Abstract:
This invention is directed to a futon sofa sleeper having a sofa frame, a folding mechanism and a mattress assembly. The a sofa frame has a back with a cavity and a pair of opposed arms. The folding mechanism folds into and out of the sofa frame and is extendable from a first position to a second position. The folding mechanism includes a frame with a rear section rotatably coupled with the sofa frame, a middle section pivotally coupled with the rear section, and a front section pivotally coupled with the middle section. The mattress assembly is supported on the folding mechanism and contains a shell and an inner support received within the shell. The inner support including an innerspring construction and an air bladder, wherein in the first position, the rear and middle sections of the folding mechanism are located within the cavity and the front section is used as a seating surface and wherein in the second position, the rear, middle, and front sections are used as a sleeping surface.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    Not Applicable. 
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not Applicable. 
       BACKGROUND OF THE INVENTION 
       [0003]    This invention relates generally to a folding mechanism for a sofa sleeper and, more particularly, to a folding mechanism for a futon type sofa sleeper having a mattress that contains both an innerspring construction and an air bladder, whereby the air bladder may be deflated for easy storage of the mattress within the futon sofa sleeper. 
         [0004]    Traditional futon sofa sleepers are designed to be used as both a sofa and a bed. The futon sofa sleepers are designed with a folding frame mechanism that allows the futon mattress to be used as the support for the user when the unit is used as a sofa as well as a bed. Specifically, the futon mattress rests upon a support surface and the support surface can be moved from a sofa configuration to a sleeping configuration. The mattress supports the user in both the seated position and the sleep position. The mattress is typically foldable and includes an outer shell and an inner material. Due to the necessity of the mattress to fold, the inner material is typically a bedding material, including but not limited to, foam, feathers, cotton stuffing, and the like. Thus, while the mattress may be folded, the composition of the inner material does not provide a sleeping or sitting surface that is as comfortable as a typical sofa sleeper. Further, standard futon sofa sleepers typically sit low to the floor. As such, the futon sofa sleeper, when in the sofa configuration, is very low and not as comfortable to the seated user as a typical sofa. 
         [0005]    Thus, it would be desirable to manufacture a futon sofa sleeper that provides the enhanced comfort and the look of a conventional sofa sleeper for the individual sleeping or sitting thereon. 
       BRIEF SUMMARY OF THE INVENTION 
       [0006]    This invention is directed to a futon sofa sleeper having the appearance of a conventional sofa. The sofa sleeper contains a sofa frame, a folding mechanism, and a mattress. The folding mechanism is coupled to the sofa frame by a mounting frame. The folding mechanism is movable between a stowed, sofa position and a deployed, sleeper position. The sofa frame includes a pair of sides and a back with a cavity. The folding mechanism contains a frame with rear, middle and front sections. The cavity houses the rear and middle sections of the frame when the frame is in the sofa position. The rear section is rotatably coupled to the section and the middle section is rotatably coupled with the front section. Coupling is achieved via hinges. Each of the portions of the folding mechanism contain a support surface. The support surfaces are used to support the mattress. 
         [0007]    The mattress contains a shell and an inner support. The shell includes a lower panel, a sidewall portion, and a cover. The lower panel, sidewall portion, and cover fit together to form a cavity to receive the inner support. The inner support includes both an innerspring portion and an air bladder portion. The air bladder portion has a valve apparatus, which is adapted to selectively allow air into and out of the air bladder. 
         [0008]    The air bladder and innerspring portions are configured to provide the support of a conventional mattress while also allowing for easy folding during storage. This is accomplished due to the fact that the air bladder may be deflated when not in use. The air bladder portion once deflated is relatively thin thereby resulting in a compact configuration that fits within the cavity in the back of the sofa frame. Moreover, the location of the spring portion when in the stowed, sofa configuration allows the futon sofa sleeper to have the feel of a conventional sofa for a person sitting thereon. Thus, the inherent nature of the folded mattress when stored and the positioning of the innerspring portion, provides a seating surface that retains the form and fit of a conventional sofa. 
