WO2022251338A1

WO2022251338A1 - Bed system and retainer system therefor

Info

Publication number: WO2022251338A1
Application number: PCT/US2022/030892
Authority: WO
Inventors: Joseph Ermalovich
Original assignee: Ergomotion, Inc.
Priority date: 2021-05-26
Filing date: 2022-05-25
Publication date: 2022-12-01
Also published as: AU2022283288A1; US20220378215A1

Abstract

A retainer system is configured to retain a mattress to an adjustment mechanism configured to move the mattress between a flat configuration and one or more inclined configurations. The retainer system includes a strap and an elongated stiffener. The strap is configured to extend through a sleeve on an underside of the mattress and having first and second ends that are releasably coupled to the adjustment mechanism proximate each left and right sides thereof. The elongated stiffener is coupled to the strap and configured to, when pushed through the sleeve, insert the strap through the sleeve.

Description

BED SYSTEM AND RETAINER SYSTEM THEREFOR

CROSS-REFERENCE TO RELAT 46(E.G, ED APPLICATION(S)

[0001] This application claims priority to and the benefit of U.S. Provisional Application No. 63/193,467, filed May 26, 2021, and U.S. Provisional Application No. 63/243,574, filed September 13, 2021, the entire disclosures of which are incorporated by reference herein.

TECHNICAL FIELD

[0002] This invention relates generally to the field of articulating bed frames and more particularly to a magnetically centered strap assembly for mattress retainer during articulation.

BACKGROUND

[0003] Modem bedroom furniture is typically modular with features that are adjustable for comfort. Articulating bed frames provide various mattress supports which articulate relative to one another to provide angled support for the upper body, seat, thighs and lower legs. In the articulated position, a mattress which is firm enough for comfort may not maintain contact with the various articulating supports. It is therefore desirable to have a retainer system to maintain engagement of the mattress with the supports.

SUMMARY

[0004] Disclosed herein are implementations of bed systems and retainer systems therefor.

[0005] The implementations disclosed herein provide a mattress retainer system having a tension assembly received in a sleeve on an underside of a mattress. In an implementation, the tension assembly incorporates an insertion flange and a strap is threaded through alternating slots in the insertion flange. The strap and insertion flange are received in the sleeve with the insertion flange providing resilient rigidity to thread the flexible strap into the sleeve. A magnetic engagement element mounted centered on the tension assembly and one or more magnets is embedded or attached to a support of an articulating system for a bed.

[0006] In an implementation, a retainer system is configured to retain a mattress to an adjustment mechanism configured to move the mattress between a flat configuration and one or more inclined configurations. The retainer system includes a strap and an elongated stiffener. The strap is configured to extend through a sleeve on an underside of the mattress and having first and second ends that are releasably coupled to the adjustment mechanism proximate each left and right sides thereof. The elongated stiffener is coupled to the strap and configured to, when pushed through the sleeve, insert the strap through the sleeve.

[0007] The retainer system may further include a magnetic component that is configured to be attracted by one or more magnets at a corresponding location of the adjustment mechanism. The elongated stiffener may have a substantially constant width over a majority of a length thereof, and the strap may have a width that is less than the substantially constant width of the elongated stiffener. Over a majority of a length of the elongated stiffener, the strap may be positioned between the mattress and the elongated stiffener when the retainer system is positioned in the sleeve. The elongated stiffener may include a plurality of slots through which the strap extends in an alternating manner.

[0008] In an implementation, a bed system includes a mattress, an adjustment mechanism, and a retainer system. The mattress includes a sleeve on an underside thereof. The adjustment mechanism configured to move the mattress between a flat configuration and one or more inclined configurations. The retainer system extends through the sleeve and is coupled to the adjustment mechanism on each side of the sleeve to mechanically the mattress to the adjustment mechanism. The retainer system includes a strap and an elongated stiffener coupled to the strap. The strap may be positioned between the mattress and the elongated stiffener over a majority of a length of the elongated stiffener, the strap may be positioned between the mattress and the elongated stiffener over a majority of a length of the elongated stiffener, the elongated stiffener may include a plurality of slots through which the strap extends in an alternating manner, and/or the retainer system may be magnetically coupled to the adjustment mechanism.

