WO1993013698A1

WO1993013698A1 - Furniture spring construction

Info

Publication number: WO1993013698A1
Application number: PCT/US1993/000388
Authority: WO
Inventors: Larry I. Bullard; James R. Barber
Original assignee: BARBER MANUFACTURING COMPANY Inc; BARBER Manufacturing Co
Current assignee: BARBER MANUFACTURING COMPANY Inc; BARBER Manufacturing Co
Priority date: 1992-01-15
Filing date: 1993-01-15
Publication date: 1993-07-22
Anticipated expiration: 1994-07-15
Also published as: AU3485093A

Abstract

A furniture spring construction assembly comprised of a plurality of component assemblies. Each component assembly has three coil springs (15, 16, 17) arranged in spaced-apart relationship and mounted to an elongated closed wire frame being in the form of closed wire loop having first (32) and second (36) ends separated by two parallel spars (20, 21). The component assemblies are arranged in a series and are attached to a boundary wire framework (11) at the tops of the peripheral springs. The tops of the coil springs are interconnected by a plurality of coupling wires (19) which connect adjacent springs to each other.

Description

FURNITURE SPRING CONSTRUCTION

BACKGROUND OF THE INVENTION

This invention relates to furniture spring cons iuction assemblies and more particularly to a spring coil assembly made up of a plurality of component spring assemblies arranged in a series.

There are various types of spring coil constructions used in manufacturing furniture. Most of these constructions usually utilize a sinuous wire to support the base of each spring, as shown, for example, in Barber, U.S. Patent No. 4,819,920. Over time, these sinuous support wires often become fatigued and are no longer able to support the base of each spring with a force directed axially along the axis of the spring. In other words, after repeated flexing, the sinuous wire eventually is not able to recover its original shape. This causes the springs to deflect from their normal upright support position when weight is supported by the piece of furniture. Eventually, this deterioration of the sinuous support wire results in a sagging piece of furniture which is less comfortable to the person sitting thereon.

The various spring coil assemblies utilizing the sinuous wire base often result in noisy operation after several years of use. This noise is the result of the various wires and coils rubbing against one another as the weight is added and/or removed from the piece of furniture. One solution to this problem shown in the Barber patent is to dispose a layer of material between the support base and the coil springs. One disadvantage to this alternative is that the material eventually deteriorates and the noise returns. What is needed is a furniture spring construction assembly which retains the original springiness and supportability of a sinuous wire support base but maintains

SUBSTITUTESHEET this springiness and support over a much longer duration than is capable with a sinuous wire construction.

Description of the Prior Art

Several patents have been discovered which disclose various furniture spring construction assemblies. The following is a list of patents which relate in one way or another to the present invention.

Patent No. Patentee Issue Date

1,206,073 Young 11/28/1916 2,234,253 Hopkes 11/09/1936

2,272,807 Kronheim 02/10/1942

2,642,929 Stubnitz 06/23/1953

2,680,475 Caton 06/08/1954

2,729,380 Gleason 01/10/1956 2,280,912 Hopkes 04/28/1942

4,303,232 Crosby 12/01/1981

4,348,014 Litkewycz 09/07/1982

4,819,920 Barber 04/11/1989

Young (1,206,073) discloses a seat spring construction having a plurality of hourglass coil springs arranged in rows and columns. The coil springs are connected together at their tops by clips. The tops of the peripheral coil springs are connected to a boundary wire frame. However, Young does not show or suggest supporting the bases of the coil springs by a dual parallel spar construction. In fact, Young offers no explanation as to how the base portions of each coil spring is supported in the furniture assembly.

Hopkes (2,234,253) discloses a spring support assembly with a plurality of sinuous springs forming a top spring surface and bottom spring surface joined by a second plurality of sinuous springs transversally oriented with regard to the top sinuous springs. Coil springs are disposed between the top surface and the bottom surface, and strips of webbing are placed between the coil springs and the sinuous springs to prevent squeaking caused by metal-to-metal rubbing. Hopkes shows the bottom of the coil springs being supported by a sinuous wire spring rather than a plurality of parallel spars.

