Adjustable foundation for a seating unit

• US 9,022,474 B2
• Filed: 07/06/2009
• Issued: 05/05/2015
• Est. Priority Date: 07/06/2009
• Status: Active Grant

• Current Assignee: L&P Property Management Company (Leggett & Platt Incorporated)
• Original Assignee: L&P Property Management Company (Leggett & Platt Incorporated)
• Inventors: Bullard, Larry I.
• Primary Examiner(s): GABLER, PHILIP F
• Application Number:
  US12/498,053
• Publication Number:
  US 20110004371A1
• Time in Patent Office: 2,129 Days
• Field of Search: 297/284.1, 297/284.2, 297/284.3, 297/452.56
• US Class Current: 297/284.2
• CPC Class Codes: A47C 7/285 with metal strips or webs
• CPC Class Codes: A47C 7/30 with springs meandering in a flat plane
• CPC Class Codes: B60N 2/66 Lumbar supports
• CPC Class Codes: B60N 2/667 having flexible support member bowed by applied forces
• CPC Class Codes: B60N 2/6673 with motor driven adjustments
• CPC Class Codes: B60N 2/72 Attachment or adjustment thereof

Abstract

A seating unit that includes an adjustable foundation, a torque-inducing mechanism, and a base structure for interconnecting a backrest and a seat is provided. The adjustable foundation provides adjustable support for, and is controlled by, an occupant of the seating unit. The adjustable foundation includes extensible supports that each have a first and second end, and a frame assembly. The frame assembly includes a stationary member that is fixedly attached to the first ends and a drive bar that is configured to secure the second ends of the extensible supports such that longitudinal tension is generated upon rotating the drive bar with respect to the stationary member. The torque-inducing mechanism adjusts an angular position of the drive bar. In this capacity, the drive bar is configured to convert torque applied by the torque-inducing mechanism into a directional force that controls the longitudinal tension of the extensible supports.

Claims

1. An adjustable foundation of a seating unit having a base structure for suspending the adjustable foundation above an underlying surface, the adjustable foundation comprising:

extensible supports each having a first end and a second end; and

a frame assembly for controlling tension of the extensible supports, the frame assembly comprising;

(a) a forward lateral member that is fixedly attached directly to the first end of each of the extensible supports;

(b) a rearward lateral member that is in a substantial parallel-spaced relationship with the forward lateral member;

(c) a drive bar that is rotatably coupled to the rearward lateral member and directly secures the second end of each of the extensible supports such that the extensible supports are directly coupled to the drive bar at a distance from the rearward lateral member,

wherein the extensible supports span directly between the forward lateral member and the drive bar, and wherein rotation of the drive bar comprises rotation about a central longitudinal axis of the drive bar and direct tensioning applied to of each of the extensible supports directly coupled to the drive bar,

wherein an amount of tensioning applied to each of the extensible supports corresponds to an amount of rotation about the central longitudinal axis, wherein the central longitudinal axis of the drive bar is substantially parallel with the rearward lateral member, wherein rotation of the drive bar about the central longitudinal axis in a counterclockwise direction of movement towards the rearward lateral member escalates longitudinal tension retained by the extensible supports to increase a desired level of firmness of the adjustable foundation based at least in part on direct contact between each of the extensible supports and the drive bar, and further wherein rotation of the drive bar about the central longitudinal axis in a clockwise direction of movement away from the rearward lateral member relaxes longitudinal tension retained by the extensible supports to decrease a desired level of firmness of the adjustable foundation based at least in part on direct contact between each of the extensible supports and the drive bar,

wherein rotation about the central longitudinal axis comprises wrapping each of the extensible supports around an outer circumference of the drive bar; and

(d) a seat supported by the extensible supports, wherein the seat is configured to accommodate a posterior of an occupant of the seating unit, wherein rotation about the central longitudinal axis of the drive bar corresponds to an indication provided by the occupant of the desired level of firmness,

wherein the drive bar comprises a nonuniform diameter along the central longitudinal axis such that adjustment of a rotational position of the drive bar increases or decreases a longitudinal tension applied to at least two of the extensible supports at an uneven rate,

wherein the nonuniform diameter of the drive bar comprises a nonuniform cam, wherein an amount of tension of one or more of the extensible supports changes at a first rate of adjustment and an amount of tension of one or more of the extensible supports changes at a second rate of adjustment different than the first rate of adjustment.

