Patent Publication Number: US-9895002-B1

Title: Folding frames for furniture and bedding

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS 
     The present application claims priority to and benefit from U.S. Provisional Patent Application No. 61/909,863 titled “Folding Frames for Furniture and Bedding” filed on Nov. 27, 2013, the entire content of which is herein expressly incorporated by reference. 
    
    
     BACKGROUND 
     Foldable furniture is used in a variety of applications including tables, recliners, portable apparatuses, and convertible sofas (which are sometimes referred to as sleeper sofas). Generally, foldable furniture has multiple positions. In one of the positions, the foldable furniture is unfolded. 
     With reference to convertible sofas, for ease of reference, the convertible sofa has a bed frame folded into the sofa. The bed frame is unfolded to form a sleeping surface. Generally, the sleeping surface includes three frame parts, which will be referred to as the leg frame section, the torso frame section, and the frame head section. The head section is conventionally considered the portion of the bed frame between the arm rests of the sofa or, when no arm rests are included, the bed frame generally above the sofa base or casing. 
     The bed frame where it folds, e.g., between the leg and torso frame sections and between the torso and head frame sections, may bend or bow with the application of pressure or weight. This problem with foldable furniture is exasperated by the length and width of the furniture and the weight applied. Again, with specific reference to a sleeper sofa, the seam or junction between the head frame and torso frame may be inhibited from bowing or bending by the sofa base or casing. 
     Thus, against this background, it would be desirable to provide a folding frame for furniture to decrease or inhibit the bending or bowing of the frame at the junction between foldable parts. 
     SUMMARY 
     This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary, and the foregoing Background, is not intended to identify key aspects or essential aspects of the claimed subject matter. Moreover, this Summary is not intended for use as an aid in determining the scope of the claimed subject matter. 
     A folding apparatus is provided where at least a first member and a second member unfold such that one member moves up to about 180 degrees with respect to the other member. The members are coupled by a bridge joint that provides support at the junction or seam between the first and second member such that the bridge joint resists or inhibits force on a side opposite the bridge joint from causing a bow or bend between the first and second members. 
     The bridge joint in certain embodiments may include a pivot beam having a pivot pin or axle and an anti-buckling pin, and a bridge beam having a pivot guide. The pivot guide may include a track completely or partially encircling the pivot pin. The anti-buckling pin travels in the track about the pivot pin while the first and second members are folded or unfolded. 
     In certain aspects, the folding apparatus comprises a sleeper sofa. In other aspects, the folding apparatus comprises a recliner. In yet other aspects, the folding apparatus comprises a table. 
     These and other aspects of the present system and method will be apparent after consideration of the Detailed Description and Figures herein. 
    
    
     
       DRAWINGS 
       Non-limiting and non-exhaustive embodiments of the present invention, including the preferred embodiment, are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified. 
         FIG. 1  depicts a perspective view of a conventional convertible sofa. 
         FIG. 2  depicts a side elevation, line view of a convertible sofa incorporating the technology of the present application. 
         FIG. 3  depicts a side elevation, line view of the convertible sofa of  FIG. 2 . 
         FIG. 4  depicts a side elevation, line view of the convertible sofa of  FIG. 2 . 
         FIG. 5  depicts a side elevation, line view of the convertible sofa of  FIG. 2 . 
         FIG. 6  depicts a side elevation, line view of the convertible sofa of  FIG. 2 . 
     
    
    