Kronheim (2,272,807) discloses an upholstery. construction with a wood frame having a plurality of hourglass springs arranged in rows. The tops of the hourglass frames are connected to each other and to the wood frame by a plurality of tie cords. The bottoms of the hourglass springs rest upon a piece of burlap which is supported by a plurality of sinuous springs with bends on either end to allow for attachment of the sinuous springs to the top of the wood frame. Kronheim does not teach supporting the base of the coil springs by a plurality of parallel spars.

Hopkes (2,280,912) discloses a spring structure with coil springs arranged in rows and columns. The marginal coil springs are joined at their tops to a border wire. The bases of the coil springs are supported by a plurality of sinuous wire support strips, rather than a plurality of parallel spars. Stubnitz (2,642,929) discloses a furniture spring construction assembly having a plurality of coil springs arranged in rows and columns and interconnected at their tops by a plurality of coupling wires. The tops of the peripheral springs are also connected to a boundary wire which encloses the tops of the coil springs. Stubnitz teaches supporting each coil spring at its base by a single spar spanning the construction assembly. The bases of the coil springs are further interconnected by elongated wires 11 which are situated perpendicular to the support spars. Stubnitz does not show or suggest supporting the base of each coil spring upon a pair of parallel spars. Furthermore, Stubnitz does not show or teach a furniture spring construction assembly made up of a plurality of component assemblies arranged in a series. Caton (2,680,475) discloses a spring seat construction having a plurality of fabric encased coil springs which are arranged in rows and columns. The tops of the Caton coil springs are enclosed by a boundary wire framework and the tops are further interconnected by a plurality of helical coupling wires. The base of each coil spring is supported by and attached to a pair of parallel spars. However, Caton does not teach a plurality of component assemblies each having a closed elongated wire frame which includes a pair of elongated parallel spars. Gleason (2,729,830) discloses a spring assembly unit with a plurality of coil springs arranged in rows and columns with the tops of the peripheral coil springs attached to a boundary wire framework. The base of each coil spring is connected to and supported by a sinuous support spring. Gleason does not teach or suggest supporting the various coil springs by a pair of parallel support spars which are formed into a closed elongated wire frame.

Crosby (4,303,232) shows a seat spring assembly having a plurality of coil springs arranged in rows and columns. The tops of adjacent springs are connected to one another and to the outer peripheral coil springs are connected to a boundary wire framework. The base of each coil spring is supported by a sinuous spring band. Crosby does not teach or suggest supporting the coil springs on a pair of parallel support spars.

Litkewycz (4,348,014) discloses a torsion bar spring auxiliary panel for a bedding unit. The auxiliary panel lies on a base having hourglass coil springs arranged in rows and columns within a border wire framework. The coil springs are connected in some manner with helical connector springs. Litkewycz does not teach or suggest supporting the various coil springs at their bases with a pair of parallel spars. Barber (4,819,920) discloses a spring coil assembly having a plurality of hourglass shaped coil springs arranged in rows with adjacent springs within a row connected at the top and bottom by a helical wire extending between adjacent columns. The marginal coils are attached at their top to a border wire framework extending around the assembly. The bases of each row of coil springs are supported by a sinuous support wire, rather than a pair of parallel spars.

One advantage that the present invention has over prior art spring assemblies is the ability to construct different types of furniture, such as sofas and chairs, using a plurality of identical component assemblies. None of the above-described prior art devices is constructed by assembling together a plurality of component assemblies, each having a number of springs and its own spring support means.

SUMMARY OF THE INVENTION

One embodiment of the present invention is a component assembly for a furniture spring construction assembly of a piece of furniture. The component assembly includes an elongated wire frame having first and second ends with a pair of spaced elongated parallel spars extending between the ends. A plurality of coil springs each have a base coil with a diameter substantially equal to the distance between the spars. The base coil for each coil spring is attached to both of the parallel spars. One coil spring is attached to the spars proximate the first end of the wire frame. A second coil spring is attached proximate the second end of the wire frame. The component assemblies may be connected to one another and arranged in a series to form a complete furniture spring construction assembly for a piece of furniture.

