Abstract:
Furniture convertible between a seating position and a bed position. The furniture may include a frame including spaced apart arms, a first section having a closed position and an open position, where, in the closed position, the first section is substantially horizontal between the spaced apart arms, and a second section separately moveable from the first section. The second section is movable from a folded position, where the second section is stored substantially within the frame, to an unfolded position, where the second section is unfolded outside of the frame and disposed adjacent to the first section in the closed position, thus forming a horizontal sleeping surface.

Description:
FIELD OF INVENTION 
     The present disclosure relates to furniture, particularly seating furniture. More particularly, the present disclosure relates to seating furniture that is convertible from a folded configuration to an unfolded configuration, where the unfolded configuration may be used as a bed. 
     BACKGROUND 
     Convertible furniture has long existed to provide multi-functionality and space saving design. Sleepers, furniture pieces that unfold to provide a bed, have been particularly popular. Sleepers have been developed with several unfolding patterns and configurations to result in virtually every commonly available bed size, from cot to California king. Sleepers have found homes in health care for overnight guests in a hospital room. They are commonly seen in hospitality settings, provided as an extra bed within a hotel room. Sleepers are also common in residential settings were a sleeper can be used to accommodate friends and family visiting for the night. 
     Early convertible sleepers were often uncomfortable in both their folded and unfolded positions. In general the bed mechanisms limited the design options of the furniture when folded, leading to suboptimal comfort and appearance. Likewise, the need to be folded limited the comfort of the furniture when unfolded. Mattresses used with sleepers were necessarily thin and failed to adequately compare to traditional sleeping surfaces. Users could often feel the support structure used under the mattress. The design of the motion mechanisms used within the furniture often led to exposed linkages or springs when unfolded, resulting in undesirable gaps, pinch points or hard edges around the perimeter of the mattress. 
     There continues to be a need for a furniture piece that provides a folded position that is comfortable and aesthetically pleasing, minimizing or eliminating the ability to outwardly discern the furniture&#39;s ability to convert to a bed. Simultaneously, the furniture piece should produce an unfolded bed position that is able to provide a comfortable sleeping surface while minimizing the appearance and accessibility of a motion mechanism. 
     SUMMARY 
     In some embodiments, the present disclosure includes furniture convertible between a seating position and a bed position. The furniture may include a frame including spaced apart arms, a first section having a closed position and an open position, where, in the closed position, the first section is substantially horizontal between the spaced apart arms, and a second section separately moveable from the first section. The second section is movable from a folded position, where the second section is stored substantially within the frame, to an unfolded position, where the second section is unfolded outside of the frame and disposed adjacent to the first section in the closed position, thus forming a horizontal sleeping surface. 
     The present disclosure includes furniture convertible between a seating position and a bed position according to other embodiments having a frame including spaced apart arms, and a first section movable between a closed position and an open position where, in the closed position, the first section is substantially horizontal and a top surface of the first section is substantially flush with a top surface of the arms. The furniture may also include a second section and a third section moveable from a folded position, where the second and third sections are stacked within the frame, to an unfolded position, where the second and third sections are aligned horizontally and disposed adjacent to the first section in the closed position, to form a horizontal sleeping surface. 
     Furniture convertible between a seating position and a bed position is also described with a frame including spaced apart arms, each arm having a cavity between a side wall and an inner face thereof. The furniture may also include a first section pivotable between a closed position and an open position where, in the closed position, the first section is substantially horizontal, and where, in the open position, the first section is substantially upright. The furniture may have a first pivot assembly located substantially within the cavity for attaching the first section to the side wall. At least a second section pivotable from a folded position within the frame to an unfolded position at least partially outside of the frame may be part of the furniture, where the unfolded position is a horizontal position disposed adjacent to the first section in the closed position, to form a horizontal sleeping surface. The furniture may also have and a second pivot assembly located substantially within the cavity for attaching the second section to the side wall, where there are substantially no gaps between the sides of the first section and the inner face of the arms when the first section is in the closed position. 