     
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
         [0009]    These and other objectives and advantages of the present invention will be more readily apparent from the following detailed description of the drawings of the preferred embodiment of the invention that are herein incorporated by reference and in which: 
           [0010]      FIG. 1  is a perspective view a futon sofa sleeper in a stowed, sofa position according to the present invention; 
           [0011]      FIG. 2  is a cross-sectional view of the futon sofa sleeper of  FIG. 1  in the stowed, sofa position, taken along the line  2 - 2 ; 
           [0012]      FIG. 3  is a view similar to  FIG. 2 , with the futon sofa sleeper in the stowed, sofa position and the back cushion rotated upwardly and over the back; 
           [0013]      FIG. 4  is a view similar to  FIG. 3 , but with the futon sofa sleeper in an intermediate, folded position and the air bladder portion of the mattress being deflated; 
           [0014]      FIG. 5  is a view similar to  FIG. 4 , but with the futon sofa sleeper in a deployed, sleeper position and the air bladder portion of the mattress being inflated; 
           [0015]      FIG. 6  is a perspective view of the futon sofa sleeper of  FIG. 3  with the mattress removed; 
           [0016]      FIG. 7  is an enlarged portion of  FIG. 6  showing a lock assembly; 
           [0017]      FIG. 8  is a perspective view of the futon sofa sleeper of  FIG. 5  with the mattress removed; and 
           [0018]      FIG. 9  is an front, exploded, perspective view of the mattress. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0019]    With initial reference to  FIGS. 1-3 , a sofa sleeper according to the principles of the present invention is designated generally with the reference numeral  10 . Throughout this specification, the term sofa sleeper  10  is also intended to encompass love seats and other smaller units. The sofa sleeper  10  can be converted from a stowed, sofa position, shown in  FIGS. 1-3  to a deployed, sleeper position, shown in  FIG. 5 . As shown in  FIGS. 1 and 2 , the sofa sleeper  10  includes a sofa frame  12 , a folding mechanism  14 , a mattress  16 , and a lock assembly  18 . The sofa frame  12  includes a pair of arms  20  and a back  22 . Both the arms  20  and the back  22  are upholstered in a traditional manner. As shown in  FIGS. 2 ,  4 , and  6 , the back  22  contains a cavity  24  that houses a portion of the folding mechanism  14  and mattress  16  when the sofa sleeper is in the sofa configuration. As seen in  FIGS. 1-3 , the sofa sleeper  10 , when in the stowed, sofa configuration, contains a back and cushion  26  that supports the user when seated. Further, the mattress  16  also supports the user when seated, as will be further discussed below. The back cushion  26  may be coupled to an upper surface  30  of the back  22  or may be a loose cushion design. As such, the back cushion  26  can be rotated upwardly and out of the way when the futon sofa sleeper  10  is converted from stowed, sofa position to the deployed, sleeper position. 
         [0020]    Referring now to  FIG. 8 , the folding mechanism will be discussed. The folding mechanism  14  is coupled to the arms  20  of the sofa frame  12  and unfolds from within the cavity  24 . The folding mechanism  14  includes a frame  32 , a support surface  34 , and a pair rolling supports  36 . The frame  32  includes a rear section  38 , a middle section  40 , and a front section  42 . The frame  32  is 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. 
         [0021]    The rear section  38  includes front, side, and rear portions  44 ,  46 ,  48 . The front, side, and rear portions  44 ,  46 ,  48  can be separate pieces or can be an integral unit. As shown here, the front portion  44  and side portions  46  are integral and the rear portion  48  is coupled to the sides portions  46 . The rear section  38  further includes a plurality of cross members  50  that are coupled between the front and rear portions  44 ,  46  and are spaced apart to provide support. The side portions  46  of the rear section  38  are rotatably coupled to the arms  20  of the sofa sleeper  10 . Coupling occurs via a nut and bolt arrangement  52  and apertures  54  in both the side portions  46  of the rear section  38  as will be discussed further below. However, it should be understood that any suitable coupling method may be used. The rear section  38  is coupled to the middle section  40  by a plurality of hinges  56 . Specifically, the front portion  44  of the rear section  38  is coupled with a rear portion  58  of the middle section  40 . 
         [0022]    The middle section  40  includes front  60 , side  62 , and rear portions  58 . The front, side, and rear portions  60 ,  62 ,  58  can be separate pieces or can be an integral unit. As shown here, the rear portion  58  and side portions  62  are integral and the front portion  60  is coupled to the side portions  62 . The middle section  40  further includes a plurality of cross members  64  that are coupled between the front and rear portions  60 ,  58  and are spaced apart to provide support. As seen in  FIGS. 7 and 8  the cross members  64  of the rear and middle sections  38 ,  40  are aligned with one another. The middle section  40  is coupled to the front section  42  by a plurality of hinges  66 . Specifically, the front portion  60  of the middle section  40  is coupled with a rear portion  68  of the front section  42 . 
         [0023]    The front section  42  includes a front, side, and rear portions  70 ,  72 ,  68 . The front, side, and rear portions  70 ,  72 ,  68  can be separate pieces or can be an integral unit. As shown here, the front portion  70  and side portions  72  are integral and the rear portion  68  is coupled to the side portions  72 . The front section  42  further includes a pair of inner cross members  74  and a pair of outer cross members  76  that are coupled between the front and rear portions  70 ,  68  and are spaced apart to provide support. The front section  42  further includes a front foot portion  71  that is coupled to the front portion  70  and extends between the arms  20 . 
         [0024]    As seen in  FIGS. 5 and 8  the folding mechanism further includes the pair of rolling supports  36 . The rolling supports  36  are coupled to each of the outer cross members  76  via a nut and bolt arrangement, not shown. Each rolling support  78  includes an arm  80 , a front fork  82 , a rear fork  84 , and a pair of wheels  86 . The arm  80  is coupled with a lower surface  88  of the outer cross members  76 . The arm  80  is shaped as shown and contains a downward bend  90  proximate the rear portion  68  of the front section  42 . The arm  80  also contains an end  92  with the rear fork  84  attached thereto. The rear fork  84  contains a pair of legs  94  with the wheel  86  coupled therebetween. Each of the legs  94  contain an aperture  97  for attaching the wheel  86 . The front fork  82  is mounted vertically near the front portion  70  of the front section  42  and abuts the arm  80 . The front fork  82  depends downwardly from the lower surface  88  of the outer cross members  76 . The front fork  82  contains a pair of legs  96  with the wheel  86  coupled therebetween. Each of the legs  98  contain an aperture  96  for attaching the wheel  86 . 
         [0025]    As seen in  FIGS. 4 and 6 , the folding mechanism  14  is coupled to the arms  20  of the sofa frame  12  by a mounting frame  100 . The mounting frame  100  includes a pair of side portions  102  and a back portion  104 . The side portions  102  include upper, lower, front, and rear members  106 ,  108 ,  110 ,  112  that are coupled to the arms  20  of the sofa frame  12  via a plurality of screws  113 . It should be understood that any suitable coupling method may be used. The upper and lower members  106 ,  108  run parallel to one another along a lower portion  111  of the arms  20  of the sofa frame  12 . The front and rear members  110 ,  112  interconnect the upper and lower members  106 ,  108 . The back portion  104  includes upper and lower members  114 ,  116  that are coupled to the back  22  via a plurality of screws  118 . The upper and lower members  114 ,  116  of the back portion  104  run parallel to one another along a lower portion  120  of the back  22  of the sofa frame  12 . The upper and lower members  114 ,  116  are coupled to the rear members  112  of the side portions  102 . A support bracket  119  is coupled between the lower members  108  of the mounting frame. 
         [0026]    Referring now to  FIGS. 3 ,  4  and  7 , the lock assembly  18  will be discussed. The lock assembly  18  includes a pair of brackets  120  and a pair of latches  122 . The brackets  120  each contain a leg  124  and a riser  126 . The leg  124  of each lock assembly  18  is coupled to a front portion  128  of the lower member  108  of the side portion  106  of the mounting frame  100 . The legs  124  are oriented vertically. The riser  126  contains an upper portion  130  and a ramp  132 . The upper portion  130  contains a front  134  and a rear  136  and is oriented generally horizontally. The ramp  132  depends downwardly at an angle from the front  134  of the upper portion  130 , the purpose of which will be discussed further below. 
