COMPACT FOLDING FRAME FOR FOLDING FURNITURE SUCH AS A SOFA BED AND MATCHING FOLDING FURNITURE

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001]This application claims priority to Belgian Patent Application No. 20245574, filed Aug. 28, 2024, the entire disclosure of which is hereby incorporated by reference herein.

TECHNICAL FIELD

[0002]The invention relates to a folding frame for a piece of folding furniture such as a sofa bed, as well as a piece of folding furniture comprising this frame.

PRIOR ART

[0003]Such folding frames for folding furniture, particularly a sofa bed, are often used in the prior art.

[0004]Thus, such a folding frame is known from WO 2004 086 913 (WO '913). The frame according to WO '913 comprises two rototranslational links, which are connected at a first end to a body support link and at a second end are connected to two different base beams.

[0005]The frame according to WO '913 is disadvantageous since the two ends of the rototranslational links are connected vertically spaced to the two said base beams. Such vertical spacing requires a frame that requires a substantial amount of (vertical) space for folding and unfolding. In addition, the inventors note that the shape and placement of the rototranslational links does not allow a smooth unfolding of the frame.

[0006]In addition, the frame from WO '913 has an additional drawback. In many situations, it happens that users sit on the edge of the bed for a moment when they get up. It is not comfortable here due to the high protruding links above the mattress surface.

[0007]The present invention aims to provide at least a solution for some of the above-mentioned problems or disadvantages. The aim of the invention is to provide a method which eliminates those disadvantages.

SUMMARY OF THE INVENTION

[0008]In a first aspect, the present invention concerns a folding frame for folding furniture such as a sofa bed. The frame provides improved kinematics for easy folding out or unfolding, wherein the user is assisted in folding and unfolding the furniture with less force, and thereby with increased control (without the risk of the furniture “running away”).

[0009]In a second aspect, the invention relates to a piece of folding furniture such as a sofa, sofa bed, or sleeper sofa comprising the frame according to the first aspect.

DESCRIPTION OF THE FIGURES

[0010]FIG. 1A shows a side view of an unfolded frame according to an embodiment of the present invention.

[0011]FIG. 1B shows a side view of an unfolded frame according to another embodiment of the present invention.

[0012]FIG. 2A shows a side view of a folded frame according to an embodiment of the present invention.

[0013]FIG. 2B shows a side view of a folded frame according to another embodiment of the present invention.

[0014]FIGS. 3A, 4A, 5A, and 6A show side views of the folding and/or unfolding of a frame according to an embodiment of the present invention.

[0015]FIGS. 3B, 4B, 5B, and 6B show side views of the folding and/or unfolding of a frame according to another embodiment of the present invention.

[0016]FIG. 7 shows a variant of the system in which a number of base beams are combined.

DETAILED DESCRIPTION

[0017]Unless otherwise defined, all terms used in the description of the invention, including technical and scientific terms, have the meanings as commonly understood by a person skilled in the art to which the invention pertains. For a better understanding of the description of the invention, the following terms are explained explicitly.

[0018]In this document, the articles “a”, “an” and “the” may denote both the singular and the plural, unless the context requires otherwise. For example, “a segment” means one or more segments.

[0019]When “about” or “around” is used in this document with reference to a measurable quantity, a parameter, a time period or moment, or the like, it is intended to refer to variations of +/−20% or less, preferably +/−10% or less, more preferably +/−5% or less, even more preferably +/−1% or less, and even more preferably +/−0.1% or less of the quoted value, insofar as such variations are applicable to the disclosed invention. However, it must be understood that the value of a quantity used where the term “about” or “around” is used, is itself specifically disclosed.

[0020]The terms “comprise”, “comprising”, “consist of”, “consisting of”, “provided with”, “have”, “having”, “include”, “including”, “contain”, “containing” are synonyms and are inclusive or open terms that indicate the presence of what follows, and which do not exclude or prevent the presence of other components, characteristics, elements, members, steps, as known from or disclosed in the prior art.