     Another embodiment includes furniture convertible between a seating position and a bed position that comprises a frame including spaced apart arms and at least two movable sections disposed between the arms in the seating position. A motion mechanism is included that is configured to allow the at least two movable sections to convert between the seating position and the bed position. All upholstered components are connected and non-removable from the furniture. A first section of the at least two sections is moved while converting from the seating position to the bed position, but is in the same position in the seating position as in the bed position. Further, there is substantially no gap between the arms and the first section in either the seating position or the bed position. 
     These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiments, when considered in conjunction with the drawings. It should be understood that both the foregoing general description and the following detailed description are explanatory only and are not restrictive of the invention as claimed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of furniture in a seating position according to an embodiment of the present disclosure. 
         FIG. 2  is a perspective view of the furniture of  FIG. 1  in a partially unfolded position. 
         FIG. 3  is a perspective view of the furniture of  FIG. 1  in a bed position. 
         FIG. 4  shows the seating position of the furniture with the upholstery and cushions removed. 
         FIG. 5  shows the partially open position of the furniture with the upholstery and cushions removed. 
         FIG. 6  shows the bed position of the furniture with the upholstery and cushions removed. 
         FIG. 7  is an underside view of the bed position shown in  FIG. 6 . 
         FIG. 8  is a detailed underside view of the inside of an arm of the furniture in a partially open position. 
         FIG. 9  shows a top panel pivot assembly in a partially open position. 
         FIG. 10  shows a middle panel pivot assembly in the seating position. 
         FIG. 11  is a cut away view of an arm of the furniture in the seating position. 
         FIG. 12  is a cut away view of the arm of the furniture in the bed position. 
     
    
    
     DETAILED DESCRIPTION 
     Exemplary embodiments of this disclosure are described below and illustrated in the accompanying figures, in which like numerals refer to like parts throughout the several views. The embodiments described provide examples and should not be interpreted as limiting the scope of the invention. Other embodiments, and modifications and improvements of the described embodiments, will occur to those skilled in the art and all such other embodiments, modifications and improvements are within the scope of the present invention. Features from one embodiment or aspect may be combined with features from any other embodiment or aspect in any appropriate combination. For example, any individual or collective features of method aspects or embodiments may be applied to apparatus, product or component aspects or embodiments and vice versa. 
       FIG. 1  is a front perspective view of a convertible furniture piece, referred to herein as seat  100 , in a seating position according to an embodiment of the present disclosure. The illustrated embodiment shows the seat  100  as an ottoman. Ottomans are often provided as foot rests adjacent to other seats such as sofas or chairs. Ottomans may be used for sitting directly on the top thereof. Therefore an ottoman would be considered a seat as used herein. As used herein the term “seat” should be broadly constructed to include soft-topped tables, sometimes used instead of a traditional coffee table. The ottoman embodiment shown in  FIG. 1  may be described as backless, i.e. lacking a backrest in the seating position. Seats  100  of the present disclosure are not limited to such backless designs but may also include chairs or sofas with backrests provided when used in the seating position. 
     In the illustrated embodiment, the seat  100  is designed with a “tight,” finished appearance due to upholstered surfaces visible from each generally accessible direction. In one embodiment, all upholstered components are connected and irremovable from the seat  100 . In comparison, similar sleeper ottomans of the prior art are constructed with a slip cover merely draped over a folding bed frame, requiring the slip cover to be removed prior to unfolding the prior art products into a bed. A slip cover could be fit over the seat  100  of the present disclosure, but such a slip cover is not expected to be necessary to provide a finished look to the furniture. 
     As seen in  FIG. 1 , the seat  100  may include arms  102 , a top cushion  104 , and a front cross member  106 , all of which are preferably upholstered. A rear cross member  108  ( FIG. 2 ) is also provided. The arms  102  and the cross members  106 ,  108  may be supported off the ground by a set of feet  110 . The width W, i.e. the inside spaced-apart distance between the arms  102 , may vary, but should substantially correspond to the width of a bed being unfolded from the seat  100 . In the example of a cot-size bed, W may be about 30 inches. In one example, the top surface of the arms  102  is substantially flush with the upper surface of the top cushion  104 . 