         [0027]    The latches  122  are coupled to an underside  138  of the side portions  72  of the front section  42  intermediate the front and rear portions  70 , 68 . The latches  122  depend downwardly from the side portions  72 . The latch  122  is shaped as shown and contains a mating surface  140  and a rest surface  142 . The mating surface  140  is an angled surface that contacts the ramp  132  of the riser  126  when the futon sofa  10  is moved from the deployed, sleeper position to the stowed, sofa position. The rest surface  142  is a horizontal surface and a portion of the mating surface  140  projects above the rest surface  142  to create a stop  144 . The stop  144  locks the folding mechanism  14  in place when the futon sofa  10  is moved from the deployed, sleeper position to the stowed, sofa position. Specifically, the stop  144  contacts the rear  136  of the upper portion  130  of the riser  126  as will be further discussed below. 
         [0028]    Turning now to  FIGS. 5 and 8 , the support surface  34  will be discussed. The support surface  34  contains a rear portion  148 , a middle portion  150 , and a front portion  152 . Each of the rear, middle, and front portions  148 ,  150 ,  152  are constructed of a wire grid that is coupled to the rear, middle, and front sections  38 ,  40 ,  42  of the frame  32 . Coupling occurs via weldment, however, it should be understood that any suitable coupling method may be used. 
         [0029]    As best seen in  FIGS. 5 and 8 , the mattress  16  rests upon the support surface  34  of the frame  32  of the folding mechanism  14 . Referring now to  FIGS. 5 and 9 , the mattress  16  includes a shell  154  and an inner support  156 . The shell  154  includes a lower panel  158 , a sidewall  160 , and a cover  162 . The lower panel  158  rests on the support surface  34 . The sidewall  160  contains a lower edge  164  and an upper edge  166 . The sidewall  160  is attached on its lower edge  164  to the lower panel  158  and extends around its perimeter. The cover  162  is attached to the upper edge  166  of the sidewall  160 . As is understood by one of ordinary skill in the art, the shell  154  consisting of the lower panel  158 , the sidewall  160 , and the cover  162  fit together to form a cavity  168  to receive the inner support  156 . Further, it will be appreciated by one of ordinary skill in the art that any attachment method for the cover could be used, such as a zipper, stitching, sewing or the like. In one embodiment, the sidewall has a zipper, not shown, attached on its upper edge  166  that is used to removably couple the cover  162  to the sidewall  160 . This embodiment provides a cover  162  that is removably attached so that the user has direct access to the inner support  156 . In another embodiment, the cover  162  is attached to the upper edge  166  of the sidewall  160  by stitching or sewing. This embodiment provides a permanent enclosure where the user will not have direct access to the inner support. 
         [0030]    With continued reference to  FIGS. 5 and 9 , the inner support  156  is shown received within the shell  154 . The inner support  156  broadly includes an innerspring portion  168  and an air bladder portion  170 , both portions having a height comparable to a conventional sofa mattress  16 . As is apparent to one of ordinary skill in the art, the mattress  16  further contains a foot end  172 , a middle section  174 , and a head end  176 . The innerspring portion  168  is generally located at the foot end  172  of the mattress  16  while the air bladder portion  170  is located at the middle section  174  and head end  176 . The air bladder  170  portion is sized to correspond to middle section  174  and head end  176  of the mattress  16  such that when the mattress  16  is folded for storage, the air bladder portion along with the rear and middle sections  38 ,  40  of the frame  32  fit within the cavity  24  in the back  22 . As best seen in  FIG. 5 , the innerspring portion  168  abuts the air bladder portion  170  to form a continuous support surface for the user when the mattress  16  is in the deployed position. The innerspring portion  168  of the mattress  16  is any one of a number of existing innerspring configurations available and known to one of ordinary skill in the art. As an example, innerspring portion can be a pocketed coil. 