Another embodiment of the present invention comprises a furniture spring construction- assembly having two sides and comprising a plurality of component assemblies arranged in a series between the two sides of the construction assembly. Each component assembly is similar to those described in the preceding paragraph except the elongated wire frame is in the form of a closed loop and the coil springs are merely attached in spaced apart relationship along the length of the spars. A boundary wire framework is attached to the component assemblies at a plurality of the tops of the coil springs. Finally, there are a plurality of coupling wires interconnecting the tops of the coil springs.

One object of the present invention is to provide an improved furniture spring construction assembly which provides a longer useful life for the piece of furniture constructed therefrom.

Another object of the present invention is to eliminate the problem of noise and squeaking which often occurs in prior art devices over prolonged periods of use.

Still another object of the present invention is to allow a spring assembly for a piece of furniture to be easily constructed from a plurality of identical component assemblies.

Other objects and advantages of the present invention will be apparent from the following description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of a furniture spring construction assembly according to the present invention.

FIG. 2 is a bottom perspective view of the furniture spring construction assembly of FIG. 1.

FIG. 3 is a partial side perspective view of the furniture spring construction assembly of FIG. 1 showing one of the component assemblies.

FIG. 4 is a top sectional view of a furniture spring construction assembly according to the present invention attached to the wooden base suppor -of a chair.

FIG. 5 is a partial side sectional view of the chair support and spring assembly of FIG. 4 taken along the lines 5-5 in the direction of the arrows.

DESCRIPTION OF THE PREFERRED EMBODIMENT

For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.

Referring now to FIG. 1, there is illustrated a furniture spring construction assembly 10 according to one embodiment of the present invention. Construction assembly 10 includes a boundary wire framework 11, which in this case is square to correspond to use of the assembly in the construction of a chair. Boundary framework 11 is preferably formed from high carbon 6 gauge wire in which the two ends of the wire have been welded to each other to form a closed continuous loop structure. In this embodiment, construction assembly 10 includes three component assemblies designated as components 12, 13 and 14, respectively. Each component assembly 12, 13 and 14 is substantially identical. Each component assembly, includes three spring coils, which in the case of component 14 are designated as spring 15, spring 16 and spring 17. The component assemblies are attached to framework 11 by attaching the top of the peripheral springs with a plurality of attachment clips 18. Attachment clips 18 are preferably about 1 inch wide and are formed from sheet metal. Finally, the top of the construction assembly is completed by a plurality of coupling wires 19 which interconnect the tops of the various springs to each other and to framework 11. Coupling wires 19 are preferably formed from high carbon 14-1/2 gauge wire.

Referring to FIG. 2, there is shown a bottom perspective view of the construction assembly shown in FIG. 1. Again, the construction assembly includes three identical component assemblies respectively designated 12, 13 and 14. Each component assembly, in this case referring to component 14, includes at its base an elongated closed wire frame 29. Elongated wire frame 29 includes parallel spars 20 and 21 which separate respective ends 22 and 23. Frame 29 is preferably formed from 6 gauge high carbon wire in which the two ends have been bent back upon themselves and welded together to form a continuous closed loop. Component assembly 14, and the other component assemblies, are. formed by attaching a base coil of each spring to both spars 20 and 21 via attachment clips 24, which are similar, to attachment clips 18 used on the top of the assembly.

FIG. 3 shows a partial side perspective view of construction assembly 10 which shows component assembly 14 in detail. Component assembly 14 includes three spring coils respectively designated as 15, 16 and 17. These spring coils are preferably formed in an hour-glass shape from 8 or 9 gauge high carbon wire. Spring 15 includes base coil 25 and top coil 26. The use of the term "hour-glass" with respect to the springs means that at least one intermediate coil is of a smaller diameter than the base and top coils. Hour-glass springs are preferred because the smaller intermediate coils have the ability to pass through the base coil and between support spars 20 and 21 when the furniture is supporting an extreme load. This ability prevents the furniture component assembly from being damaged due to permanent deformation when the load is removed. Base coil 25 of spring 15 is connected to spars 20 and 21 by attachment clips 24, and top coil 26 is attached to framework 11 via an attachment clip 18. Likewise, spring 16 includes base coil 27 which is attached to spars 20 and 21 via attachment clips 24, and includes top coil 28 which is attached to framework 11 by attachment clip 18. Spring 17 is connected to the construction assembly in a similar manner. Spars 20 and 21 can be thought of as being divided into four separate sections, namely forward section 32, transition section 33, middle section 34 and rearward section 36. The respective sections are separated by bends 30, 31 and 35 formed in spars 20 and 21. Bends 30* and 31 are of equal angles such that the plane defined by section 32 is parallel with the plane defined by section 34. The result is that each component assembly, such as component 14 shown, includes a short spring 15 attached at the forward section 32 and two longer springs 16 and 17 attached in middle section 34 of elongated frame 29. It is important to note that, for purposes of stability, the base coil of each spring defines a diameter which is substantially equal to the distance between the two spars 20 and 21.