       FIG. 2  is a perspective view of the seat  100  in a partially open position, such that the unfolding sequence of the seat  100  may begin to be understood. The top cushion  104  has been rotated in the direction R 1  from a substantially horizontal closed position in  FIG. 1  to a generally upright open position as seen in  FIG. 2 . When the top cushion  104  is pivoted to the open position, in the present embodiment, access is provided to a foot section  112  and a middle section  114 . To unfold the foot section  112  and the middle section  114 , a user can pull upwardly and outwardly on the front cross member  106  with respect to the arms  102 . In the illustrated embodiment, the seat  100  unfolds with two independent actions, moving the top cushion  104 , and separately moving the bed portion having the foot section  112  and the middle section  114 . 
     The foot section  112  may generally comprise a foot panel  116  attached to the bottom of a foot mattress  118 . Therefore the foot section  112  would be facing upward when the foot mattress  118  is above the foot panel  116 . The foot panel  116  may be formed from wood or other rigid supportive material. The foot panel  116  may be between about ½″ and about 1″ thick. The foot mattress  118  may have any known mattress material, such as coil springs, gels, memory foams, or combinations thereof. The foot mattress  118  may be between about 3″ and about 6″ thick to provide a comfortable sleeping surface. Similarly, the middle section  114  may include a middle panel  120  and a middle mattress  122  constructed similarly to the elements of the foot section  112 . 
     In the folded position ( FIG. 1 ), the middle section  114  may be stored generally horizontally and facing downwardly within the footprint of the arms  102 . Unfolding the middle section  114  as shown in  FIG. 2  may cause the middle section  114  to rotate in the direction R 2  substantially through 180 degrees to an upright facing position ahead of the arms  102 . The foot section  112  may be stored below the top cushion  104  in a generally horizontal, upward facing orientation relatively stacked above the middle section  114 . As the foot section  112  is lifted and pulled from the folded position, a hinge  124  ( FIG. 7 ) pivotably links the foot section  112  to the middle section  114  so that they may unfold as a pair. 
     The foot section  112  and the middle section  114  are supported by foot legs  126  and middle legs  128  respectively in the unfolded position. The process of folding and unfolding the foot section  112  and the middle section  114  concurrently facilitate the folding and unfolding of the foot legs  126  and the middle legs  128  from a substantially horizontal stored position substantially between the foot section  112  and the middle section  114  to their respective vertical unfolded positions. The operation of the middle legs  128  and the foot legs  126  may be done by any suitable mechanism that links the unfolding motion of the foot section  112  and the middle section  114  to the unfolding of the legs. A particularly suitable arrangement of the legs may be described by US Patent Publication US 2014/0101846, assigned to American Leather Operations, Dallas, Tex. 
     The arms  102 , the rear cross member  108 , and a front cross support  132  may be bolted or otherwise fixedly connected together to form a stationary frame for the seat  100 .  FIG. 2  shows an optional upholstery layer  130  may be provided along the inside of each arm  102  to conceal moving parts located behind the upholstery layer  130 , such as portions of the top panel pivot assembly and the middle panel pivot assembly discussed below. 
       FIG. 3  shows the seat  100  in the fully unfolded bed position. Flowing from  FIG. 2  to  FIG. 3 , one skilled in the art will recognize that the foot section  112  and the middle section  114  have been fully unfolded to each achieve an upwardly facing horizontal position with the foot mattress  118  and the middle mattress  122  laid out in front of the frame of the seat  100 . The top cushion  104 , supported by a top panel  134  ( FIG. 2 ) was rotated back from the upright open position to the horizontal closed position such that the top cushion  104  lies in close proximity to the middle mattress  122  to form a three-segment horizontal bedding surface. 
     As shown in  FIG. 3 , dimension G 1  is the gap between the side of the top cushion  104  and the inside face of a respective arm  102 . In some embodiments, the side of the upholstered top cushion  104  contacts the upholstery layer  130  or other upholstered portion of the arm  102  such that G 1  is substantially zero when the top cushion  104  is in the closed position. A similar gap-free fit (G 2 ,  FIG. 1 ) is preferred between the inside of each arm  102  and the ends of upholstered front cross member  106 . Accordingly, this allows the seat  100  to be attractive when used as a bed and to minimize the visibility of, and user contact with, portions of a motion mechanism of the seat. 