[0009] In an implementation, a method is provided for retaining a mattress to an adjustable mechanism that moves the mattress between a flat configuration and one or more inclined configurations. The method includes: providing a mattress having an underside with a sleeve extending across a majority of a width thereof, providing a retainer system having a strap and an elongated stiffener, providing an adjustment mechanism, inserting the retainer system in the sleeve by pushing the elongated stiffener through the sleeve to pull the strap through the sleeve, positioning the mattress on the adjustment mechanism, and coupling first and second ends of the strap to left and right sides of the adjustment mechanism after inserting the retainer system in the sleeve.

[0010] The retainer system may include a magnetic component attached to the elongated stiffener, and the adjustment mechanism may include a magnet. The method may further include positioning the mattress on the adjustment mechanism for the magnetic component of the of the retaining assembly to magnetically couple to the magnet of the adjustment mechanism, and may further include performing the coupling of the first and second ends of the strap to the left and right sides of the adjustment mechanism while the magnetic component of the retaining assembly is coupled to the magnet of the adjustment mechanism.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The disclosure is best understood from the following detailed description when read in conjunction with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not to-scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity.

[0012] FIG. l is a pictorial depiction of an example adjustment mechanism for an adjustable bed system with an implementation of a mattress retainer system;

[0013] FIG. 2 is a detailed pictorial depiction of the implementation of the mattress retainer system;

[0014] FIG. 3 is a pictorial depiction of a mattress with the mattress retainer system inserted in an engagement sleeve of the mattress;

[0015] FIG. 4 is a detailed pictorial depiction of the mattress and retainer system;

[0016] FIG. 5 is a detailed pictorial depiction of a clip of a first end of the mattress retainer system;

[0017] FIG. 6 is a top pictorial depiction of the magnetic component of the mattress retainer system;

[0018] FIG. 7 is a bottom pictorial depiction of the magnetic component;

[0019] FIG. 8 is a detailed pictorial depiction of an example buckle for a second end of the mattress retainer system;

[0020] FIG. 9 is an exploded depiction of the first end of the mattress retainer system and a coupling feature;

[0021] FIG. 10 is an exploded depiction of the second end of the mattress retainer system; [0022] FIG. 11 is an exploded depiction of the magnets the adjustment mechanism and the magnetic component of the mattress retainer system; and,

[0023] FIGS. 12A-D are depictions of a magnet assembly for the magnets of FIG. 11.

DETAILED DESCRIPTION

[0024] Implementations shown in the drawings and described herein provide a mattress retainer system with a tension assembly received in a sleeve on an underside of a mattress. The tension assembly has an insertion flange and a strap threaded through alternating slots in the insertion flange. The strap and insertion flange are received in the sleeve with the insertion flange providing sufficient rigidity to thread the flexible strap into the sleeve. A magnetic engagement element is mounted centered on the tension assembly. One or more magnets embedded or attached to a support of an articulating system for a bed magnetically engages the magnetic engagement element to center the tension assembly with respect to the bed. A clip element on a first end of the strap is removably attached to a mating stub on a support of the articulating system of the bed and a tension element mounted on the support engages a second end of the strap. These and various other embodiments of a bed system and retainer system therefor are discussed in further detail below.