     DETAILED DESCRIPTION 
     The technology of the present application is described more fully below with reference to the accompanying figures, which form a part hereof and show, by way of illustration, specific exemplary embodiments. These embodiments are disclosed in sufficient detail to enable those skilled in the art to practice the technology disclosed. However, embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. The following detailed description is, therefore, not to be taken in a limiting sense. 
     The technology of the present application is described with respect to convertible or sleeper sofas, and specifically to sleeper sofas, designed for use in recreational vehicles. However, the technology of the present application is applicable to other foldable furniture including, for example, tables, recliners, portable apparatuses, and the like. Moreover, the technology of the present application will be described with relation to exemplary embodiments. The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. Additionally, unless specifically identified otherwise, all embodiments described herein should be considered exemplary. 
     A convertible sofa  10  is shown in  FIG. 1 . The convertible sofa  10  includes a sofa frame  11  having a sofa base, a back rest, and a plurality of arm rests. The sofa frame is sometimes referred to as a casing or the like. The convertible sofa  10  includes a foldable bed frame  12  that is shown unfolded in the sleeping position in  FIG. 1 . The bed frame  12  includes leg frame section  13 , a torso frame section  15 , and a head frame section  17 . The bed frame  12  may be provided with a mattress or a mattress may be placed on the bed frame, as shown in phantom in  FIG. 1 . Typically, the leg frame section  13  is supported by a U-frame leg  14 . The U-frame leg  14  may be parallel to the longitudinal axis  20  of the bed frame  12  as shown or the U-frame leg  14  may traverse the longitudinal axis  20  similar to the front casing panel  16  of the sofa. 
     As can be appreciated, the torso frame section  15  and leg frame section  13  are joined at a fold line  18  of the bed frame  12 . The fold line  18  is typically a weak point in the frame and the bed frame  12  has a tendency to bow or bend in the direction shown by arrow  22  when weight is applied to the bed frame  12 . Conventionally, the bowing or bending is only resisted by the frames and cushions pressing laterally on themselves, which is frequently insufficient to resist the downward movement. Of course, legs or other supports would tend to resist the downward movement as well. References to down, up, forward, left, right, rear, and the like are for purposes of orientation and should not be construed as limiting. 
       FIG. 2  shows a side elevation view of a convertible sofa  200  incorporating the technology of the present application. As will be explained below, the bed frame of the convertible sofa  200  provides a bridge joint extending between the torso frame section and the leg frame section. The bridge joint acts as a reinforcing member preventing the bed frame from bowing or bending at the junction between the two frame section. While described with reference to a sleeper sofa having a leg frame section and a torso frame section, the bridge joint may extend between any foldable apparatus&#39;s first member and second member to resist or inhibit bowing due to weight or force applied to a side opposite the bridge joint. 
     The convertible sofa  200  is shown in  FIG. 2  with the bed frame  201  in the sleeper position  202 . The bed frame  201  includes a head frame section  204 , a torso frame section  206 , and a leg frame section  208 . Each of the head frame section  204 , the torso frame section  206 , and the leg frame section  208  have a top side and a bottom side in the sleeper position, which may be identified by a numerical designator (such as first top side and second top side) to differentiate the section. Each of the head frame section  204 , the torso frame section  206 , and the leg frame section  208  have opposed sides. Thus, for example, the torso frame section  206  has a first side and a second side opposed to the first side. The first side is adjacent a side of the head frame section  204 . The second side is adjacent a side of the leg frame section, which side of the leg frame section may be designated as a third side, etc. In this particular exemplary embodiment, the head frame section  204  comprises the back rest  218  of the sofa  200 . The back rest  218  includes a frame and cushion component. Each of the frame sections  206  and  208  support a cushion  210  or the like. The cushions  210  could be removable or affixed to the frame section as a matter of design choice. The convertible sofa  200  includes a sofa casing  212  including a sofa base  214  with arm rests  216  extending upwards from the sofa base  214 . The back rest  218 , which comprises a frame and cushions, rests on the sofa casing  212 , which may include frame members  211  contained in the sofa base  214 . In the sleeper position  202 , as shown, the back rest  218  is pivoted about axle  220  to a horizontal or supine position. In the sofa position, the back rest  218  would be pivoted to the upright or vertical position (as shown in  FIG. 3 ). Cushions  210  would be removed from, for example, the torso section  206  and placed against the head frame section  204  for comfort. Alternatively, the cushions on the back rest  218  may be affixed to the front or back of the back rest  218  or removably coupled to the back rest  218  to be flipped from the sofa position to the sleeper position as needed. Still alternatively, the cushions on back rest  218  may be stitched to the top edge of the back rest  218  and flipped over the top edge from one position to the other. The head frame section extends from a back of the sofa base  214  to a front of the sofa base  214 . The sofa base  214  of the casing  212  (or equivalent portion of the sofa  200 ) generally provides a support for the junction or seam between the head frame  204  and the torso frame  206  that limits or completely inhibits downward movement or bowing of the frame at that junction or seam. 