2. The adjustable foundation of claim 1, wherein the frame assembly further comprises a pair of opposed pivot brackets each having a mounting area extending from the rearward lateral member and an attachment surface that is fixedly attached to the rearward lateral member such that each mounting area is separate from the rearward lateral member, and wherein the rotatable coupling between the drive bar and the rearward lateral member is formed by rotatably coupling the drive bar to the mounting area of each of the pair of opposed pivot brackets such that the drive bar is substantially disposed therebetween.

3. The adjustable foundation of claim 1, further comprising a control system for adjusting the longitudinal tension retained by the extensible supports, the control system comprising a torque-inducing mechanism that is radially engaged to the drive bar to rotate the drive bar about the central longitudinal axis.

4. The adjustable foundation of claim 3, wherein the torque-inducing mechanism is fixedly attached to the rearward lateral member and is configured to adjust an angular position of the drive bar with respect to the rearward lateral member.

5. The adjustable foundation of claim 4, wherein the torque-inducing mechanism comprises a ratchet device that, upon receipt of manual actuation, advances rotary motion of the drive bar thereby escalating or relaxing torque applied thereto, wherein the ratchet device comprises:

a gearwheel that includes a centrally located opening and radially directed teeth, wherein the gearwheel is radially engaged to the drive bar via the opening; and

a spring-loaded finger that is pivotably coupled to the rear lateral member and that engages with the teeth to prevent unintended rotary motion of the drive bar.

6. The adjustable foundation of claim 4, wherein the control system further comprises an electronic-control device that, upon actuation by an occupant of the seating unit, initiates operation of the torque-inducing mechanism to escalate or relax torque applied to the drive bar.

7. The adjustable foundation of claim 6, wherein the torque-inducing mechanism comprises:

a pulley that includes a centrally located bore that is radially engaged to the drive bar;

a cable that includes a first end connected to the pulley and a second end that is connected to a linear motor, wherein the pulley is circumferentially engaged to a section of the cable; and

the linear motor for applying the torque to the drive bar by exerting a linear draw on the cable.

8. The adjustable foundation of claim 6, wherein the torque-inducing mechanism comprises:

a gear that includes a centrally located opening that is radially engaged to the drive bar; and

a rotary motor with a sprocket output that is drivably engaged to the gear for applying the torque on the drive bar.

9. The adjustable foundation of claim 6, wherein the control system further includes a processor that is operably coupled to the electronic-control device and the torque-inducing mechanism and acts as an interface therebetween, wherein the processor is configured with a memory functionality for storing preset levels of firmness.

10. The adjustable foundation of claim 1, wherein each of the extensible supports comprise fabric webbing, wherein the first end of the extensible supports is fixedly attached to the forward lateral member by wrapping the extensible supports thereabout, and wherein the second end of the extensible supports is secured to the drive bar by inserting the second end into slots that are longitudinally fabricated into the drive bar.

11. The adjustable foundation of claim 1, wherein each of the extensible supports comprises sinuous wire, wherein the first end of the extensible supports is fixedly attached to the forward lateral member by attachment clips, and wherein the second end of the extensible supports is secured to the drive bar by fasteners that allow for rotational movement between the second end and the drive bar.

12. The seating unit of claim 1, wherein the drive bar comprises a cross-section that is non-uniform in radius such that adjustment of an angular position of the drive bar increases or decreases the longitudinal tension of the extensible supports at an uneven rate based on wrapping each of the extensible supports around a nonuniform outer circumference along a length of the drive bar.

13. The adjustable foundation of claim 1, wherein the forward lateral member of the frame assembly is positioned on a front-facing side of the occupant of the seating unit, and wherein the drive bar of the frame assembly is positioned on a back-facing side of the occupant of the seating unit.

16. The adjustable foundation of claim 1, wherein the increasing or decreasing of the longitudinal tension corresponds to an increasing or decreasing of a level of firmness.