[0025] Referring to the drawings, an adjustable bed system generally includes an adjustment mechanism 10, one or more retainer systems 20, and a mattress 30 that is retained (e.g., coupled) to the adjustment mechanism 10 with the one or more retainer systems 20. The retainer systems 20 may, for example, be configured to retain portions of the mattress 30 near to the adjustment mechanism 10 when the mattress 30 might otherwise resist bending and, thereby, move away from the adjustment mechanism 10. The adjustable bed system may also be referred to as a bed system. The adjustment mechanism 10 may also be referred to as an articulating assembly. The retainer system 20 may also be referred to as a tension assembly, retainer assembly, or mattress retainer system. Various combined components of the adjustment mechanism 10, the retainer system 20, and/or the mattress 30 may also be considered to form a mattress retainer system. [0026] FIG. 1 shows the adjustment mechanism 10 for the adjustable bed system 2. The adjustment mechanism 10 is configured to support the mattress 30 and articulate (e.g., move) the mattress 30 between a flat configuration and one or more inclined configurations in which different portions of the mattress 30 are raised relative to the flat configuration. The adjustment mechanism 10 includes an upper body support 12, a seat support 14, a thigh support 16 and a lower leg support 18. The supports are pivotable relative to (e.g., are rotatably engaged) to one another for articulation of the mattress 30 as is known in the art, for example, being movable with an electric motor and suitable mechanisms (e.g., linkages and/or hinges). Each of the supports 12, 14, 16, 18 may be configured as or otherwise include one or more planar members (e.g., a rigid panel) and/or a frame that individually or cooperatively support a corresponding portion of the mattress 30 thereabove (e.g., corresponding upper body, seat, thigh, and lower leg portions thereof).

[0027] As referenced above, each of the retainer systems 20 is configured to retain (e.g., couple) the mattress 30 to the adjustment mechanism 10 to prevent, limit, or otherwise hinder relative movement therebetween. The retainer systems 20 may retain the mattress 30 to the adjustment mechanism 10 mechanically or a combination of mechanically and magnetically. [0028] A first one of the retainer systems 20 (e.g., a first retainer system 20a) is engaged on the seat support 14, and a second one of the retainer systems 20 (e.g., a second retainer system 20b) is engaged on the lower leg support 18 proximate a foot end of the adjustable bed system. The first and the second retainer systems 20a, 20b retain corresponding seat and lower leg portions of the mattress 30 to the seat support 14 and the lower leg support 18, respectively to prevent or otherwise limit relative movement therebetween, such as lifting of the mattress 30 off the supports. While two of the retainer systems 20 are shown as an example, one of the retainer systems 20 may be sufficient in certain bed configurations and additional ones of the retainer systems 20 may be desired in other configurations.

[0029] Each of the retainer systems 20a, 20b, shown in detail in FIG. 2, includes an elongated stiffener 22 and a strap 26 that is coupled to (e.g., received by or otherwise engages) the elongated stiffener 22. For example, the elongated stiffener 22 includes slots 24 through which the strap 26 is threaded. The elongated stiffener 22 may, for example, be a substantially planar member having a substantially constant width over a length thereof, which is greater than a width of the strap 26. For example, the width of the elongated stiffener 22 may be greater than the width of the strap 26 by 25%, 50%, 100%, 200%, or more.

[0030] The slots 24 may be positioned proximate each of two ends of the elongated stiffener 22 and may further include two of the slots 24 at one or more intermediate locations along the elongated stiffener 22 (e.g., at a center location thereof, as shown). The strap 26 is inserted through the slots 24 in an alternating manner, so as to alternate the side of the elongated stiffener 22 on which the strap 26 is positioned. The slots 24 are positioned such that over a majority of the length of the elongated stiffener 22 (e.g., 60%, 70%, 80%, or more), the strap 26 is positioned on a first side of the elongated stiffener 22, which may correspond to a mattress-side of the elongated stiffener 22. As a result, the strap 26 is positioned between the elongated stiffener 22 and the mattress 30 over the majority of the length of the elongated stiffener 22).

[0031] The elongated stiffener 22 is configured to facilitate insertion of the retainer system 20, including both the elongated stiffener 22 and the strap 26 thereof, through a sleeve 32 in the underside 34 of the mattress 30, as discussed in further detail below. The retainer system 20 (e.g., the elongated stiffener 22) may also be configured to magnetically locate and/or couple the mattress 30 to the adjustment mechanism 10. For example, the retainer system 20 may include a magnetic component 28 that is coupled to the elongated stiffener 22, such as being mounted centered on the elongated stiffener 22 along the length thereof. Two of the slots 24 may be positioned between ends of the magnetic component 28 and/or the strap 26 may extend between the elongated stiffener 22 and the magnetic component 28.