     The leg frame section  208  has an end portion  222  distal to the sofa base  214  in the sleeper configuration as shown in  FIG. 2 . The end portion  222  is support by a plurality of legs  224 . The leg frame section  208  may be supported by two or three legs  224 . While U-shaped legs consistent with  FIG. 1  are possible, the technology of the present application generally provides legs that are generally straight poles, in some embodiments with a flared or cushioned foot. Providing a singular leg allows a single manufacturing item for beds having different lengths and widths. For example, when providing double, queen, and king size convertible sofas, a U-shaped leg for each different size bed would be of a different size. Whereas, when providing two or three legs comprising a vertical pole, the singular legs may all be identical regardless of the length and width of the bed. Thus, a double convertible sofa bed may have, for example, two (2) legs  224  whereas a king sized sofa bed may have, for example, three (3) legs  224 . 
     When two legs  224  are provided, the legs  224  are on opposing left and right sides of the leg frame section  208 . When three or more legs  224  are provided, the legs  224  include at least one leg positioned between the outer left and right legs. Typically, the legs  224  would be symmetrically placed. Each leg  224  is pivotally coupled to a bracket  226  on the leg frame section  208 . For example, a fastener  228 , such as a pin, bolt, or rivet, may couple the leg  224  to the bracket  226  such that the leg  224  can pivot about the fastener  228 . The bracket  226  has at least one stop  230  to inhibit the leg from being over extended. The stop  230  may be a bolt, rivet, or protrusion. As can be seen, the leg  224  is slightly canted towards the end portion  222  such that gravity holds the leg  224  firmly against the stop  230  when deployed. In the stowage position (e.g., folded up parallel to the plane defined by the leg frame section), a clip may hold the leg  224  up. 
     The torso frame section  206  and the leg frame section  208  are pivotally coupled by a bridge joint  232 . The bridge joint  232  includes a leg (or first) portion  234  and a torso (or second) portion  236 . The leg portion  234  comprises a bracket  238  fixedly coupled to the leg frame section  208  by fasteners  240 , such as bolts or rivets, and a pivot beam  242  extending down from the bracket  238 . The pivot beam  242  includes a pivot  244  and an anti-buckling pin  246 , which will be explained below. The leg portion  234  has a generally L-shape although other shapes, including square, rectangular, triangular, circular or the like are possible. In other words, the pivot beam  242  could be a section of a larger rectangular or square leg portion  234  where the leg portion  234  has a portion extending below the leg frame section  208 . The pivot  244  or axle may be formed from a bolt, rivet, pin, protuberance or the like and is generically referred to as a pivot pin  244 . The anti-buckling pin  246  similarly may be formed by a bolt, rivet, pin, protuberance or the like and is generically referred to as a pin. The torso portion  236  comprises a bracket  248  fixedly coupled to the torso frame portion by fasteners  250 , such as bolts or rivets. The torso portion  236  further has a bridge beam  252  extending down from the bracket and forward to a position below the leg frame section and adjacent to the pivot beam  242 . The bridge beam  252  may be an extension of the bracket  248  rather than extending down from and forward of the bracket  248  making a large rectangular torso portion  236  instead of one have a generally Z shape as shown. The bridge beam  252  terminates in a pivot guide  254 . The pivot guide  254  comprises a track  256  in which the anti-buckling pin  246  moves as the leg frame section  208  unfolds or pivots about the pivot pin  244  relative to the torso frame section  206 . The track  256  partially or fully encircles the pivot pin  244 . The track  256  in this exemplary embodiment is 180° around the pivot  244  to allow for full travel without excessive track  256 . The anti-buckling pin  246  travels along the track  256  as the leg frame portion  208  folds or unfolds with respect to the torso frame portion  206  as the bed frame moves between the sleeper position  202 , shown in  FIG. 2 , and the sofa position, shown in  FIG. 3 . To facilitate folding of the frames, the pivot guide  254  extends along the bracket  238  of the leg portion  234 . 
     The bridge joint  232  provides a brace between the torso frame section  206  and the leg frame section  208  under the seam  260 . The bridge joint  232  resists bending or bowing in a downward direction between the torso frame section  206  and the leg frame section  208 . In particular, the bridge beam  252  prevents from further downward movement because the anti-buckling pin  246  engages the end of the track  256  that stops the bridge beam  252  from further movement, which inhibits downward bending or bowing of the seam or junction. 
