coil spring. With the support spring positioned between two seat springs, the seat springs and the support spring extend across the frame. A coil spring may be positioned on and attached to the support spring. The coil spring may extend to and bias against the two seat springs positioned on either side of the support spring.

The seat support assembly of the present disclosure may support the cushion without interfering with components positioned under the seat support assembly. For example, the cushion may rest upon the frame and is supported by the seat springs that extend across the frame. The coil spring may support and bias the seat springs toward the cushion, and the support spring may support and bias the coil spring toward the seat springs. Accordingly, the springs of the seat support assembly provide support to the cushion without the use of bulky fixtures that may interfere with other components positioned under the cushion.

DETAILED DESCRIPTION

The terminology used herein is for the purpose of describing particular example embodiments only, and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and, therefore, specify the presence of stated features, elements, and/or components, but do not preclude the presence or addition of one or more other features, elements, components, and/or groups thereof.

With reference toFIG. 1, a furniture member100, such as a chair, includes a seat back member102, a leg rest member104, and a cushion106. The seat back member102may rotate in a recline direction108with respect to a base member110from a fully upright position to a full reclined position or in an upright direction112to return to the fully upright position. The seat back member102may also be adjusted to any position between the fully upright position and the fully reclined position. The leg rest member is moveable in an extension direction114to extend the leg rest member104to an extended position away from the base member110and in a retraction direction116to return the leg rest member104to a stowed position toward the base member110.

The cushion106supports an occupant sitting in the furniture member100. The cushion106may also move based on the movement of the seat back member102and/or the leg rest member104. For example, when the seat back member102rotates in the recline direction108, the cushion106may extend away from the seat back member102, as represented by arrow120. Conversely, when the seat back member102rotates in the upright direction112, the cushion106may move toward the seat back member102, as represented by arrow122. Furthermore, when the leg rest member104extends, one or more portions of the cushion106may move down toward the base member110, as represented by arrow124. When the leg rest member104retracts, one or more portions of the cushion106may move up away from the base member110, as represented by arrow126.

The furniture member10further includes a frame assembly130that includes a movement mechanism132and a seat support assembly134. The movement mechanism132is attached to the base member110and provides one or more mechanisms for rotating the seat back member102and moving the leg rest member104. For example, the movement mechanism132may include a rotational linkage136and a leg rest mechanism138.

The rotational linkage136rotates the seat back member102in the recline direction108and the upright direction112. The rotational linkage136may be moved by a force applied by an occupant against the seat back member102and/or by an actuator (not shown), such as an electric servo motor disposed under the seat support assembly134and controlled by a button operable by the occupant.

The leg rest mechanism138may include a pair of pantograph linkages140(only one shown). In the example embodiment, the pantograph linkages140are moveable by an electric motor142that is operable by the occupant via a control interface (not shown), such as a button. Alternatively, the pantograph linkages may be manually operated by the occupant by way of a handle.

The seat support assembly134supports the cushion106and prevents the cushion106from interfering with the movement mechanism132. More particularly, the cushion106and the movement mechanism132are separated by a void144. The seat support assembly134is positioned under the cushion106to prevent the cushion106from extending into the void144and possibly interfering with the movement mechanism132.

With additional reference toFIGS. 2 and 3, the seat support assembly134includes a frame148and at least one spring support subassembly150having two seat springs152, a support spring154, and a coil spring156. The frame148is attached to the movement mechanism132. The frame148supports the cushion106and may be separate from or integral with the cushion106. The frame148may have one or more support members160that are fixedly attached to each other to form a rectangular shape and define an enclosed opening162. The cushion106may rest on or is attached to the support members160. In addition, a portion of the cushion106is positioned over the opening162. While the frame148is illustrated as having a rectangular like shape, the frame148may be configured to have other suitable shapes for supporting the cushion106, such as a square or circular shape, and is not limited to the shape illustrated. The support members160may be fixedly attached by way of, for example, an adhesive, welding, fasteners (i.e., bolts, screws, washers), and/or other suitable attachment mechanism. Alternatively, the frame148may be formed out of one support member.

The spring support subassembly150includes the two seat springs152and the support spring154positioned between the two seat springs152. The coil spring156is positioned on top of and is attached to the support spring154. The coil spring156extends between the support spring154and the two seat springs152to contact and bias against the seat springs152. In the example embodiment, at least two spring support subassemblies150are provided for supporting the cushion106. It is readily understood that any number of seat spring sub-assemblies may be used, and is not limited to the number illustrated.

The seat springs152and the support spring154are flat sinuous springs that span across the frame148. The seat springs152and the support spring154may be collectively referred to as sinuous springs152and154. The sinuous springs152and154extend from a first side164of the frame148to a second side166of the frame148that is opposite to the first side164. The sinuous springs152and154may be made of wire, and more specifically metal wire that has a circular cross-section. Due to their construction and composition, the sinuous springs152and154are elastic and resilient, such that they may stretch and/or be deflected when acted on by a force and then spring back to their initial length and/or position when the force is removed. This may occur, for example, when a person sits or lies on the cushion106.

Each of the sinuous springs152and154is attached to the frame148by way of spring clips168that are disposed at each end170of the sinuous springs152and154. The spring clips168anchor each end170of the sinuous springs152and154to the frame148. The spring clip168may include a clip base172that is flat and rectangular and a channel174that protrudes upwardly from the clip base172. The channel174receives a portion of the sinuous springs152and154and clamps that portion against the frame148. The clip base172is fixedly connected to the frame148. For example, the clip base172may include a hole for receiving a fastener. The clip base172may be connected using other suitable methods, such as welding or adhesives, and is not limited to mechanical fasteners.

The seat springs152extend in parallel across the frame148and may define a support plane180with the frame148. The cushion106may rest on top of the seat springs152along the support plane180and be supported by the seat springs152. The support plane180may have a variety of different orientations, and the support plane180itself may be flat, bent, curved, or contoured based on the elastic property and structure of the seat springs152. The cushion106is generally supported along the support plane180formed by the seat springs152regardless of orientation.

The support spring154extends across the frame148in an arc-like shape. Specifically, the support spring154extends from the first side164of the frame148toward the base member110(i.e., opposite direction of the support plane180) and then extends upward toward the support plane180to attach to the second side166of the frame148. As illustrated inFIG. 1, the support spring154defines a gap area181with the seat springs152. Furthermore, the support spring154extends into the void144and is positioned relative to the movement mechanism132so that a predetermined clearance is maintained between the seat support assembly134and the movement mechanism132.

The coil spring156may be a helical spring that extends between the support spring154and the two seat springs152within the gap area181. More particularly, the coil spring156extends vertically from the support spring154to the seat springs152in an outwardly direction opening helix to contact both of the seat springs152. The coil spring156biases the seat springs152toward the support plane180. The coil spring156is attached to the support spring154by way of one or more clamps182. While a variety of materials may be used, the coil spring156may be made of wire, and more specifically metal wire that has a circular cross-section. Due to its construction and composition, the coil spring156is elastic and resilient, such that it may compress and/or be deflected when acted on by a force and then spring back to its initial length and/or position when the force is removed. This may occur for example when the occupant sits or lies on the cushion106.

The seat support assembly134may also include one or more upper transverse wires186and one or more lower transverse wires187, which are collectively referred to as transverse wires186and187. The upper transverse wires186span the frame148in a direction that is across (i.e., transverse to) the seat springs152. The upper transverse wires186may be disposed just below the seat springs152on opposite sides of the coil spring156. Each upper transverse wire186is attached to the seat springs152and the coil spring156by way of clamps188. The lower transverse wire187spans the frame148in a direction that crosses the support spring154. The lower transverse wire187is attached to each of the support springs154by way of the clamps188.

The transverse wires186and187provide additional support for the seat springs152, the coil spring156, and the support springs154. Specifically, the upper transverse wires186spread out the load of the force that is applied to adjacent seat springs152and/or coil spring156and prevent the seat springs152from being pushed out of alignment. Similarly, the lower transverse wire187prevents the support springs154from being pushed out of alignment due to pressure exerted onto the support springs154by respective coils springs156. When a plurality of spring support subassemblies150are provided in the seat support assembly134, the upper transverse wires186may be connected to each seat spring152and each coil spring156, and the lower transverse wires187may be connected to each support spring154. The location of the transverse wires186and187can be changed and is not limited to the location illustrated in the figures. For example, the lower transverse wires187may be positioned closer to an area where the support spring154is attached to the coil spring156.

The seat support assembly134supports the cushion106and prevents the cushion106from interfering with the movement mechanism132located between the seat support assembly134and the base member110. More particularly, the seat springs152support the cushion106along the support plane180, the coil spring156supports and biases the seat springs toward the support plane180, and the support spring154supports and biases the coil spring156toward the seat springs152. When a force is exerted on to the cushion106by the occupant, the seat springs152maintain the position of the cushion106about the support plane180to prevent the cushion106from caving into the void144and interfering with the movement mechanism132. The coil spring156maintains the position and/or minimizes the elastic deformation of the seat springs152, so that the seat springs152do not interfere with the movement mechanism132even when the movement mechanism132reclines the seat back member102and/or extends the leg rest member104. The support spring154maintains the position and/or minimizes the movement of the coil spring156within the void144to maintain a predetermined clearance from the movement mechanism132. Accordingly, the seat support assembly134provides the necessary support to the cushion106while maintaining a predetermined distance from the movement mechanism132.

By supporting the cushion106, the seat support assembly134further improves the sitting comfort for an occupant. Specifically, the seat support assembly134may provide a firmer and more supportive cushion106that does not sag under the weight of the occupant.

Furthermore, by having the support spring154, the seat support assembly134has a compact design for preventing interference with the movement mechanism132. Specifically, the coil spring156is supported by a wire (i.e., support spring154) that accommodates significantly less space than, for example, a rigid box like fixture that can be disposed under the coil spring156.

In the example embodiment the seat support assembly134includes two spring support subassemblies150. The seat support assembly134may further include additional seat springs152that are not supported by a coil spring156. As an example,FIG. 3illustrates a seat support assembly300that includes at least one seat spring302positioned between two spring support subassemblies150. The seat spring302extends across the frame148and is attached to the frame148by way of clips168as seat springs152of the spring support subassemblies. The additional seat spring302provides additional support in an area between the spring support subassemblies150. More particularly, the two, spring support subassemblies150are separated by a predetermined distance that prevents the coil springs156from interfering with each other. The seat spring302is positioned within the predetermined distance to provide additional support to the cushion106. WhileFIG. 3illustrates only one seat spring302between the two spring support subassemblies150, more than one seat spring302may be used based on the space between the two spring support subassemblies.