         [0031]    The air bladder portion  170  is preferably made from a durable, air impermeable material, such as vinyl. The air bladder  170  may be one of a number of existing bladders currently available and known to one of ordinary skill in the art. The air bladder  170  includes a valve  178  that is integrally formed therein. The valve  178  is sized to accommodate an inflating pump, not shown that may be either external or internal to the bladder. In either configuration, the pump can contain a reversible deflation feature and/or a dump valve release system. Both the valve  178  and the pump are also conventional items known to one of ordinary skill in the art. Further, while the valve  178  is shown in  FIG. 9  in the upper corner, the placement of the valve is not material to the discussion. It will be appreciated by one of ordinary skill in the art that the valve  178  may be located in the air bladder when the cover is removably attached with a zipper, as discussed above. This embodiment would provide access to the valve by opening the zipper. Additionally, it is also understood that the valve may extend through the shell for outside access if the cover and, thus, the shell are permanently sealed. 
         [0032]    The operation of the sofa sleeper  10  will now be discussed.  FIG. 5  illustrates the sofa sleeper  10  in the deployed, sleep position, wherein the mattress  16  is useful as a sleeping surface. The air bladder portion  170  of the mattress  16  is inflated and the air bladder portion  170  and the innerspring portion  168  abut to provide a continuous support surface for the user.  FIG. 4  illustrates the sofa sleeper  10  in the intermediate, folded position, wherein the mattress  20  is ready to be stored. The air bladder portion  170  of the mattress  16  is deflated. From this position, the frame  14  is pushed inwardly to fully stow the mattress  16 . In the stowed, sofa position, shown in  FIGS. 2 and 3 , the stop  144  of the latch  122  is engaged with the rear  136  of the riser  126 , see  FIG. 7 . Further, the innerspring portion  168  of the mattress  16  provides a support for the seated user on the sofa sleeper  10 . Because the innerspring portion  168  is shaped and sized similarly to the support portion of a traditional sofa, the innerspring portion  168  provides a support closely resembling the feel of a traditional sofa. 
         [0033]    Referring again to  FIGS. 2 and 3 , to place the sofa sleeper  10  in a position for sleeping, the back cushion  26  is rotated upwardly and over the back  22 . The front foot portion  71  of the front section  42  of the frame is pulled upwardly so that the stop  144  may disengage from the rear  136  of the riser  126 . Once the stop  144  is disengaged, the folding mechanism  14  is pulled from within the sofa sleeper to the position shown in  FIG. 4 . It should be understood that the frame  32  unfolds as the user pulls on the front foot portion  71 . Specifically, the rear and middle sections  38 ,  40  are pulled from within the cavity  24  in the back  22  of the sofa sleeper. In this position the air bladder portion  170  is deflated. The rear section  38  rotates in a clockwise manner about the nut and bolt connection  52  between the mounting frame  100  and the side portion  46 . The sofa  10  is now in the deployed position as shown in  FIG. 5 . While  FIG. 5  shows the air bladder portion  170  inflated, it should be understood that when the mattress  16  and folding mechanism  14  are pulled from within the sofa sleeper  10 , the air bladder portion  170  is deflated. 
         [0034]    The description that follows takes into account an inner support that is enclosed by a shell with a removable cover as described above. Referring now to  FIG. 9 , the zipper, not shown, is used to expose the valve  178  as is understood by one of ordinary skill in the art. The pump, not shown, is engaged with the valve  178  and the air bladder portion  170  is inflated. When the air bladder portion  170  is fully inflated the pump is disengaged and the cover  162  is then re-zipped to hide the valve  178 . The sofa sleeper  10  in this position is ready for sleeping. 
         [0035]    When the mattress  16  is to be stowed within sofa sleeper  10 , the zipper, not shown, is used to expose the valve  178 . The valve  178  is then opened, allowing air to escape from the bladder  170 . Once the air is removed from the bladder  170 , the cover  162  is then re-zipped. 
         [0036]    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. 
         [0037]    From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects set forth above, together with other advantages which are obvious and inherent to the system and method. It will be understood that certain features and sub-combinations are of utility and may be employed without reference to other features and sub-combinations. This is contemplated and within the scope of the claims.