       FIGS. 4-6 , respectively, show the seat  100  in the seating position, the partially open position, and the bed position substantially similar to  FIGS. 1-3 .  FIGS. 4-6 , however, begin to show more of the inner workings of the seat  100  by omitting the upholstery and the cushion and mattress portions. Seen from  FIGS. 4 and 5 , each arm  102  may be constructed as an inwardly open box shape created from a side wall  136 , a top wall  138 , a bottom wall  140 , a front wall  142  and a rear wall  144 . The inwardly open box defines an arm cavity  146  ( FIG. 5 ) with an arm thickness  148 . 
       FIGS. 5 and 6  illustrate notches  150  of various sizes and shapes formed through the top panel  134 , the foot panel  116  and the middle panel  120 . The notches  150  into or through the foot panel  116  and the middle panel  120  may be particularly useful in accommodating portions of the foot legs  126 , the middle legs  128  or linkages thereof, particularly in the folded, stored position. 
       FIG. 7  shows an underside view of the un-upholstered seat  100  in the unfolded bed position. The hinge  124  is shown here. The hinge  124  may be a hinge having a pair of leaves  152  attached to the foot panel  116  and the middle panel  120  respectively. The hinge  124  may be arranged to provide a mandrel through the center of one or more torsion springs  154  so as to locate the center of the torsion spring  154  at and on the hinge line between the foot panel  116  and the middle panel  120 . The torsion spring  154  may have opposing legs arranged to be substantially parallel and opposite each other in their related state and with such legs contacting the surfaces of the foot panel  116  and the middle panel  120  when the panels are in the bed position. Accordingly, when the foot panel  116  and the middle panel  120  are in the folded and closed position, the legs of the torsion spring  154  may have undergone a 180 degree rotation to impart a torque on the foot panel. Such a torque is expected to be sufficient to reduce the force necessary to lift the front of the foot panel  116  when moving the foot panel from the folded position to the bed position. In other words, the torsion spring  154  may be configured to bias the foot section  112  and the middle section  114  into the unfolded position. The number of torsion springs  154  used may vary based on the desired magnitude of force needed. The desired force is likely to depend upon the size of the seat  100 . As a result, the user is given an assist when attempting to move the foot section  112  upwardly during the initial unfolding motion. Further, with the hinge  124  biasing toward the unfolded position, the hinge  124  helps control the motion in the folding direction as well, by providing a force opposing gravity as the foot section  112  seeks to collapse back into the folded position. 
       FIG. 8  is a detailed partial inside perspective view of an arm  102  with the top panel  134  in the open position and the middle panel  120  approaching the horizontal stored position. Shown are the side wall  136  and the top wall  138  partially defining the arm cavity  146 . As will be more fully described, a top panel pivot assembly  156  and a middle panel pivot assembly  158  are configured to facilitate and assist motion of the top cushion  104  and the foot and middle sections  112  and  114  respectively. 
       FIG. 9  is a detailed view of the top panel pivot assembly  156  in a partially open position. The top panel pivot assembly  156  may include a gas cylinder  160 . Generally it should be understood that the top panel may be supported by mirror symmetric top panel pivot assemblies  156  attached to the respective right and left arms. However, a gas cylinder  160  on only one side of the seat  100  may be sufficient to provide the desired motion control forces. The top panel pivot assembly  156  may include a mounting plate  162  bolted or otherwise attached to the side wall  136  of the arm  102  ( FIG. 8 ). The top panel pivot assembly  156  may also include a support bracket  164  bolted or otherwise attached to the top panel  134  ( FIG. 8 ). A pivot link  166  may be pivotally attached at one end to the mounting plate  162  at a first pivot point  168  and at its opposite end to the top of the gas cylinder  160 . The pivot link  166  may be rotationally fixed to the support bracket  164  by a first offset bar  170 . The first offset bar  170  may pass through the upholstery layer  130  ( FIG. 2 ). The lower end of the gas cylinder  160  may be pivotally attached to a lower portion of the mounting plate  162 . 
