Patent Publication Number: US-6704974-B2

Title: Squeakless furniture spring anchor clip

Description:
RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 10/066,798, filed on Feb. 4, 2002, which has issued as U.S. Pat. No. 6,481,067, which, in turn, is a continuation of U.S. patent application Ser. No. 09/169,179, filed on Oct. 8, 1998, and which has issued as U.S. Pat. No. 6,415,481 entitled “SQUEAKLESS FURNITURE SPRING ANCHOR CLIP”, which, in turn, claims priority from U.S. provisional patent application Ser. No. 60/061,423, filed Oct. 8, 1997. This application also claims the benifit of provisonal 60/061,423 filed on Oct. 8, 1997. 
    
    
     FIELD OF THE INVENTION 
     The invention is concerned with an anchor clip for fastening one member to another, and more particularly with an anchor clip for securing a supporting spring arrangement of a seat or back cushion in an article of furniture. 
     In general anchor clips are well known for securing furniture springs to the furniture rails which form the framework of an article of furniture. The framework typically includes four elongated furniture rails joined as a rectangle. Corresponding anchor clips are secured by means of staples or depending legs to respective, opposing sides of the rails. The anchor clips typically terminate at one end with a generally curved spring receiving portion. Opposing end portions of a bowed sinuous furniture spring extend between the opposing rails and are secured to the anchor clips within the spring receiving portion. The spring presents a generally inward directed spring force on each of the respective opposing rails via the anchor clips. 
     DESCRIPTION OF THE RELATED ARTS 
     Various improvements in anchor clips have been made, but a problem common to all of them is squeaking. The foregoing problem was solved to some extent by incorporating a plastic liner on the interior surface of the hook. However, due to improper installation of the spring and/or clip, and also due to spring irregularities, the liner would sometimes become ineffective, or in the alternative, the liner failed to remain permanently in place within the hook. In an attempt to overcome these shortfalls, an anchor clip was introduced which was made entirely from a plastic material. However, this plastic clip had two distinct disadvantages: it required a metal fastener for securing it to the rail of the furniture; and also, it suffered from a lack of strength. Furthermore, securing the plastic anchor clip to the furniture involved an additional operational step since it required the implementation of a nail to attach it to the frame, as opposed to an anchor clip made of steel which has an integral attachment means. 
     SUMMARY OF THE INVENTION 
     It is an object of the invention to provide an anchor clip for securing an end of a furniture spring to a rail comprising the frame of an article of furniture. 
     Another object of the invention is to provide a squeakless anchor clip having a plastic liner permanently secured to a hook portion of the anchor clip. 
     According to the invention, the anchor clip presented herein all generally comprise a base portion, a leg portion, and a reversed curved portion. The base portion is adapted to sit on top of the furniture rail, the reversed curved portion defines a hook for engaging a portion of the spring, while the leg portion is provided with a leg or prong that is driven into the side of the rail for attaching the clip thereto. 
     More specifically, presented herein are anchor clips for securing an end of an upholstery spring to a rail comprising the frame of an article of furniture, the clip having a base portion adapted to over hang and be completely supported by the upper surface of the rail. A rail-engaging leg portion is integrally joined to one side of the base portion, the leg portion having an integral anchoring means in the form of a leg or prong adapted to be embedded into the rail for securing the anchor clip to the side of the rail. A reversed curved portion is integrally joined to the other side of the base portion for receiving the end of an upholstery spring and is adapted to be wrapped thereover. The reversed curved portion is supported on the upper surface of the rail and the base portion. 
     The present invention consists of a fold means for mechanically holding a plastic liner securely within the hook portion of the anchor clip. The fold means has a variety of shapes and combinations to securely hold the opposite ends of the plastic liner. 
     In one embodiment, a plastic liner is secured within the hook portion of the anchor clip by means of a folded tab formed along the outer-most region of the hook portion which is located farthest from the base portion. A plurality of semi-circular prongs are punched out on the innermost region of the hook, closest to the base portion. The tab and prongs are bent over the plastic liner to secure the plastic liner to the hook. In a variation to this embodiment, the semi-circular prongs may be prongs of a square configuration. 
     In another embodiment, a plurality of the semi-circular prongs are formed along the outer-most region of the hook, while the folded tab lies along substantially the entire innermost region of the hook closest to the base portion. In a variation to this embodiment, a plurality of squared prongs are located at the outermost region of the hook and a folded tab forms substantially the entire length of the innermost region of the hook nearest the base. In another variation, a folded tab is formed along the entire edge of both the outermost and innermost regions. 
     In a third embodiment, a plurality of semi-circular prongs are formed along the outermost region of the hook and additionally are formed along the innermost region of the hook. In a variation to the third embodiment, a plurality of squared prongs are located along the outermost region of the hook and along the innermost region of the hook. 
