Abstract:
Improved methods and apparatuses relating to installation of a sleeper mechanism into a frame of a sofa sleeper are disclosed. In one embodiment, initially the frame is aligned such that an open bottom portion of the frame is upright and facing outwardly. The sleeper mechanism is then advanced towards the open bottom portion and hook apertures on the brackets are engaged with upper fasteners on the frame. The sleeper mechanism is then swung inwardly towards the top portion of the frame until notches on the bracket are passed lower fasteners on the frame and then swung back towards the open bottom portion to engage the notches with the lower fasteners.

Description:
RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Application No. 61/234,204, filed Aug. 14, 2009, which is hereby fully incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to sofa sleepers and more particularly to an improved method of installing a sleeper mechanism into a sofa sleeper. 
     BACKGROUND OF THE INVENTION 
     Sofa sleepers are popular with consumers because they can function both as a standard sofa and as a bed. A sleeper mechanism, essentially a foldable mattress supported by a sofa sleeper mechanism, can be folded within sofa frame underneath the sofa cushions to allow the sofa sleeper to be used as if it were a standard sofa. When the cushions are removed and the sleeper mechanism is extended out, the sofa sleeper can function more similar to a bed. 
     The sofa sleeper mechanisms of sofa sleepers are typically installed into the frame of the sofa sleeper along an assembly line. The frame typically being formed of wood or wood products fastened together to form a pair of sides, a back, and a lower base, the lower base being open on top and on bottom. The “sides” include a pair of side panel members that face the cavity to receive the sleeper mechanism. Typically, the sofa frame is “dressed” with fiber board, padding, and upholstery before the sleeper mechanism is installed. The sofa sleeper mechanisms have a pair of elongate horizontal brackets, one on each side of the sleeper mechanism upon which several linkages are connected. The sleeper mechanisms attach to the sofa frames exclusively or primarily by fasteners extending through the pair of brackets and into or through the sides of the frame. Each of the elongate horizontal brackets have a plurality of L-shaped slots extending downwardly from a top edge of the brackets. The lower leg of the L pointing towards the “head side” or top of the sleeper mechanism and mattress combination, that is they point toward the back of the sofa sleeper. Conventionally, the sleeper mechanism is positioned on a table and the sofa sleeper frame is lifted up and over the sleeper mechanism and is then lowered, by an individual on each end, down over the sleeper mechanism. Each end of the sofa frame maneuvered and adjusted to position studs or screws that are extending horizontally inward from each of the respective two side panel members down into the L-shaped slots of the elongate horizontal brackets that extend downwardly from the top edge of the bracket. Typically at least two studs, bolts or screws are extending from each side of the sofa frame that need to be guided into the slots extending from the top of the mechanism. The threaded fasteners are guided downward, by maneuvering the fully dressed sofa frame, and then are guided rearwardly in the lower leg of the L-shaped slots. The at least two studs, bolts, or screws are then tightened and additional wood screw type fasterners may be added through existing holes in the bracket into the side panel member. The sleeper frame with sleeper mechanism attached therein is moved to the next operation in the sofa assembly process. 
     Such assembly process demands at least two individuals to lift and maneuver the “fully dressed” sofa frame over the sleeper mechanism. Such sofa frame is typically much heavier than the sleeper mechanism. Thus, this type of assembly is awkward and inefficient as it is difficult to precisely maneuver the heavy fully dressed sofa frame so that the extending threaded members are guided into the L-shaped slots and then are guided rearwardly to finally seat at the end of the slot. Other than the workers forcing the threaded members into the end of the slot there is no assurance that the sofa mechanism will be properly seated therein. With the fasteners being inside the sofa and not readily accessible or viewable, such misalignment may go unnoticed and can lead to subsequent loosing of the overall sleeper mechanism to sofa frame attachment. 
     Moreover, the fasteners that extend from the side panel members are attached to downwardly extending slots on the horizontal brackets of the sleeper. If the fasteners securing the brackets to the sofa frame loosen, the mechanism can fall out of the sofa frame when the sleeper sofa is lifted by the consumer. If there is any shift forward of the threaded members with respect to the horizontal brackets the sleeper mechanism can fall within the sleeper mechanism cavity and can fall out of the sofa frame when lifted by the consumer. 
     Such an assembly above also dictates at least two people handling the sofa frame and sleeper mechanism install. A more reliable and efficient means of assembling sleeper mechanisms into sofa frames is needed. 
