Furniture spring support system restrictor wire

Abstract

A deflection limitation system for upholstered furniture seat members includes a rectangular-shaped support frame having opposed front and rear members and opposed sides. Sinuous-shaped springs are connected to both the front and rear members. Each spring is deflectable over a limited range defined between a non-deflected position and a maximum deflected position. A wire element crossing below the spring elements has ends each connected to different frame sides. A central portion of the wire element is downwardly curved. A predefined spacing separates the wire element central portion from each of the spring elements in the non-deflected position. The maximum deflected position of the spring elements wherein the spring elements contact the central portion of the wire element is reached when a predefined load is distributed to the spring elements. The spring elements are thereafter restrained from further deflection by the wire element.

1 . A furniture structural support system, comprising: 
 a frame;    a plurality of biasing elements connected to the frame, the biasing elements being each deflectable over a limited range defined between a non-deflected position and a maximum deflected position; and    a restrictor element overlapping each of the biasing elements, the restrictor element including opposed ends each connected to the frame;    wherein a predefined load distributed to the biasing elements is operable to deflect the biasing elements to the maximum deflected position defined as the biasing elements being in contact with the restrictor element, the biasing elements being thereafter restrained from further deflection by the restrictor element.    
     
     
         2 . The system of  claim 1 , further comprising a clearance gap created between the central portion of the restrictor element and each of the biasing elements in the non-deflected position.  
     
     
         3 . The system of  claim 2 , wherein each of the spring elements further comprises: 
 a longitudinal axis; and    opposed ends;    wherein the longitudinal axes of the biasing elements are arranged substantially parallel with each other.    
     
     
         4 . The system of  claim 3 , further comprising: 
 a substantially rectangular frame shape having sides defining a first opposed pair and a second opposed pair of sides; and    a plurality of connectors operable to fasten the opposed ends of the biasing elements to each side of the first opposed pair of sides;    wherein the opposed ends of the restrictor element are connectable to opposite ones of the second opposed pair of sides, the restrictor element being substantially perpendicular to the longitudinal axes of the biasing elements.    
     
     
         5 . The system of  claim 4 , wherein each of the opposed ends of the restrictor element are connected at a mid-span position of each frame side of the second opposed pair of sides.  
     
     
         6 . The system of  claim 4 , wherein the frame comprises a wood material.  
     
     
         7 . The system of  claim 6 , further comprising a contact plate disposed between each of the opposed ends of the restrictor element and the frame.  
     
     
         8 . The system of  claim 1 , further comprising at least one stiffening member connected to each of the biasing elements and arranged substantially perpendicular to the longitudinal axes of the biasing elements.  
     
     
         9 . The system of  claim 1 , wherein each of the biasing elements comprises a sinuous type spring.  
     
     
         10 . A furniture structural support system, comprising: 
 a rectangular-shaped support frame having opposed front and rear members and opposed sides;    a plurality of sinuous-shaped springs connected to both the front and rear members, each spring being deflectable over a limited range defined between a non-deflected position and a maximum deflected position;    a wire element crossing below the spring elements, the wire element including: 
 opposed ends each connected to different ones of the opposed sides of the frame;  
 a central portion defining a curve between the opposed ends; and  
   a clearance gap created between the central portion of the wire element and each of the spring elements in the non-deflected position;    wherein the maximum deflected position of the spring elements having the spring elements in contact with the central portion of the wire element is reached when a predefined load is distributed to the spring elements, the spring elements being thereafter restrained from further deflection by the wire element.    
     
     
         11 . The system of  claim 10 , further comprising an upholstered element connected to the spring elements.  
     
     
         12 . The system of  claim 11 , further comprising a cloth element positioned between the upholstered element and the spring elements.  
     
     
         13 . The system of  claim 11 , wherein the upholstered element comprises a seat cushion, the wire element being positioned generally below the spring elements and the seat cushion.  
     
     
         14 . The system of  claim 10 , wherein the predefined load comprises an occupant weight of at least 400 pounds.  
     
     
         15 . The system of  claim 10 , wherein the predefined load comprises an occupant weight of at least 500 pounds.  
     
     
         16 . The system of  claim 10 , further comprising at least one stiffening member connected to each of the spring elements and arranged substantially perpendicular to the longitudinal axes of the spring elements.  
     
     
         17 . The system of  claim 10 , further comprising a plurality of connectors operable to fasten the opposed ends of the spring elements to each side of the first opposed pair of sides.  
     
     
         18 . A seating frame suspension assembly, comprising: 
 a frame including connected elements defining a frame outer perimeter;    a plurality of spring elements substantially positioned within the outer perimeter of the frame and each connected to the frame, the spring elements being each deflectable over a limited range varying between a non-deflected position and a maximum deflected position;    an upholstered element connected to the spring elements; and    a support element transversely crossing each of the spring elements, the support element including: 
 opposed ends each connected to the frame; and  
 a central portion defining a curve between the opposed ends;  
   wherein a predefined load distributed to the spring elements through the upholstered element is operable to deflect the spring elements to the maximum deflected position defined as the spring elements being in contact with the central portion of the support element, the spring elements being thereafter restrained from further deflection by the support element.    
     
     
         19 . The suspension assembly of  claim 18 , further comprising a predefined spacing separating the central portion of the wire element from each of the spring elements in the non-deflected position.  
     
     
         20 . The suspension assembly of  claim 19 , further comprising a contact plate disposed at the frame adjacent each of the opposed ends of the restrictor element.  
     
     
         21 . The suspension assembly of  claim 18 , wherein each of the spring elements further comprises a sinuous wire spring.  
     
     
         22 . The suspension assembly of  claim 18 , wherein each of the connected elements of the frame further comprises a top surface supporting one of the spring elements and one of the opposed ends of the support element.  
     
     
         23 . The suspension assembly of  claim 18 , wherein the frame further comprises opposed front and rear members, the spring elements being supported from the front and rear members.  
     
     
         24 . The suspension assembly of  claim 18 , wherein the frame further comprises opposed side members, the opposed ends of the support element being connected to one of the side members.  
     
     
         25 . A seat assembly, comprising: 
 a frame including a front rail, a rear rail and two opposing side rails, each of the rails having a top edge;    a plurality of substantially parallel sinuous wire springs traversing the frame between the front and rear rails, the sinuous wire springs including first and second attachment ends connectable to the top edges of the front and rear rails, respectively;    at least one stabilizer wire extending substantially perpendicular to the sinuous wire springs and connected to each of the sinuous wire springs; and    a restrictor wire having opposed connecting ends, each connecting end connected to the top edge of one of the side rails, the restrictor wire having an arc-shaped central portion between the connecting ends operable to space the central portion from each of the sinuous wire springs in a non-deflected position of the sinuous wire springs.    
     
     
         26 . The seat assembly of  claim 25 , wherein a maximum deflection position of the sinuous wire springs is reached when the sinuous wire springs contact the arc-shaped central portion of the restrictor wire.  
     
     
         27 . The seat assembly of  claim 26 , further comprising a predetermined load applied to the sinuous wire springs operable to deflect the sinuous wire springs to the maximum deflection position.  
     
     
         28 . The seat assembly of  claim 27 , wherein the predetermined load is at least 400 pounds.  
     
     
         29 . The seat assembly of  claim 27 , wherein the predetermined load is approximately 500 pounds.  
     
     
         30 . The seat assembly of  claim 25 , wherein the connecting ends of the restrictor wire further comprise: 
 a hooked free end; and    a bend area;    wherein the hooked free end is received within the side rail and the bend area operably contacts the top edge of the side rail.    
     
     
         31 . The seat assembly of  claim 30 , further comprising an aperture created on the top edge of each side rail operable to receive the hooked free end of the restrictor wire.  
     
     
         32 . The seat assembly of  claim 25 , further comprising a loaded condition of the seat assembly wherein a load applied to the sinuous wire springs is operable to deflect the sinuous wire springs from the non-deflected position but insufficient to deflect the sinuous wire springs to the maximum deflection position.  
     
     
         33 . The seat assembly of  claim 25 , further comprising a contact plate positioned on each of the top edges of the side rails, each contact plate having an aperture to receive one of the opposed connecting ends of the restrictor wire.  
     
     
         34 . A method for restricting a seating assembly spring deflection, the seating frame including a frame, a plurality of spring elements connected to the frame, an upholstered element connected to the spring elements, and a restrictor element transversely crossing each of the spring elements, the method comprising: 
 creating a geometrically-shaped body of the restrictor element;    positioning the geometrically-shaped body of the restrictor element below and spatially separated from each of the spring elements in an unloaded condition of the spring elements;    applying a load to the upholstered element distributable to each of the spring elements operable to deflect the spring elements; and    limiting a deflection of the spring elements to a contact position of each spring element with the geometrically-shaped body of the restrictor element.    
     
     
         35 . The method of  claim 34 , further comprising predetermining a maximum value of the load.  
     
     
         36 . The method of  claim 35 , further comprising: 
 determining a maximum deflection value of the spring elements corresponding to the maximum value of the load;    dimensionally sizing the body of the restrictor element to initially offset the body from the spring elements by the maximum deflection value to operably establish the contact position.    
     
     
         37 . The method of  claim 34 , further comprising forming the geometrically-shaped body as an arc.