     In a fourth embodiment, a plurality of pointed prongs are located along both the outermost and innermost regions of the hook. The prongs may be simply folded downwardly over the edges, or the prongs may penetrate through the lining and then be pressed down. A variation to this fourth embodiment provides a plurality of pointed prongs at the outermost region of the hook and a folded tab at an innermost region of the hook. Still another variation to this fourth embodiment provides a plurality of pointed prongs at the innermost region of the hook while a folded tab is provided along the edge of the outermost region of the hook. 
     This invention as set out in the foregoing clip embodiments is also concerned with a method of preparing a series of said anchor clips which are interconnected together by integrally connecting bands. 
     In the method of the first embodiment, the method includes the steps of uncoiling a steel strip, binding a liner, which may be a plastic strip, to the steel band using adhesive or mechanical means, sending the strip to a multistage die for slitting the strip to form separate clip sections, folding and staking an end of each of the clip sections, punching of separating and indexing holes, punching of leg holes, forming strengthening ridges, forming the legs, and forming the hook and base portions. 
     It is to be noted that the liner may also be fed directly into the die for attachment. 
     Other features and advantages of the invention will be apparent from the following specification taken in conjunction with the following drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a top view of a series of interconnected anchor clip sections in accordance with the first embodiment of the present invention; 
     FIG. 1A is a view similar to FIG. 1 showing a lower cut out portion in the clip sections to form prongs for being driven into a furniture rail; 
     FIG. 1B is a side elevational view of one of the clip sections shown in FIG. 1A; 
     FIG. 1C is a side elevational view of a formed anchor clip from the clip section of FIG. 1B in accordance with the first embodiment of the present invention. 
     FIG. 2 is a top view of a series of interconnected anchor clip sections in accordance with the second embodiment of the present invention; 
     FIG. 2A is a view similar to FIG. 2 showing a lower cut out portion in the clip sections to form prongs for being driven into a furniture rail; 
     FIG. 2B is a side elevational view of one of the slip sections shown in FIG. 2A; 
     FIG. 2C is a side elevational view of a formed anchor clip from the clip section of FIG. 2B in accordance with the second embodiment of the present invention; 
     FIG. 3 is a top view of a series of interconnected anchor clip sections in accordance with the third embodiment of the present invention; 
     FIG. 3A is a view similar to FIG. 3 showing a lower cut out portion in the clip sections to form prongs for being driven into a furniture rail; 
     FIG. 3B is a side elevational view of one of the clip sections shown in FIG. 3A; 
     FIG. 3C is a side elevational view of a formed anchor clip from the clip section of FIG. 3B in accordance with the third embodiment of the present invention; 
     FIG. 4 is a top view of a series of interconnected anchor clip sections in accordance with the fourth embodiment of the present invention; 
     FIG. 4A is a view similar to FIG. 4 showing a lower cut out portion in the clip sections to form prongs for being driven into a furniture rail; 
     FIG. 4B is a side elevational view of one of the clip sections shown in FIG. 4A; 
     FIG. 4C is a side elevational view of a formed anchor clip from the clip section of FIG. 4B in accordance with the fourth embodiment of the present invention; 
     FIG. 4D is a side elevational view of another one of the clip sections shown in FIG. 4A; 
     FIG. 4E is a side elevational view of a formed anchor clip from the clip section of FIG. 4D in accordance with the fourth embodiment of the present invention; 
     FIG. 5 is a top view of the series of interconnected anchor clip sections shown in FIG. 4, with the inner and outer regions having their respective folding means interchanged from the position previously shown; 
     FIG. 5A is a view similar to FIG. 5 showing a lower cut out portion in the clip sections to form prongs for being driven into a furniture rail; 
     FIG. 5B is a side elevational view of one of the clip sections shown in FIG. 5A; 
     FIG. 5C is a side elevational view of a formed anchor clip from the clip section of FIG. 5B in accordance with the present invention; 
     FIG. 5D is side elevational view of another one of the clip sections shown in FIG. 5A; 
     FIG. 5E is a side elevational view of a formed anchor clip from the clip section of FIG. 5D in accordance with the invention; 
     FIG. 6 is a top view of a series of interconnected anchor clip sections of the present invention wherein the left clip section is a variation of the third embodiment, the middle clip section is a variation of the fourth embodiment, and the right clip section is another variation of the fourth embodiment of the present invention; 
     FIG. 6A is a view similar to FIG. 6 showing a lower cut out portion in the clip sections to form prongs for being driven into a furniture rail; 
     FIG. 6B is a side elevational view of one of the clip sections shown in FIG. 6A; 
     FIG. 6C is a side elevational view of a formed anchor clip from the clip section of FIG. 6B in accordance with the invention; 
     FIG. 6D is a side elevational view of another one of the clip sections shown in FIG. 6A; and 
     FIG. 6E is a side elevational view of a formed anchor clip from the clip section of FIG. 6D in accordance of the invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     As shown in FIGS. 1-1C, an anchor clip  10  of the present invention has a body  11  of metal material including a generally flat base portion  12  that includes a first end  12 A and a second end  12 B, a leg portion  14  integrally extending from said second end  12 B in a direction normal to said base portion, and a spring supporting or reverse curved portion  16  integrally extending out from said first end  12 A in a direction opposite to said leg portion, said curved portion  16  curving back over the base portion  16  and terminating in edge  17  to define a hook  18  which is lined interiorly with a liner  20 . Other configurations of the clip  10  are also known and are within the purview of the present invention. The base portion  12  is provided with an indexing hole  36  which is used for guidance in moving the steel strip including clip sections from which the anchor clips are formed, through shape-forming dies (not shown). The leg portion  14  has a leg or prong comprised of parts  38  and  40  extending outwardly out of the surface  32 . Holes  70  are provided to facilitate separating the clips. FIGS. 1B and 1C show that a plastic liner  20  is retained on the interior surface  18   i  of hook  18  to prevent squeaking of the clip during use. In the two variations of the first embodiment shown in FIG. 1, it is seen in the left and middle clip that liner is retained therein by the combination of an upper raised detent  50  located at the outermost region  16 A of the hook  16  that is located farthest from the base  12 , and a plurality of liner holding members struck from the metal material of the clip body  11  in the form of semicircular prongs  52  located at the innermost region  16 B of the hook  16 , closest to the base  12 . As shown, there are pairs of tabs or prongs  52  that are spaced laterally from each other across the width of the clip body  11 . The liner is pushed or abutted up against the detent  50 , while the prongs  52  are folded over and on top of the liner. 