     With reference to  FIG. 3 , the convertible sofa  200  is shown in the sofa or sitting position  300 . The back rest  218  is pivoted about axle  220  to the upright or sitting position  300 . The torso frame section  206  is folded over a pivot axle  302  at the forward edge  304  of the sofa base  214 . When in the sitting position, the torso frame section  206  is contained within the sofa base  214 . The bridge joint  232  is folded over on itself in the sitting position  300 . In particular, the leg portion  234  and the torso portion  236  pivot or fold with respect to each other. The anti-buckling pin  246  travels during the folding along the track  256  to the opposite end. As can be appreciated, the bridge joint is one example of a means for pivotally coupling the torso frame section and leg frame section of the bed frame. The torso frame  206  is inverted in the sofa or sitting position ( FIG. 3 ) as compared to the alignment when in the sleep position ( FIG. 2 ). 
     With reference to  FIGS. 4, 5, and 6 , the folding operation of the convertible sofa  200  is visualized. While described with reference to moving the convertible sofa from the sleeper position  202  to the sitting position  300 , the operations would be reversed to unfold the convertible sofa  200  from the sitting position  300  to the sleeper position  202  and will, therefore, not be explained separately. As can additionally be appreciated, the bridge joint  232  was described and attached to the sofa  200  in view of the particular orientation of the torso frame portion  206  and the leg frame portion  208  with respect to each other. The bridge joint  232  could be oriented for other configurations and folding relationships without undue experimentation. 
       FIG. 4  shows initially moving the bed frame  201  from the sleeper position  202  to the sitting position  300 . The leg frame section  208  is lifted vertically. The leg  224  is pivoted up to the leg frame section  208  about fastener  228  by either manual operation or automatically by a spring or the like. Lifting the leg frame section  208  causes the torso frame section  206  to pivot up about pivot axle  302 , which is contained in the sofa base  214  on a frame member  211 . Rather than lifting the leg frame section  208 , the leg frame section  208  could be moved horizontally to push the torso frame section  206  to pivot about the pivot axle  302 . The bridge joint  232  pivots such that the torso portion  236  and the leg portion  234  pivot with respect to each other about pivot  244 . The anti-buckling pin  246  begins traveling in the track  256  from a stop side to the opposite side, and in  FIG. 4 , the anti-buckling pin  246  has traveled approximately ½ the distance of the track  256 . 
     The torso frame section  206  has been pivoted about pivot axle  302  into the sofa base  214  in  FIG. 5 . As shown, the initial lifting of the leg frame section  208  and the pivoting of the torso frame section essentially pivots the leg frame section  208  90 degrees with respect to the torso frame section  206  and pivots the torso frame section  206  90 degrees to 180 degrees with respect to the sofa base  214  until the torso frame section  206  is flipped and stored in the sofa base  214 . The frame sections, however, may pivot a different amount depending on the actual operation performed. 
       FIG. 6  shows the convertible sofa  200  mostly folded to the sitting position  300 . The anti-buckling pin  246  has traveled about three quarters of the way in track  256  from the stop position to the opposite end. The bridge beam  252  forms a guide for the leg frame section  208  as it is folded into the sitting position  300 . When fully collapsed into the sitting position, the anti-buckling pin  246  will have traveled the remaining distance in the track  256  (although the track could extend beyond the require amount). As can be appreciated, the cushion support side of the torso frame section  206  is inverted with respect to the cushion support side of the leg frame section  208  when the frames are in the sitting position  300 . It should be noted that while shown as discrete folding steps, the movement of the various sections of the frame would be more fluid such that specific angles and orientations may or may not be realized. 
     Although the technology has been described in language that is specific to certain structures, materials, and methodological steps, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific structures, materials, and/or steps described. Rather, the specific aspects and steps are described as forms of implementing the claimed invention. Since many embodiments of the invention can be practiced without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. Unless otherwise indicated, all numbers or expressions, such as those expressing dimensions, physical characteristics, etc. used in the specification (other than the claims) are understood as modified in all instances by the term “approximately.” At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the claims, each numerical parameter recited in the specification or claims which is modified by the term “approximately” should at least be construed in light of the number of recited significant digits and by applying ordinary rounding techniques. Moreover, all ranges disclosed herein are to be understood to encompass and provide support for claims that recite any and all subranges or any and all individual values subsumed therein. For example, a stated range of 1 to 10 should be considered to include and provide support for claims that recite any and all subranges or individual values that are between and/or inclusive of the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more and ending with a maximum value of 10 or less (e.g., 5.5 to 10, 2.34 to 3.56, and so forth) or any values from 1 to 10 (e.g., 3, 5.8, 9.9994, and so forth).