     It is possible to install such sleeper mechanisms with the sofa frame rotated 90 degrees backwards and with the open bottom of the unit facing outwardly. This is quite difficult in that conventional slots on the horizontal brackets of sleeper mechanisms extend from the top edge and go rearwardly (toward the users&#39; head when the mechanism and mattress are open), the sleeper mechanism must be manually held upward to seat the threaded members in the slot while the threaded members are being secured. This also is awkward and increases the potential of the threaded fasteners not being properly seated in the end of the L-shaped or hook shaped slots. The sleeper generally must then be partially opened to secure the threaded fasterners in place, while the workers are bearing the weight of the sleeper mechanism, and to drive additional fasteners, typically screws, through the horizontal bracket (oriented vertically for this step) for additional support. The assembled sofa frame and sleeper then continue along the assembly line. 
     Although this process allows lifting of the relatively lighter sleeper mechanism compared to the sofa frame, there remains a need for a more efficient and less labor intensive method of installing a sleeper mechanism in a sofa sleeper. 
     SUMMARY OF THE INVENTION 
     An improved system and method for installing a sleeper mechanism into a frame of a sofa sleeper increases efficiency of installation and the safety of the finished product. 
     In an embodiment of the invention, the sofa frame is rotated backwardly so that it rests on its back and so that the open base of the frame is facing outwardly. The sofa frame has hanging support, such as threaded members, extending into a sleeper mechanism cavity. A sleeper mechanism with horizontal brackets on each end of the sleeper mechanism have slots or apertures, in said brackets, adapted to receive the threaded members by a simple horizontal placement motion to allow the sleeper mechanism to be inserted in the sleeper mechanism cavity and to be hung on the extending threaded members, whereby the weight of the sleeper member can be supported by the threaded members within the sleeper mechanism cavity during completion of the fastening of the horizontal brackets, rather than having the weight of the sleeper mechanism supported by the workers during such fastening. 
     A further feature and advantage of embodiments of the invention is that at least one of two “original” fasteners on each side of the sofa frame may be utilized to engage the horizontal bracket at a slot underneath or through a hole in the horizontal bracket such that the weight of the sleeper mechanism when the sofa sleeper is in the normal use position, is supported by said original fastener without an opening of said slot extending upwardly. 
     In an embodiment of the invention, hanging support members, configured as threaded fasteners extend horizontally inward from each of the frame side panel, at least one on each side panel, toward the opposite side panel, the horizontal bracket of the sleeper mechanism having a slot to engage the at least one threaded member. The slot in an embodiment having a overall y-shape, with an expanded mouth opening to initially receive and guide the threaded member during the horizontal placement motion of the sleeper mechanism into the open bottom of the sofa frame. In an embodiment the lower leg of the slot extends toward the foot end (front end) of the sleeper mechanism, such that the seating end of said slot is extending upwardly and such that the sleeper mechanism may be hung on the extending threaded member. 
     In an embodiment of the invention, once the sleeper mechanism is hung from the first original hanging support members on each side of the sofa frame, the sleeper mechanism is swung away from the workers, toward the top of the sofa frame to facilitate fastening of the mechanism to additional second original fasteners extending from the side frame members, such as screws, studs, or bolts. In an embodiment, the horizontal brackets on each side of the sleeper mechanism will have a slot, or recess extending from the bottom edge of the horizontal member to receive the second original support members. In embodiments the suspended sleeper mechanism is swung past the second original fasteners by manually deflecting the horizontal brackets inwardly toward the other respective horizontal bracket, or maneuvering the mechanism to move the bracket inwardly, and the suspended sleeper mechanism is then swung back toward the worker(s) to allow the slot or recess to engage with the second original support member, such as a threaded fastener. 
     In embodiments, the original primary support member and the original secondary support member may be conventional T nuts inbedded into the side panel member with bolts threaded therein and extending therefrom. 
     In an embodiment, the threated fasteners can be part of or attached to a bracket that is secured to the side panels. For example, a mortise can initially be cut into a side board on each side of the frame. A pair of brackets can be attached to each side board at the mortise and a pair of stud bolts can be extending from each bracket towards the open bottom of the frame. To install the sleeper mechanism, the frame can be laid on its back with the open bottom facing forwardly. The sleeper mechanism can be advanced towards the open bottom in its folded position. The stud bolts extending from the frame portion can be inserted through apertures facing the threaded members on the horizontal brackets of the sleeper mechanism. The sleeper mechanism can be affixed to the frame by tightening nuts over each stud bolt. 