     In a second variation to the embodiment just described, and also shown to the far right in FIG. 1, the semicircular prongs  52  are replaced with struck liner holding members in the form of squarely configured prongs  54 , and they are to be folded over the plastic liner  20  for maintaining it in place. 
     A second embodiment is shown in FIG. 2, where it is seen that a plurality of semi-circular prongs  52  are located at the outermost region of the hook  16 . At the innermost region of the hook  16  is located a detent  50 . As mentioned above, the detent and the semi-circular prongs  52 , hold the plastic liner  20  securely in place. 
     Also shown in FIG. 2 is a variation to the second embodiment depicting a plurality of squarely configured prongs  54  located at the outermost region of the hook  16 . The plastic liner  20  is held in place underneath the squared prongs  54  and by the detent  50  at the innermost region. 
     FIG. 3 shows a third embodiment depicting a plurality of semi-circular prongs  52  located at both the outermost and innermost regions of the hook  16 . The plastic liner  20  is maintained underneath the semi-circular prongs  52  when they are folded over the liner. The far right clip in FIG. 3 shows a variation of this embodiment wherein a plurality of squarely configured prongs  54  at the innermost and outermost regions of the hook  16 , in contrast to the roundly configured prongs of the 1ft and middle clips. 
     As shown in FIG. 4, a fourth embodiment of the present invention consists of struck liner holding members in the form of an elongate tab  90  located substantially along the entire innermost region of the hook  16 . In other words, elongate tab  90  extends substantially for the entire width of the clip body  11 . The plastic liner  20  is maintained in place under the folded tab  90  at that end. In one aspect of this embodiment, a detent  50  is located near the outermost region of the hook to hold the other end of the liner. 
     FIG. 4 also depicts another variation to the fourth embodiment with the middle clip showing semi-circular prongs  52  at the outermost region and the right clip showing squarely configured prongs  54  at the same outermost region. The plastic liner  20  is maintained in place when the respective prongs ( 52 ,  54 ) and tabs ( 90 ) are folded over and onto to liner  20 . 
     FIG. 5 shows an arrangement similar to the arrangement of FIG. 4, except now, the respective positions of the detents and the tabs have reversed on their respective clips. 
     FIG. 6 shows a further variation to the third embodiment, wherein at the extreme left clip, a plurality of struck liner holding members in the form of pointed prongs  56  are located at both the outermost and innermost regions of the hook  16 . The pointed prongs  56  may first pass through the liner before being folded over the liner  20  in order to maintain it in place. In a further variation of the second embodiment, detents  50  of the middle and far right clips may be located at either the outermost or innermost regions of the hook with pointed prongs  56  at the end opposing the detent end. 
     As the previously-described liner holding members  52 ,  54 ,  56  and  90  are struck from the metal material of the clip body  11 , there will be through holes left in the clip body  11  under the liner holding members  52 ,  54 ,  56 , or  90  when they are formed from the material of the body  11 . Accordingly, when the plastic liner  20  is fed into the curved spring supporting portion  16  of the body  11  as by sliding or dropping it into place, the liner  20  will be disposed over these through holes. Thus, folding the holding members  52 ,  54 ,  56  or  90  down onto the liner  20  so sinking of the liner  20  so as to clamp the liner in place will generally cause some sinking of the liner into the through openings associated with respective ones of the folded over or clamped holding members so as to enhance the ability of the members to keep the liner  20  fixed and clamped against the spring supporting portion  16  without sliding thereof during use with flexing of the spring. 
     It will be understood that the invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. The present embodiments, therefor, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein.