Deluxe CL rooms at BWI and WL have 2 queens and a full size sleeper sofa. Perhaps that would work for you? Should be a bit cheaper than 2 regular rooms or a villa AND you get CL service.
If sleepers count, then 1BR villas at OKW, Kidani, Jambo(non-value) and BLT have a king bed, and a Queen sleeper sofa and a twin sleeper chair. Kidani and BLT would also have 2 full bathrooms.
2 rooms at many of the resorts would be cheaper than getting a villa at one of the DVC resorts. If none of the beds can be a sleeper/single (which many of the deluxes have), I'd go for 2 rooms someplace.