     In another embodiment, installation of a sleeper mechanism into a frame of a sofa sleeper utilizes a bracket. Initially the frame is aligned such that an open bottom portion of the frame is upright and facing outwardly. The sleeper mechanism is then advanced towards the open bottom portion and hook apertures on the brackets are engaged with upper fasteners on the frame. The sleeper mechanism is then swung inwardly towards the top portion of the frame until notches on the bracket are passed by lower fasteners on the frame and then swung back towards the open bottom portion to engage the notches with the lower fasteners. The notches may be V-shaped. When the sofa is completed the V-shaped notches are inverted and facilitate support of the sleeper mechanism whether or not the lower fasteners are securely tightened, that is even if they loosen they still can carry the weight of the sleeper mechanism. 
     In a further embodiment, a sofa sleeper includes a frame and sleeper mechanism connected by a pair of brackets. Frame includes a top portion, an opposing bottom portion and an upper and a lower fastener disposed on each of an opposing pair of sides. Sleeper mechanism is disposed within the frame in a collapsed position. The brackets are connected to the sleeper mechanism with fasteners extending through a top slot and a bottom notch in each bracket. The top slots are hook shaped to capture the fasteners and secure their seating in the slot by gravity. 
     A feature and advantage of embodiments of the present invention is that installation of the sleeper mechanism into the frame can be done much more quickly and efficiently than with prior methods. 
     Another feature and advantage of embodiments of the present invention is that the sleeper mechanism can be more securely held within the frame. In some embodiments, even if the fasteners become loose, the sleeper mechanism will remain secured to the frame. 
     Another feature and advantage of embodiments of the present invention is a safer installation process. The elimination of the need to unfold and fold each sleeper mechanism eliminates that likelihood of pinching of body parts that comes with folding and unfolding the unit. 
     A feature and advantage of the invention is that the heavier fully dressed sofa frame does not need to be lifted or maneuvered during the sleeper mechanism to sofa frame install. A further feature and advantage of the invention is that once the sleeper mechanism is hung on the extending threaded fasteners, the workers can focus on the attachment procedures rather than on supporting the weight of the sleeper mechanism. 
     A feature and advantage of embodiments of the invention is that support fasteners are urged to seat in L-shaped slots during assembly by gravity. 
     A feature and advantage of embodiments of the invention is that the engagement of notches and the retention of the engagement of notches on the horizontal brackets of the sleeper mechanism with horizontal extending support fasteners is facilitated by gravity operating on the supported sleeper mechanism. 
     Another feature and advantage of embodiments of the present invention is that during the time that the workers are supporting the weight of the sleeper mechanism, the workers only need to guide the sleeper mechanism onto a pair of hanging members extending from the side panel members of the sofa frame, and that an expanded, such as a V-shape opening of a receiving slot on the horizontal mechanism facilitates and simplifies the guidance of the sleeper mechanism onto said hanging members. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an isometric view of a sofa sleeper frame according to an embodiment of the present invention. 
         FIG. 2  is a side view of the sofa sleeper frame of  FIG. 1  with brackets at the mortise, the sofa frame rotated 90 degrees on the sleeper mechanism ready for insertion. 
         FIG. 3  is a partial view of the sofa sleeper frame of  FIG. 1 . The sleeper mechanism is not shown for clarity. 
         FIG. 4  is a side view of a different embodiment of a sofa sleeper frame and a sleeper mechanism ready for insertion into the open bottom of the base of the sofa frame. 
         FIG. 5  is a detailed perspective view of a bracket shown in  FIG. 2 . 
         FIG. 6  is side elevational view of a horizontal bracket according to the embodiment of  FIG. 4 . 
         FIG. 7  is a side elevational view of a sleeper mechanism with the horizontal bracket of  FIG. 6  installed in a sofa frame. 
         FIG. 8  is a cross-sectional view taken at line  8 - 8  of  FIG. 5  and illustrating a primary hanging support configured as a t-nut and bolt. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIG. 1 , a sofa frame portion  100  of a sofa sleeper according to an embodiment of the present invention is illustrated. Sofa frame portion  100  includes a front  102 , a back side  104 , and a pair of sides. Sofa frame  100  can be comprised of wood or wood product and have an open bottom  105  at a base  107 . Although the present disclosure describes the invention with regard to a sofa sleeper, it will be understood that the concepts described herein could be applied to any other type of furniture employing a foldable sleeper mechanism, such as, for example, a chair. 