[0021]“Frame” in the context of the present text is to be understood as an assembly of parts that serves as a supporting structure for further elements and/or structures. Such components may, for example, be links, connectors, brackets, or frames. Such structures can be a sofa bed. Preferably, a frame is provided internally to such structures. Such a frame can also be provided externally to said structures. Such a frame can be provided both internally and externally to said structures.

[0022]“Link” is to be understood in the context of the present text as an element suitable for forming a connection with another link, bracket and/or frame, etc. This may be achieved, for example, by means of a simple opening in which the link and one of the aforementioned elements are anchored, for instance by a hook, screw, or other connector. “Beam” should be understood in the context of the current text as a substantially beam-shaped frame element.

[0023]“Pivotable” or “hingeable” should be understood in the context of the current text as rotatable about a support point. The support point may be a connection point between two links or between a link and another frame element.

[0024]The term “longitudinal axis” should be understood within the context of the current text as a rectilinear axis that is parallel to a side of a surface or a rectilinear axis that connects two connection points to each other.

[0025]“Longitudinal” should be understood in the context of the present text as a direction that is horizontal when the frame is placed on a horizontal surface. In essence, said direction is the direction in which the frame, i.e., the various mattress brackets, is folded and/or unfolded.

[0026]Quoting numerical intervals by the endpoints comprises all integers, fractions and/or real numbers between the endpoints, these endpoints included.

[0027]In a first aspect, the invention relates to a folding frame suitable for folding furniture such as a sofa bed.

[0028]In a second aspect, the invention relates to a piece of folding furniture such as a sofa bed, sleeper sofa, pull-out sofa, etc., comprising the frame according to the first aspect. Preferably, the folding furniture is a sofa bed, sleeper sofa or similar, and more preferably it comprises a seat, back support and mattress.

[0029]In what follows, both aspects of the present invention are discussed together. Any feature described herein may refer to any aspect, even if the feature is described in conjunction with a specific aspect of present invention.

[0030]It will be apparent to a person skilled in the art that any technical element described according to the aspects of the invention can be provided in appropriate numbers without departing from the subject matter of the present invention. In particular, the head support link, the body support link as well as the lever links can be provided in two, three, four, five, six, seven, eight, nine or tenfold. Preferably, the head support link, the back support link and the body support link are provided in duplicate. More preferably, said links are provided in duplicate respectively on each (longitudinal) side in a direction perpendicular to the longitudinal direction of a frame.

[0031]It will be apparent to a person skilled in the art that any technical element described according to the aspects of the invention can be provided in appropriate numbers without departing from the subject matter of the present invention. In particular, the components of the frame, such as the head support links, the body support links, as well as the other links and components, can be provided in multiples, for instance, in duplicate, triplicate, quadruplicate, quintuplicate, etc. Preferably, at least the head support links, the body support links, the body support mattress- and head support mattress brackets, and the links therebetween are provided in duplicate. Preferably, said components are provided in duplicate respectively on each (longitudinal) side in a direction perpendicular to the longitudinal direction of a frame.

[0032]The terms “head support mattress bracket” (and the like) and “body support mattress bracket” (and the like) do not imply any functional limitation in terms of length or function (i.e., that they exclusively support the head or body), but merely serve to indicate which end of the frame is concerned (head or foot). As is visible in the figures, the two pieces—or at least the sections of the unfolded piece of furniture that they support—are substantially equal in size, which is more compact in the folded state.

[0043]The frame described above provides, by means of the suspension elements, improved support for sofa beds, in that the foot portion can have a greater weight without adversely affecting the foldability of the mechanism. The user is supported in these actions by the suspension elements, whereby typically only a small application of force is needed to initiate the movement, and the further movement can then be continued with minimal force and guidance. Thus, the user has full control at all times, and the folding and unfolding can be stopped in a fraction of a second. Ergonomically as well, the proposed mechanism offers substantial advantages, which allows for a weighted frame, and in particular, a weighted foot member, that can be easily folded and unfolded with limited initial force.

[0044]In a preferred embodiment, the second end of the first body support link is fixedly connected to the second end of the front pivot link at the point where the first body support link is pivotally connected to the head support mattress bracket.

[0045]By using this point for both connections, the degree of synchronization is increased, but the number of machining operations (and links) is also reduced when manufacturing the frame. Moreover, the presence of a fixed connection at the same position as a pivotable connection has a stabilizing influence on the pivotable connection.

[0046]In a preferred embodiment, the first suspension element (A) has a first length when the frame is in an extended state, a second length when the frame is in a folded state, wherein the length of the first suspension element (A) between the folded and extended state has a convex profile. The suspension element contributes to the movement away from the folded and extended states, and ensures that the user experiences (the most) assistance during these actions at the beginning and the end, and therefore has to use less force. Thus, the user needs minimal force at the start of the movement, which is beneficial given that this usually starts from an ergonomically awkward position for the user. Furthermore, the suspension element ensures that at the end of the movement, it is automatically decelerated because the spring lengthens more quickly in this final stage of movement, thus providing an ever-increasing counterforce to prevent the movement from ending too abruptly. In this way, it is prevented, among other things, that a finger or hand can become trapped in a mechanism, but also that the folding or unfolding ends abruptly and could cause damage to the mechanism, the floor, or other things (such as a foot or toes). Preferably, the first suspension element has a local minimum that is located between the folded and extended states. At this local minimum, the first suspension element provides minimal “assistance” to the movement, but at that moment, the movement has already progressed to a point where the mass is located less far from the fulcrum of the movement, and continuing also requires less force.

[0047]In a preferred embodiment, the frame is provided with a foot assembly that is fixedly connected to the body support mattress bracket and extends as an extension thereof, away from the head support mattress bracket, wherein the foot assembly comprises an upper horizontal support surface and a foot support which extends substantially perpendicularly to the horizontal support surface at the distal end of the horizontal support surface relative to the head support mattress bracket.

[0048]In this version, the frame comprises a fixed foot assembly, which is always in the “unfolded” position. Since the foot support rests on the ground in both the folded and the unfolded or extended position, no space is lost, the mechanism becomes simpler and sturdier, and it also provides additional support at the foot end of the folded sofa bed (in sofa mode).

[0049]In a preferred embodiment, the frame is provided with a foot assembly that is fixedly connected to the body support mattress bracket and extends as an extension thereof, away from the head support mattress bracket. Herein, the foot assembly comprises an upper horizontal support surface, and the foot assembly comprises a foot mounting bracket at the free end, wherein the frame further comprises a foot member with a first end configured to rest on the ground in the unfolded state of the frame. The foot member has a second end pivotally connected to a first end of a foot support link, the foot support link having a second end pivotally connected to the first body support link near the first end thereof. The foot member is pivotally connected at a first pivot point (U) to the foot mounting bracket, the first pivot point (U) being located between the first and second ends of the foot member, the foot member being positioned substantially parallel to the foot support link when the frame is in the folded state.

[0050]In this version, the frame comprises a foldable foot assembly, of which the foot support, in the unfolded position, is approximately perpendicular to the support surface of the foot assembly, and thus comes to be perpendicular to the ground. In the folded position, the foot support lies against the support surface. Preferably, an additional support element is provided at the front of the piece of folding furniture to compensate for the absence of the foot support. The advantage of this is that, instead of a solid foot support as in the version described earlier, a more compact version is provided, which is lighter and makes folding ergonomically easier.

[0051]In a preferred embodiment, the second pivot point (K), at which the first body support link is pivotally connected to the body support mattress bracket, is positioned more distally on the first body support link relative to the second end of the first body support link than the third pivot point (S), at which the foot support link is connected to the first body support link.

[0052]The positioning of the third pivot point (S) at a less distal location than the second pivot point (K) ensures that the foot mechanism (specifically the foot support link) is driven in a highly reliable manner, in contrast to situations in which this is done from a distal position. The limited loss of force can be easily compensated for by the length of the lever arm, whereby the effect thereof on user comfort is negligible.

[0053]In a preferred embodiment, the base beams (on both lateral sides) consist of two horizontal beams that extend from the foot end to the head end, with multiple vertical or upright beams therebetween, substantially perpendicular to the horizontal beams. Preferably, the horizontal beams are positioned at a limited distance from each other relative to their length, such as a ratio of at most 1:2, 1:3, or even 1:4, which provides a sturdy base for the upright beams.

[0054]The upright beams serve to support the pivotable connections, and for this purpose provide a stable anchorage that can withstand large forces both horizontally and vertically, but especially also bending moments under the influence of the pivoting mechanism. Thus, the forces can be absorbed during the entire movement, given that their orientation changes throughout the movement. Because these upright beams have a limited (unsupported) length, they can withstand large transverse forces with a limited risk of bending or other damage.

[0055]In a preferred embodiment, the one or more of the base beams to which the first end of the front pivot link is pivotally connected extends horizontally along the length of the frame and is located at a foot end of the frame, thus forming a horizontal base beam. Preferably, this embodiment builds upon the preceding embodiment.

[0056]The front pivot link supports the first body support link, and is better supported by the connection on this horizontal base beam, since the first body support link assists in supporting parts at the foot end during use, whereby the load arm can become large.

[0057]Preferably, this horizontal base beam is again very limited in terms of unsupported length, whereby the risk of bending or deformation is greatly reduced. Through a combination with the preceding embodiment, the base beams form a grid structure that substantially increases the strength. The horizontal base beam is located between the two horizontal beams and between two upright beams that are connected to (or integral with) the horizontal beams. The horizontal base beam preferably has a maximum length of 30 cm, more preferably a maximum of 25 cm.

[0058]In an alternative preferred embodiment, the first end of the front pivot link is pivotally connected to a protrusion of an upright base beam, at the foot end of the frame, and this protrusion is integral with the said base beam.

[0059]In a preferred embodiment, the base beams, to which the front pivot link and the first head support link are pivotably connected, form a single component. This on the one hand simplifies production, because fewer components need to be connected, and on the other hand improves the sturdiness and reliability.

[0060]In a preferred embodiment, at least one of the base beams comprises a first support element, wherein the second body support link rests on the first support element when the frame is in the folded state.

[0061]The provision of the first support element ensures that the second body support link, which has a considerable length, is supported at an intermediate point between the two pivot points in the folded state, in which it is indirectly loaded by the load on the body support mattress bracket (which in turn is itself indirectly loaded). This ensures that the second body support link runs no risk of bending or deforming under a heavy load.

[0062]In a further preferred embodiment, the base beams to which the front pivot link and the first head support link are pivotally connected and the at least one of the base beams which comprises the first support element (R) form the single component.

[0063]As previously indicated, providing a number of parts of the base beams as a single component is advantageous for assembly, but also for the strength and reliability of the entire construction, given that there are fewer connections present that can break and typically act as a weak point.

[0064]In a preferred embodiment, the first head support link, the second suspension element, and preferably also the first support element (R), are located on vertically upright sections of the base beams. As indicated, this provides additional support for forces (and moments) from different directions. The base beams in this way together form a frame, especially with the horizontal beams connecting the vertical ones at the top and bottom, which increases the structural strength.

[0065]In a preferred embodiment, the body support mattress bracket comprises a second support element (M), wherein the first body support link lies against the second support element (M) in the unfolded state of the frame.

[0066]The provision of the second support element ensures that the first body support link, which has a considerable length, is supported at an intermediate point between the two pivot points in the folded state, in which it is indirectly loaded by the load on the body support mattress bracket (which in turn is itself indirectly loaded). This ensures that the first body support link runs no risk of bending or deforming under a heavy load.

[0067]In a further preferred embodiment, an adjustable bed stop is fixedly provided on the body support mattress bracket, wherein the adjustable bed stop lies against the second support element (M) in the unfolded state of the frame.

[0068]In yet another preferred embodiment, the second body support link lies against the second support element (M) in the folded state of the frame, preferably wherein the second body support link has a recess in which the second support element (M) lies in the folded state of the frame.

[0069]By using a recess, the correct mutual positioning of the second support element and the second body support link is ensured.

[0070]According to an embodiment, the frame comprises multiple cross-links, wherein the cross-links are connected transversely to the frame. Said cross-links in this way connect a plurality of links, brackets, frames, etc., in the frame to each other. Preferably, the cross-links connect two sub-frames, each provided laterally on the mattress mounting surface. Such cross-links have the advantage of providing a sturdier structure in the frame.

[0071]According to a preferred embodiment, the frame comprises the aforementioned parts on both lateral sides, wherein one or more of the parts on both lateral sides are connected to each other via a cross-link. The components on both lateral sides can be unitary, with the cross-link forming part of the unitary components, or they may be two (often symmetrical) components that are interconnected by one or more cross-links.

[0072]In a second aspect, the invention relates to a piece of folding furniture, preferably a sofa or couch in the folded state, which can be unfolded into a bed or sofa bed in the unfolded state, comprising a seat portion and a back portion, the seat portion comprising a hollow housing in which a folding frame according to the first aspect is mounted with the base beams on the inner side of the hollow housing.

[0073]Preferably, the frame further comprises one or more frames that connect the two lateral sides, whether directly or not, and provides a support surface or attachment point for cushions, mattresses, or other support surfaces.

[0074]In a preferred embodiment, the first body support link is S-shaped and elongated. Herein, the second pivot point is located at the first end, and the first suspension element is attached to the second end.

[0075]In a preferred embodiment, the second head support link is L-shaped, and is connected with its first end to a base beam, wherein the second end, where the second head support link is pivotally connected to the head support mattress bracket, is located at the connection between the two legs of the L-shape.

[0076]In a preferred embodiment, the lower pivot link is L-shaped, wherein it is pivotally connected with its first end to a base beam and pivotally connected with its second end to the first end of the upper pivot link. At the connection between the two legs of the L-shape, the lower pivot link is pivotally connected to the second suspension element.

[0077]In what follows, the invention is described by way of non-limiting examples illustrating the invention, and which are not intended to and should not be interpreted as limiting the scope of the invention.

EXAMPLES

[0078]FIGS. 1A-6A and FIGS. 1B-6B show the progression during the unfolding from the sofa to a sofa bed for two embodiments. The first set (1A-6A) shows a sofa bed with a “fixed” foot, while the second set (1B-6B) shows a version of the sofa bed with a foldable foot. In what follows, both versions are discussed simultaneously, with additional remarks regarding the foldable foot mechanism for the second set.

[0079]FIGS. 1A and 1B show the sofa bed in the folded state. Herein, a fixed frame is provided in which the frame is incorporated on the inside, and this frame also comprises a fixed back support. In this form, the first and second suspension elements (A) and (B) are at a local maximum of extension, and they exert a force that assists in unfolding from the folded form.

[0080]The base beams comprise two long horizontal beams (14), with six upright base beams therebetween (1, 9, 15, an additional upright beam more towards the head end than the fourth base beam, and the two outer upright beams) and a bracket structure as the second base beam (5). The third base beam (9) comprises a horizontal section that is connected to the outer upright beam. By this means, the frames are attached in the piece of furniture, typically to a frame or furniture cabinet.

[0081]Preferably, a number of the base beams are made as one piece, as in FIG. 7, where the first, third, and fourth base beams (1, 9, 15) are made as a single piece, and are connected at the top and bottom sides via a beam that is connected to the horizontal beams (14). In this variant, the horizontal section of the third base beam (9) is no longer connected to the outer base beam, but is simplified to a lateral protrusion of the third base beam (9).

[0082]In the folded or closed position, there is contact between the fourth base beam (15) and the second body support link (6), and the latter rests on the fourth base beam (15) via the first support element (R). The hinge mechanism is directly connected to the frame and the base beams via pivot points (S, D, I).

[0083]FIGS. 2A and 2B show the movement during the unfolding of the sofa. Through movement A-A, the sofa opens by moving the seat frame portion forward. At this point, the second body support link (6) is no longer supported by the fourth base beam (15) via the first support element (R). In this step, the four-link mechanism (12, 11, 6, 3), which causes the sofa to unfold, moves. In this process, the second body support link (6), which is attached to the body support mattress bracket (12), moves by means of pivot point (J). Simultaneously, the first body support link (11), which is also attached to the body support mattress bracket (12), moves via pivot point (K). The lower and upper pivot links (7, 8) remain stationary because the extension of the second suspension element (B) does not change. During this phase, the head support mattress bracket (3) also moves slightly upward.

[0084]In addition, in FIG. 2B the foot support link (16) moves as a result of the movement of the first body support link (11) and the pivot connection (S), thereby driving the foot support (17) into an upright position via the pivot connection (T), around the pivot point (U) on the foot mounting bracket (18).

[0085]FIGS. 3A and 3B show the continuation of the unfolding in movement A-A, wherein the foot portion moves forward. Here, it can be seen that the lower pivot link (7) is connected to the second base beam (5) via pivot point (E). In turn, the upper pivot link (8) is connected to the head support mattress bracket (3) via pivot point (G). In this process, the first suspension element (A) exerts a tensile force on the first body support link (11) via the suspension points (N, P), which simplifies further opening as it facilitates the forward movement of the body support mattress bracket.

[0086]In addition, in FIG. 3B the hinge of the foot support (17) opens further, the foot support link (16) causing the foot support (17) to pivot about the pivot points (S, T) and via the pivot point (U) on the foot mounting bracket (18).

[0087]FIGS. 4A and 4B again show the continuation of movement A-A, and in particular illustrate the opening of the four-link mechanism (12, 11, 6, 3), such that the seat frame (front side) gradually comes to rest on the ground. During this movement, the first (A) and second (B) suspension elements begin to exert a counterforce, whereby the final movement automatically slows down. The second suspension element (B), which is pivotally attached to an upright beam at pivot point (Q), also exerts a tensile force on the lower pivot link (7) via pivot point (O). As a result, the rotational movement of the lower pivot link (7) is counteracted and slowed down, and thereby also the movement of the upper pivot link (8).

[0088]The first head support link (2) is pivotally connected to the head support mattress bracket (3) at pivot point (W), and also to the first base beam via pivot point (V). The second head support link (4) is attached to the second body support link (6) at pivot point (C), and is also pivotally attached to the second base beam (5) via pivot point (D).

[0089]During the movement in FIGS. 4A and 4B, the front pivot link (10), which is fixed to the first body support link (11), pivots around pivot point (H) on the head support mattress bracket (3). In addition, the front pivot link (10) is also pivotally connected to the third base beam via pivot point (I).

[0090]In FIG. 4B, it is further visible that the foot portion opens further and moves further toward a perpendicular position.

[0091]In FIGS. 5A and 5B, movement B-B is performed, to ultimately touch the ground as shown in FIGS. 6A and 6B.

[0092]In this movement, it can be seen how the second suspension element (B) exerts an increasing tensile force, thus further slowing the unfolding (of the foot end), such that it lands softly on the ground. This is possible due to the connections of the lower and upper pivot links (7, 8), which are assembled via the pivot point (F) that is aligned, and thus stretch the second suspension element (B).

[0093]The first suspension element (A) also continues to exert force, but this force remains substantially constant in this final phase.

[0094]At this point, the four-link mechanism (12, 11, 6, 3) is almost completely open. The first head support link (2) is attached to the first base beam (1) via pivot point (V), and to the head support mattress bracket (3) via pivot point (W). The second head support link (4) has thereby rotated and is pivotally attached on the one hand to the second base beam (5) via pivot point (D) and on the other hand to the second body support link (6) and/or the head support mattress bracket (3) via pivot point (C). The first body support link (11) is pivotally attached to the body support mattress bracket (12) via pivot point (K), while the second body support link is pivotally attached to the body support mattress bracket via pivot point (J).

[0095]The adjustable bed stop (13) thereby comes to rest against the second support element (M). The bed stop (13) is fixed to the first body support link (11) to improve the support on the floor, depending on the weight.

[0138]The present invention should not be construed as being limited to the embodiments described above and certain modifications or changes may be added to the examples described without having to re-evaluate the appended claims. For example, the present invention has been described with reference to sofa beds and the like, but it should be clear that the invention can be applied to, for example, garden furniture and other applications.