[0032] As seen in FIGS. 3 and 4, the mattress 30 includes at least one sleeve 32 proximate a foot end on the underside 34 of the mattress 30 (e.g., in the lower leg portion of the mattress 30). The sleeve 32 may, for example, be formed by or otherwise include a flexible cloth that is sewn, clipped, adhered, or otherwise coupled to the underside 34 of the mattress 30. The sleeve 32 may extend from one side of the mattress 30 to the other. For example, the sleeve 32 may extend laterally substantially continuously over a majority of a width (i.e., left-to-right) of the mattress 30 (e.g., greater than 50%, 60%, 70%, 80% or more of the width of the mattress 30). The cloth forming the sleeve 32 may be substantially continuously coupled (e.g., sewn) to the underside 34 of the mattress 30 over a substantial majority of a length thereof (e.g., greater than 90%, such as the entire length thereof).

[0033] While one of the sleeves 32 is shown as an example in FIGS. 3 and 4 (e.g., corresponding to the lower leg support 18), the mattress 30 may include a second sleeve 32, for example, approximately the midpoint for the example arrangement (e.g., as shown in FIG. 1, and corresponding to the seat support 14). [0034] As referenced above, the elongated stiffener 22 is configured to facilitate insertion of the strap 26 through the sleeve 32. The elongated stiffener 22 is sufficiently stiff (e.g., rigid) that when inserted and pushed into and through the sleeve 32, the elongated stiffener 22 does not buckle and inserts (e.g., pulls) the strap 26 therewith through the sleeve 32. The elongated stiffener 22 may, for example, be formed from and plastic material (e.g., being stamped, machined, molded, and/or otherwise formed to form the overall shape and slots 24 therein). [0035] Each of the retainer systems 20 is configured to mechanically couple to left and right sides the adjustment mechanism 10 on each side of the sleeve 32, for example, adjacent left and right sides of the mattress 30. The retainer systems 20 thereby mechanically the mattress 30 to the adjustment mechanism 10.

[0036] The retainer systems 20a, 20b may each include a releasable clip 36 on a first end 38 of the strap 26 as shown in FIGS. 5 and 9. The releasable clip 36 is fixedly coupled to the first end 38 of the strap 26 and configured to releasably engage a corresponding coupling feature 40 (e.g., a button or hook) mounted on one side to the corresponding support of the adjustment mechanism 10 (e.g. the seat support 14 for the retainer system 20a and the lower leg support 18 for retainer system 20b).

[0037] A second end 42 of the strap 26 is configured to releasably couple on the other side to the corresponding support of the adjustment mechanism 10. In the example seen in FIGS. 8 and 10, a second end 42 (e.g., a loose end without a clip or similar coupling element) of the strap 26 is constrained in an adjustable buckle 44, or other fitting such as a lever lock or similar strap engagement device, that is coupled to the adjustment mechanism 10. The buckle 44 allows a total length of the retainer system 20 to be shortened. For example, the second end 42 of the strap can be threaded through, tightened, and then locked by the buckle 44. The buckle 44 may also be considered a coupling feature. Alternatively, the strap 26 may include a first strap segment (e.g., including the first end 38 and the releasable clip 36, as described previously), and a second strap segment that includes the buckle 44 (i.e., that receives and locks the second end of the first strap segment, as described previously) and another releasable clip that is configured to couple to a corresponding coupling feature (e.g., as described previously for the clip 36 and the coupling feature 40).

[0038] In some embodiments, one more of the retainer systems 20 may be located by and/or couple the mattress 30 to the adjustment mechanism 10 magnetically. For example, each of the retainer systems 20a, 20b may be centered on the underside 34 of the mattress 30 (e.g., between left and right sides thereof) and/or partially constrained by one or more magnets 46 of the adjustment mechanism 10 (seen in FIG. 11). The retainer system 20 includes the magnetic component 28 (e.g., a ferromagnetic component), while the one or more magnets 46 of the adjustment mechanism 10 attract the magnetic component 28 of the retainer system 20. As seen in FIGS. 6 and 7, the magnetic component 28 may, for example, be a steel plate attached to the elongated stiffener 22 with rivets 48, comparable fasteners (e.g., screws), or other suitable manner (e.g., adhesives). In the exemplary implementation seen in FIG. 11, two of the magnets 46 affixed to each of the associated supports (seat support 14 and lower leg support 18) are employed.