     As the top cushion is rotated open and closed about R 1 , the gas cylinder  160  is compressed during closing and expanded during opening. The maximum extension of the gas cylinder  160  may set the limit for the range of motion of the top cushion in its open position. The gas cylinder  160  may act similar to a compression spring to provide an upward expansion force creating a clockwise moment about the first pivot point  168  to counterbalance the weight of the top panel  134  so that the top panel may be raised to a fully open position with a small upward force. The gas cylinder  160  may be configured so that the maximum expansion thereof provides the opening limit for the top cushion  104 . Likewise, the gas cylinder  160  can bias and hold the top panel  134  to its open position so that the user does not have to maintain hold of the top panel to maintain the open position. Put more generally, the gas cylinder  160  provides that, at all times, the movement of the top cushion is smooth, slow, and controlled. Springs or other biasing elements that provide similar resistance to motion as provided by the gas cylinder  160  may also be used. These elements may be collectively referred to as motion controllers. In some embodiments, the top cushion is allowed to rotate without any motion controllers. In other embodiments, the motion controllers may be powered to operate the top panel pivot assembly  156  with a button. Powered actuators are known in the art. 
       FIG. 10  is a detailed view of the middle panel pivot assembly  158  in the folded position. The middle panel pivot assembly  158  may include a bed support bracket  176  bolted or otherwise attached to the middle panel  120 . The bed support bracket  176  may include an attachment flange  178  and a projecting flange  180 . The vertically projecting flange  180  may be rotationally fixed to a second offset bar  182  that may project outward perpendicular to such vertically projecting flange  180 . The opposite end of the second offset bar  182  may be fixed to a spring arm  184 . The spring arm  184  is substantially parallel to the vertical projecting flange  180 . The spring arm  184  may be bolted or otherwise rotationally fixed to a pivot plate  186 . The spring arm  184 , or a spring post  188  attached thereto may contact a portion of the arm in the folded position shown in  FIG. 10  to act as a stop. Other alternative stop pins may be provided to limit relative motion of the spring arm  184  as the middle panel  120  is folded and unfolded. 
     The spring post  188  may be attached to one end of the spring arm  184  such that an extension spring  190  can be attached to the outward facing side of the spring arm  184 . The other end of the extension spring  190  is attached to a spring pin  192 . The spring pin  192  may be fixed to an innermost face of a first anchor plate  194 , the first anchor plate  194  being bolted or otherwise fixed to the side wall  136  of the arm  102 . Accordingly, the extension spring  190  extends and contracts in a space between the innermost face of the first anchor plate  194  and the outermost face of the spring arm  184  defined by planes substantially parallel to the side wall  136 . The pivot plate  186  is pivotally attached to a second anchor plate  196  at second pivot point (not shown). The second anchor plate  196  is bolted or otherwise attached to an inner face of the side wall  136  of the arm  102 . This arrangement allows spring arm  184  to pivot 180 degrees from a substantially downward projecting position when the middle panel is in its folded position to a substantially upward position when the middle panel is in its unfolded bed position about R 2 . Accordingly, extension spring  190  minimizes the downward force of the middle panel both during folding and unfolding. In other words, because the extension spring  190  is in a relatively stretched position when the middle panel is folded, during unfolding, the extension spring seeks to contract, assisting with the desired counterclockwise motion from the perspective of  FIG. 10  about R 2 . During folding, especially after the middle section closes past vertical, gravity will act to fold the middle section into the frame. The extension spring  190  will be stretched during the last portion of the folding motion to achieve the relatively stretched position of the extension spring when the middle panel is folded. Stretching the extension spring  190  creates a resistance force to slow motion of the middle section and prevent the middle section from slamming back into the folded position. 
       FIGS. 11 and 12  show a cutaway front view of the left side of the seat  100  in the seating and bed positions respectively. These figures illustrate the packaging of the top panel pivot assembly  156  and a middle panel pivot assembly  158  within the arm cavity  146  such that only the first offset bar  170  and second offset bar  182  protrude from the arm cavity  146  between the upholstery layer  130  and the middle section  114  such that the gaps G 1 , G 2  are substantially zero. In other words, the top panel pivot assembly  156  and a middle panel pivot assembly  158  operate in the thickness of the arms  102  and are able to remain substantially hidden. There are aesthetic and safety benefits of having these pivot assemblies hidden and operating behind an upholstery layer  130  on the inside of the arm  102 . 
     Although the above disclosure has been presented in the context of exemplary embodiments, it is to be understood that modifications and variations may be utilized without departing from the spirit and scope of the invention, as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of the appended claims and their equivalents.