14. An adjustable foundation of a seating unit having a base structure for suspending the adjustable foundation above an underlying surface, the adjustable foundation comprising:

extensible supports each having a first end and a second end; and

a frame assembly for controlling tension of the extensible supports, the frame assembly comprising;

(a) a forward lateral member that is fixedly attached directly to the first end of each of the extensible supports;

(b) a rearward lateral member that is in a substantial parallel-spaced relationship with the forward lateral member;

(c) a drive bar that is rotatably coupled to the rearward lateral member and directly secures the second end of each of the extensible supports such that the extensible supports are directly coupled to the drive bar at a distance from the rearward lateral member, wherein the drive bar comprises a nonuniform cam shape that changes along a central longitudinal axis of the drive bar,

wherein the extensible supports span directly between the forward lateral member and the drive bar, and wherein rotation of the drive bar comprises rotation about the central longitudinal axis of the drive bar and direct tensioning applied to of each of the extensible supports directly coupled to the drive bar,

wherein an amount of tensioning applied to each of the extensible supports corresponds to an amount of rotation about the central longitudinal axis of the drive bar and is based on a position where each extensible support is secured along the central longitudinal axis of the drive bar relative to at least a portion of the nonuniform cam shape, such that a rate of increasing or decreasing in longitudinal tension is uneven between at least two of the extensible supports during adjustment of the drive bar based on the nonuniform cam shape of the drive bar where each of the at least two extensible supports is coupled to the drive bar, wherein adjustment of a first extensible support associated with a first portion of the nonuniform cam shape is different than a rate of adjustment of a second extensible support associated with a second portion of the nonuniform cam shape,

wherein the central longitudinal axis of the drive bar is substantially parallel with the rearward lateral member, wherein rotation of the drive bar about the central longitudinal axis in a counterclockwise direction of movement towards the rearward lateral member escalates longitudinal tension retained by the extensible supports to increase a desired level of firmness of the adjustable foundation based at least in part on direct contact between each of the extensible supports and the drive bar, and further wherein rotation of the drive bar about the central longitudinal axis in a clockwise direction of movement away from the rearward lateral member relaxes longitudinal tension retained by the extensible supports to decrease a desired level of firmness of the adjustable foundation based at least in part on direct contact between each of the extensible supports and the drive bar; and

(d) a seat supported by the extensible supports, wherein the seat is configured to accommodate a posterior of an occupant of the seating unit, wherein rotation about the central longitudinal axis of the drive bar corresponds to an indication provided by the occupant of the desired level of firmness.

15. The adjustable foundation of claim 14, wherein based on the rate of adjustment of the first extensible support being different than the rate of adjustment of the second extensible support, the adjustable foundation is configured to provide a zoned effect.

17. An adjustable foundation of a seating unit having a base structure for suspending the adjustable foundation above an underlying surface, the adjustable foundation comprising:

a plurality of extensible supports each having a first end and a second end; and

a frame assembly for controlling tension of the plurality of extensible supports, the frame assembly comprising;

(a) a forward lateral member that is fixedly attached directly to the first end of each of the plurality of extensible supports;

(b) a rearward lateral member that is in a substantial parallel-spaced relationship with the forward lateral member;

(c) a drive bar that is rotatably coupled to the rearward lateral member and directly secures the second end of each of the plurality of extensible supports such that longitudinal tension is restrained thereby, said drive bar comprising a nonuniform cam profile that changes along a length of a rotation axis of the drive bar,

wherein an amount of longitudinal tensioning applied to each of the plurality of extensible supports in response to rotation of the drive bar corresponds to a position where each of the plurality of extensible supports is secured along the nonuniform cam profile of the drive bar.

18. The adjustable foundation of claim 17, wherein the amount of tensioning applied to each of the plurality of extensible supports corresponding to a position along the nonuniform profile comprises:

an amount of tensioning applied to each of the plurality of extensible supports relative to at least a portion of the nonuniform cam shape, such that a rate of adjustment of a first extensible support associated with a first portion of the nonuniform cam shape is different than a rate of adjustment of a second extensible support associated with a second portion of the nonuniform cam shape.

19. The adjustable foundation of claim 18, wherein based on the rate of adjustment of the first extensible support being different than the rate of adjustment of the second extensible support, the adjustable foundation is configured to provide a zoned effect.

20. The adjustable foundation of claim 17, further comprising:

a seat supported by the extensible supports, wherein the seat is configured to accommodate a posterior of an occupant of the seating unit, wherein rotation about the rotation axis of the drive bar corresponds to an indication provided by the occupant of the desired level of firmness.