[0039] Each of the magnets 46 is coupled to one of the supports (e.g., the seat support 14 and the lower leg support 18). As seen in FIGS. 12A-D, each of the magnets 46 is provided in a magnet assembly 45 that further includes an insert 49. Each of the magnets 46 is coupled to the insert 49, which is in turn engaged to the associated support with the insert 49 being received in a receptacle 50 (FIG. 12B) as shown in FIG. 12C. The insert 49 may also be referred to as a capture plug. The receptacle 50 may also be referred to as a hole sleeve.

[0040] The insert 49 includes an upper flange portion 52 and a lower rod portion 54 terminating at an expanded head 56. The upper flange portion 52 is coupled to the magnet 46, for example, defining or otherwise forming a recess (e.g., a magnet cup) in which the magnet 46 is received. The magnet 46 is coupled to the upper flange portion 52, for example, with a threaded fastener (e.g., a screw, illustrated in short dashed lines, inserted through an aperture 64 of the magnet 46), or adhesive. The lower rod portion 54 extends downward from the upper flange portion 52 having a cross-sectional dimension (e.g., diameter) that is smaller than the upper flange portion 52. The lower rod portion 54 terminates at the expanded head 56, which forms a flange extending radially outward from the lower rod portion 54 and is configured to engage the receptacle 50 as described below.

[0041] The receptacle 50 includes resilient flaps 58 surrounding a bore 59. The resilient flaps 58 may, for example, extend downward from an upper flange 57. The resilient flaps 58 expand upon insertion of the lower rod portion 54 of the insert 48 into the bore 59 and resiliently contract upon passage of the expanded head 56 therethrough to engage and retain the expanded head 56 and, thereby, the insert 49 in the receptacle 50. [0042] The receptacle 50 may be received in a relief 60 (e.g., a recess) in the support (seat support 14 and lower leg support 18) as seen in FIG. 12D. The receptacle 50 may be secured with screws 62 or other appropriate fasteners to the support, for example, with the screws 62 extending through the upper flange 57. The relief 60 may be of sufficient depth to receive at least a portion of the upper flange portion 52 and/or the magnet 46 therein.

[0043] A method is provided for coupling the mattress 30 to the adjustment mechanism 10 with one or more retainer assemblies. In the method, the mattress 30, the adjustment mechanism 10, and the one or more retainer systems 20 are provided.

[0044] The retainer systems 20a, 20b are inserted in the sleeves 32 in the mattress 30. For example, the elongated stiffener 20a, 20b may be pushed into the sleeves 32 and, thereby, pull the straps through the sleeves 32. The mattress 30 is then positioned on the adjustment mechanism 10. After inserting the retainer systems 20a, 20b, the first and second ends of the straps 26 are coupled to left and right sides of the adjustment mechanism. For example, one side of the mattress 30 is then lifted and the clips 36 are engaged to the coupling features 40 releasbly locking the first ends 38 of the straps 26. The second side of the mattress is then lifted and the second end 42 of the straps 26 are inserted through the adjustable buckles 44 and tensioned. The buckles 44 are then operated to secure the straps 26. The retainer system 20, including the strap 26, thereby constrain the mattress 30 from separating from the supports of the adjustment mechanism 10 during articulation. The mattress 30 and the retainer systems 20 may, thereby, be considered mechanically coupled to the adjustment mechanism 10.

[0045] The method may further include securing the magnets 46 in the receptacles 50 in the associated supports of the adjustment mechanism 10 using the inserts 48. The magnets 46 attract the magnetic component 28 for approximate positioning of the mattress 30 relative to the adjustment mechanism 10. The positioning of the mattress 30 may, for example, include positioning the mattress 30 such that the magnets 46 attract (e.g., magnetically couple) to the magnetic component 28. The mattress 30 and the retainer systems 20 may, thereby, be considered magnetically coupled to the adjustment mechanism 10.