Fig. 4 shows a top sectional view of a furniture spring construction assembly according to the present invention attached to the wooden base support 40 of a chair. The view is sectioned such that only the elongated wire frame and the base coils 50 of each component assembly 47, 48 and 49 is shown. Wooden base support 40 has a front board 41, a rear board 42 and two side boards 43 and 44. Base support 40 further includes cross support member 46, and is strengthened by corner braces 45 which are also preferably made of wood. The various pieces of base support 40 are connected to one another by conventional means well known in the art, such as by gluing and/or by using screws. The three component assemblies 47, 48 and 49 are arranged in a series between side boards 43 and 44. Each component assembly has its forward section connected to front board 41 and its rearward section to cross support member 46 by brackets 55. For instance, forward section 51 of component assembly 49 is supported by and attached to front board 41 by bracket 55. Likewise, rearward section 52 of component assembly 49 is supported by and attached to cross member 46 by another bracket 55. Component assemblies 47 and 48 are supported by and attached to base support 40 in a similar mariner.

Fig. 5 is an exploded side sectional view along section 5-5 of Fig. 4. Fig. 5 shows in detail how the ends of the component assemblies are attached to the wooden base support 40. In particular, forward section 51 of component assembly 49 is shown supported by and attached to front board 41 via bracket 55. Bracket 55 is preferably formed from one inch wide strips of heavy gage sheet metal. Bracket 55 is bent to include hook portion 57 within which forward section 51 is received. Bracket 55 is preferably attached to the outer face of front board 41 by screws 56. Fig. 5 also shows a portion of one corner brace 45, to which leg 58 is attached in a conventional manner.

While the invention has been illustrated a d described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.

Claims

What is claimed is:

1. A component assembly for furniture spring construction comprising: an elongated wire frame having first and second ends separated by a pair of elongated parallel spars, said spars defining a distance therebetween; and a plurality of coil springs each having a base coil which defines a base diameter, said base coil of each said coil spring being attached to both said elongated parallel spars, said base diameter being substantially equal to said distance between said spars, one said coil spring being attached to said spars proximate to said first end, a second said coil spring being attached to said spars proximate to said second end, and at least one other said coil spring being attached to said spars between said first and second ends. whereby a plurality of said component assemblies may be connected in a series to form a complete furniture spring construction assembly for a piece of furniture.

2. The component assembly of claim 1 wherein said plurality of coil springs is three coil springs.

3. The component assembly of claim 2 wherein said elongated wire frame is formed and welded into defining a closed continuous loop.

4. The component assembly of claim 3 wherein said spars each includes two bends such that said spars define two parallel planes, a short said coil spring being attached to said spars in one of said parallel planes and two longer said coil springs being attached in the other of said two parallel planes.

5. A furniture spring construction assembly having first and second opposing sides comprising: a plurality of component assemblies arranged in a series between said two sides of said construction assembly, each said component assembly comprising: an elongated closed wire frame having first and second ends connected by a pair of elongated parallel spars, said first ends being disposed adjacent said first side of said construction assembly, and said second ends being disposed adjacent said second side of said construction assembly; a plurality of coil springs each having a base and a top, each said base being attached to each said pair of spars in spaced apart relationship along the length of said spars; a boundary wire framework attached to said component assemblies at a plurality of said tops of said coil springs, ; and a plurality of coupling wires interconnecting said tops of said coil springs.

6. The furniture spring construction assembly of claim 5 wherein, each said component assembly includes three coil springs.

7. The furniture spring construction assembly of claim 6 wherein, said base of each said coil spring defines a diameter, and said spars are separated by a distance substantially equal to said diameter.