     Referring to  FIGS. 1-4 , each side frame  106  of frame  100  can include a side panel  108  having a mortise  110 . The mortise  110  can be created by cutting an opening into side panel  108 . A pair of brackets  112  can be affixed to each side panel or board  108  at cutout or mortise  110 . Bracket  112 , as depicted more clearly in  FIG. 4 , can have a generally L-shaped body. Alternatively, bracket  112  can have various other shapes, such as, for example, a U-shape. Moreover a single bracket can be used on each side rather than two. Bracket can include an aperture  114  through an upper portion thereof that can be used to mount bracket to an outside surface of side board  108  with a complementary aperture  116  through side board  108 . Bracket  112  can also include apertures  118  through a lower portion thereof that can be sized to accommodate studs or bolts  120 . As shown in  FIG. 3A , side board  108  can optionally include grooves  122  for accommodating the top of the studs or bolts  120 . Alternatively, as shown in  FIG. 3B , side board  108  can include recesses  122  for accommodating the studs or bolts  120 . The bracket provides hanging support members  123  for suspending the sleeper mechanism  125 . 
     An attachment piece  124  of a sleeper mechanism may be configured as an angle iron and attached to or made an integral part of the horizontal bracket  127  associated with sleeper mechanism  125 . Such sleeper mechanisms have mattress support potions and linkages  129  that connect the horizontal bracket to the mattress support portions. The details of the sleeper mechanism will not be discussed in detail other than the horizontal bracket that is utilized to connect the sleeper mechanisms to sofa frames. Reference is made to U.S. Patent Publication No. 2008/0098518 for details of such a mechanism. The contents of said reference is incorporated by reference herein. Attachment pieces  124  are the portions of the sleeper mechanism that first come into contact with frame  100  while installing the sleeper mechanism and are used for affixing sleeper mechanism to frame  100 . Attachment piece  124  can have a generally L-shaped body with an upper portion  126  and a lower portion  128 . Upper portion  126  can include apertures  130  and lower portion  128  can include apertures  132 . Apertures  130  in upper portion  126  can be used for securing to a horizontal bracket of a convention sleeper mechanism. 
     The manufacturing process of a sofa sleeper begins with the assembly of the frame  100 . Assembly of the frame  100  can include cutting the mortises  110  into the side boards  108 . At the time the frame  100  is assembled, the brackets  112  are affixed to the side boards  108  and the stud bolts  120  are inserted through apertures such that the project downwardly and into mortises  110 . The studs may be welded to the bracket base or otherwise affixed. Upholstery or other coverings can then be added to the frame  100 . After the upholstery is added, the sleeper mechanism can be installed. 
     To install the sleeper mechanism, the frame  100  is rested on its back frame  104 , such as on a cart  131  or a table, with the open bottom facing outwardly towards the installer as depicted in  FIG. 3C . The stud bolts  120  are therefore facing the installer as well. The sleeper mechanism is then moved substantially horizontally in the y direction towards the frame  100  in its folded position and the hanging support members  120  configured as threaded  120  members are inserted through the apertures  132  in lower portion  128  of attachment piece  124 . The studs or bolts  120  ensure that the sleeper is in the proper position and temporarily support the weight of the sleeper. The sleeper is then secured to the frame by attaching four nuts to the four studs or bolts  122  on each side of the frame  100 . This securely attaches the attachment piece  124  and the horizontal bracket  127  of the sleeper with the brackets  112  of the frame  100 . The combined unit can then continue the assembly process or be prepped for sipment. 
     The above described process provides for installation of sleeper mechanisms into sofa sleepers much more quickly and safely than existing methods. The number of steps for installation is greatly decreased as the sleeper mechanism only needs to be put in place and four nuts tightened on each side. This greatly simplifies a process that heretofore has involved having to unfold and fold the sleeper mechanism and attach multiple bolts and/or screws in separate discrete steps. In addition, elimination of the need to unfold and refold the sleeper mechanism decreases the likelihood of injury due to pinching. 
     Referring now to  FIGS. 5 ,  6 , and  7 , there can be seen a horizontal bracket  202  that is part of and can be used in mounting a sleeper mechanism  204  to a sofa frame  206  of a sofa sleeper  200  according to an embodiment of the present invention. In this view the horizontal bracket is vertical such as when the sleeper mechanism is being inserted into the sleeper mechanism cavity  211 . In normal use the horizontal bracket will be horizontal. Horizontal bracket  202  can include a slot  208  intermediate the top edge  209  and bottom edge  212  of bracket  202  and a bottom notch or opening  222  at bottom edge  212  of bracket  202  for connection to a sleeper mechanism  204 . Bracket  202  also includes a y-shaped slot  216  having a mouth or opening  218  along a top of bracket  202  and a recess  220 . The length l of the mouth is preferable at least 1″. In other embodiments at least ¾ of an inch. A notch  222  that, in some embodiments, is configured as a V-notch can also be defined at the lower edge  24  of bracket  202 . In one embodiment, as depicted, L-shaped or hook slot  216  and V-notch  222  are on opposing edges of bracket  202 . The slot has a seating portion  223  which engages the hanging support member extending from the sofa frame at the side panel  229 . In other embodiments, hook aperture  216  and V-notch  222  can be presented on a common side of bracket  202 . Bracket  202  can also include a plurality of other apertures  224  therethrough used to fasten supplemental fasteners  229  such as wood screws. 
     To install a sleeper mechanism  204  in a frame  206  of a sofa sleeper  200  with brackets  202 , first a pair of horizontal brackets  202  is provided with sleeper mechanism  204 . A pair of fasteners  232   a ,  232   b  are also extended through a side frame (not pictured for sake of clarity) of frame  206 . In one embodiment, fasteners comprise a t-nut  234  inserted through side panel  229  and with a bolt  232  or screw extending inwardly from t-nut  234  toward the opposing side and threadably connected thereto. Such is a primary hanging member  235  for initial hanging of the sleeper mechanism. In various embodiments, the brackets  202  and fasteners  232  are preinstalled on the sleeper mechanism  204  and sofa frame  206 , respectively. 
     Referring to  FIGS. 5 and 7 , to install the sleeper mechanism  204 , the frame  206  is laid on its back  228  such that an open bottom  230  of the frame is oriented upwardly and outwardly. Note that  FIG. 7  illustrates the t-nuts  234  which are imbedded into the side panel  229  of the sofa frame, but in this view the side panel is omitted. 
     The sleeper mechanism is moved substantially horizontally into the sleeper mechanism cavity  211 . To connect sleeper mechanism  204  to frame  206 , first the hook slots  216  on each side of sleeper mechanism  204  are mounted on fasteners  232   a  such that the fasteners  232   a  enter through openings  218  and engage bracket  202  at recesses  220  and seating portion  223 . This can be most easily done by orienting the sleeper mechanism  204  at an angle relative to the frame portion  206 . The relatively large openings  218  and inner perimeter of hook apertures  216  provides for significant alignment tolerance in mounting the hook apertures  216  onto fasteners  232   a , which can allow both brackets  202  to easily be mounted simultaneously. This can be readily accomplished by a single installer. Because of the shape of hook slots  216 , and orientation, upwardly, the sleeper mechanism  204  is now suspended from frame  206  without having to be supported or held in place by a user. The sleeper mechanism  204  and bracket  202  are then swung inwardly from the bottom  230  of frame  206  about hook apertures  216  and fasteners  232   a , until V-notches  222  are further inward in frame  206  than the lower fasteners  232   b . This also necessitates pushing the brackets  202  inwardly relative to the sides of frame  206  to provide a clearance allowing the brackets  202  to pass beyond the fasteners  232 . The sleeper mechanism  204  is then swung back towards the bottom  230  of the frame  206  so that V-notches  222  engage lower fasteners  232   b . This step can be done for the pair of brackets  202  either sequentially or simultaneously. 
     To complete the installation process, fasteners  232  can then be tightened to further secure the sleeper mechanism  204  in place on the frame  206 . Additional supplemental fasteners, such as wood screws  229  can be attached thru apertures  224  into the sofa frame. Access to fasteners  232  for tightening can require partially opening the folded mattress of the sleeper mechanism  204 , but does not require completely opening the unit as with many prior art units. In one embodiment, the sleeper mechanism  204  only needs to be opened three inches to allow sufficient access for tightening fasteners. 
     “Attached to” and “connected to” can have intermediate members to make the connection, such as a bracket or a portion of a fastener assembly, and need not be direct component to component engagement. 
     The invention has been described above with reference to several embodiments thereof. It will be apparent to those skilled in the art that alterations may be made in the embodiments described without departing from the scope of the invention. Thus, the scope of the present invention should not be limited by the embodiments described herein, but rather by the language of the claims and the equivalents of those structures.