[0046] Having now described various embodiments in detail as required by the patent statutes, those skilled in the art will recognize modifications and substitutions to the specific embodiments disclosed herein. Such modifications are within the scope and intent of the present disclosure as defined in the following claims. The terms “upper” and “lower”, “upwardly”, “top”, and “bottom” as used herein are not limiting and specific to the depiction of the implementations shown in the drawings and may be replaced with alternative terms “first”, “second” or similar differentiations depending on the actual implementation.

[0047] While the disclosure has been described in connection with certain embodiments, it is to be understood that the disclosure is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.

Claims

CLAIMS What is claimed is: What is claimed is:

1. A bed system comprising: a retainer system configured to retain a mattress to an adjustment mechanism configured to move the mattress between a flat configuration and one or more inclined configurations, the retainer system including: a strap configured to extend through a sleeve on an underside of the mattress and having first and second ends that are releasably coupled to the adjustment mechanism proximate each left and right sides thereof; and an elongated stiffener coupled to the strap and configured to, when pushed through the sleeve, insert the strap through the sleeve.

2. The bed system according to Claim 1, wherein the elongated stiffener has a substantially constant width over a majority of a length thereof, and the strap has a width that is less than the substantially constant width of the elongated stiffener.

3. The bed system according to any of the preceding claims, wherein over a majority of a length of the length of the elongated stiffener, the strap is positioned between the mattress and the elongated stiffener.

4. The bed system according to any of the preceding claims, wherein the elongated stiffener includes a plurality of slots through which the strap extends in an alternating manner.

5. The bed system according to any of the preceding claims, wherein a first end of the strap includes a clip that is configured to releasably couple to a corresponding coupling feature of the adjustment mechanism.

6. The bed system according to Claim 5, wherein a second end of the strap is a configured to be inserted into a buckle to be retained thereby.

7. The bed system according to any of the preceding claims, wherein the retainer system further includes a magnetic component that is configured to be attracted by one or more magnets at a corresponding location of the adjustment mechanism.

8. The bed system according to Claim 7, wherein the magnetic component is a metal plate attached to the elongated stiffener.

9. The bed system according to any of Claims 6-8, wherein the metal plate is centered on the elongated stiffener along the width thereof.

10. The bed system according to any of Claims 7-9, wherein the strap extends between the elongated stiffener and the magnetic component.

11. The bed system according to any of the preceding claims, further comprising the mattress and the adjustment mechanism; wherein the mattress includes the sleeve on an underside of a lower leg portion thereof, the strap and the elongated stiffener are positioned in the sleeve, and the first and second ends are coupled to a support on the left and right sides of the adjustment mechanism.

12. The bed system according to Claim 11, wherein the sleeve extends a majority of the width of the mattress.

13. The bed system according to any of Claims 11-12, wherein the retainer system further includes a magnetic component; and wherein support of the adjustment mechanism includes a magnet that is magnetically coupled to the magnetic component of the retainer system.

14. The bed system according to Claim 13, wherein the adjustment mechanism includes a magnet assembly and a receptacle by which the magnet assembly is coupled to the adjustment mechanism; wherein the magnet assembly includes an upper flange to which the magnet is coupled and a lower rod extending downward from the upper flange and terminating at an expanded head; and wherein the receptacle is coupled to the support and includes resilient flaps that define a bore through which the lower rod is inserted, such that the resilient flaps engage the expanded head of the lower rod to retain the magnet assembly to the receptacle.

15. The bed system according to any of Claims 11-14, wherein the support defines a recess, and the magnet is positioned at least partially in the recess.

16. The bed system according to any of Claims 11-15, further comprising another retainer system; wherein the retainer system couples a lower leg portion of the mattress to a lower leg support of the adjustment mechanism; and wherein a seat portion of the mattress includes another sleeve through which is inserted the other retainer system, and the other retainer system couples the seat portion of the mattress to a seat support of the adjustment mechanism.