8. The furniture spring construction assembly of claim 7 wherein, each said coil spring is hourglass shaped.

9. The furniture spring construction assembly of claim 8 wherein, each said spar includes first, second and third bends, said first and second bends being in proximity to said first end of said elongated wire frame, each of said first and second bends defining substantially equal bend angles, said third bends being in proximity to said second end of said elongated wire frame.

10. The furniture spring construction assembly of claim 9 wherein, each said elongated wire frame includes rearward, transition, middle and forward sections, said rearward section being defined between said third bends of said spars and said second end of said elongated wire frame, said middle section being defined between said second bends and said third bends of said spars, said transition section being defined between said first and said second bends, said forward section being defined between said first end of said elongated wire frame and said first bends of said spars; and two aft said coil springs are attached to each said spar in said middle section, and one fore said coil spring is attached to each said elongated wire frame in said forward section, said fore coil spring being shorter in length than said aft coil springs.

AMENDED CLAIMS

[received by the International Bureau on 27 April 1993 (27.04.93); original claims 1,2 and 5-10 amended; new claim 11 added; other claims unchanged (3 pages)]

1. A component assembly for furniture spring construction comprising: an elongated wire frame having first and second ends separated by a pair of elongated parallel spars, said spars defining a distance therebetween; and a plurality of coil springs each having a base coil which defines a base diameter, said base coil of each said coil spring being attached to both said elongated parallel spars, said base diameter being substantially equal to said distance between said spars, one said coil spring being attached to said spars proximate to said first end,.^' a second said coil spring being attached to said spars proximate to said second end, and at least one other said coil spring being attached to said spars between said first and second ends, and said coil springs being separated from each other a distance equal to or greater than said base diameter; and whereby a plurality of said component assemblies may be connected in a series to form a complete furniture spring construction assembly for a piece of furniture.

2. The component assembly of claim 1 wherein said plurality of coil springs is not more than three coil springs.

4. The component assembly of claim 3 wherein said spars each includes two bends such that said spars define two parallel planes, a short said coil spring being attached to i ^'

said spars in one of said parallel planes and two longer said coil springs being attached in the other of said two parallel planes.

5. A furniture spring assembly having first and second opposing sides comprising: a plurality of component assemblies arranged in a series between said two sides of said assembly, each said component assembly comprising: an elongated closed wire frame having first and second ends connected by a pair of elongated parallel spars, said first ends being disposed adjacent said first side of said assembly, and said second ends being disposed adjacent said second side of said assembly; a plurality of coil springs each having a base coil with a base diameter and a top, each said base coil being attached to each said pair of spars in spaced apart relationship along the length of said spars; a boundary wire framework attached to said component assemblies at a plurality of said tops of said coil springs,; and a plurality of coupling wires interconnecting said tops of said coil springs; and said component assemblies being separated from each other a distance equal to or greater than said base diameter.

6. The furniture spring assembly of claim 5 wherein, each said component assembly includes no more than three coil springs.

7. The furniture spring assembly of claim 6 wherein, said base of each said coil spring defines a diameter, and said spars are separated by a distance substantially equal to said diameter. 1 δ

8. The furniture spring assembly of claim 7 wherein, each said coil spring is hourglass shaped.

9. The furniture spring assembly of claim 8 wherein, each said spar includes first, second and third bends, said first and second bends being in proximity to said first end of said elongated wire frame, each of said first and second bends defining substantially equal bend angles, said third bends being in proximity to said second end of said elongated wire frame.

10. The furniture spring assembly of claim 9 wherein, each said elongated wire frame includes rearward, transition, middle and forward sections, said rearward section being defined between said third bends of said spars and said second end of said elongated wire frame, said middle section being defined between said second bends and said third bends of said spars, said transition section being defined between said first and said second bends, said forward section being defined between said first end of said elongated wire frame and said first bends of said spars; and two aft said coil springs are attached to each said spar in said middle section, and one fore said coil spring is attached to each said elongated wire frame in said forward section, said fore coil spring being shorter in length than said aft coil springs-

11. The furniture spring assembly of claim 5 wherein said coil springs of each said component assembly are separated from each other a distance equal to or greater than said base diameter.