Classifications

• • A—HUMAN NECESSITIES
  • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
  • A47C—CHAIRS; SOFAS; BEDS
  • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
  • A47C27/08—Fluid mattresses or cushions
  • A47C27/081—Fluid mattresses or cushions of pneumatic type
  • A47C27/082—Fluid mattresses or cushions of pneumatic type with non-manual inflation, e.g. with electric pumps
• • A—HUMAN NECESSITIES
  • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
  • A47C—CHAIRS; SOFAS; BEDS
  • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
  • A47C27/08—Fluid mattresses or cushions
  • A47C27/081—Fluid mattresses or cushions of pneumatic type
  • A47C27/083—Fluid mattresses or cushions of pneumatic type with pressure control, e.g. with pressure sensors
• • A—HUMAN NECESSITIES
  • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
  • A47C—CHAIRS; SOFAS; BEDS
  • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
  • A47C27/08—Fluid mattresses or cushions
  • A47C27/10—Fluid mattresses or cushions with two or more independently-fillable chambers

Definitions

• This invention relates to fluid body support systems, and, more particularly, to fluid bed sleeping systems intended for home use and for some medical applications where increased comfort is of benefit to the patient.
• ischemic pressure Fifteen inches of water (28 mmHg) is normally considered to be the ischemic threshold. Those parts of the body which are subjected to pressures above ⁇ the ischemic threshold cause disco fort and hence, cause the person to shift his body to eliminate the distress and remove the excessive pressure from those prominences.
• the lack of postural support from an improper mattress causes distortion of the spine.
• Distortion of the spine can occur within or beyond the normal physiological range of motion of the spine depending on the structural condition of the spine.
• ligaments are stretched and joint integrity is compromised.
• Nerve receptors within the ligaments and joints detect distortion and relay it to the brain where it is ' received on a conscious or subconscious level.
• Action is taken on a conscious or subconscious level to relieve the distortion by movement of the body.
• Spinal alignment can only be obtained when the natural curves of the body are maintained whether in the supine or side lying position.
• Such an air bed is characterized by multiple supportive zones maintained with air at normalized pressure so that uniform support is provided to all portions of the body at subischemic pressures while maintaining spinal alignment.
• Still another objective of this invention has been to provide an improved pump and control system contained within a unitary housing for maintaining an air bed at normalized pressures when a. person is resting atop the mattress and which is relatively inexpensive and reliable.
• a pump and airflow control system contained within a unitary housing for supplying air to a fluid mattress having a plurality of rows and columns of air pockets or cells.
• the rows and columns of air pockets or cells of the mattress are divided into zones, preferably five, by sealing completely between longitudinal zones.
• one preferred form of the mattress utilizes 15 rows of cells, each row having 7 cells of equal volume.
• the first two rows of cells provide head support and are preferably inflated to approximately 4 inches of water.
• the third, fourth and fifth rows form a second section for the support of the shoulder of a person reclining atop the mattress.
• the shoulder section is inflated to approximately 6 inches of water.
• the sixth row forms a separate zone for the waist support of a person reclining atop the mattress.
• This waist section is inflated to approximately 11 inches of water.
• the fourth zone is formed by the seventh, eighth, ninth and tenth rows which support • the hips at a pressure of approximately 8 inches of water.
• the remaining last five rows support the legs and feet of a person reclining atop the mattress and are inflated to a pressure of approximately 4 inches of water.
• the five zones allow for spinal alignment by maintaining the normal curves of the body, whether in the supine or side-lying positions.
• a single reciprocating diaphragm pump is utilized to inflate all five zones.
• This pump as well as the airflow control system for supplying air to all five zones, is contained within a unitary housing. Pressure from the pump is caused to flow through four pressure regulators, one of which supplies air pressure to the head and foot sections of the mattress which are maintained at the same pressure. The other three pressure regulators supply the air pressure to the shoulder, waist and hip sections. The flow from all four pressure regulators passes through surge check valves located in the flow path between each pressure regulator and the mattress section which it supplies. The pressure regulators are operative to maintain the desired pressure in their respective zones either by supplying air to the zone or by connecting the mattress zone to atmosphere so as to dump air from that zone of the mattress. The pressure regulators and surge check valves of each zone are connected to the mattress by hoses which extend from the housing to the zones.
• Figure 1 • is a diagrammatic illustration of an air bed incorporating the novel pump and airflow control system housing of this invention.
• Figure 2 is a perspective view of an air mattress and cover encasing that mattress utilized in the bed of Figure 1.
• Figure 3 is a perspective view of the air mattress only of Figure 2.
• Figures 3A and 3B are enlarged views of the respective encircled areas 3A and 3B of Figure 3.
• Figure 4 is a cross-sectional view taken on line 4-4 of Figure 2.
• Figure 5 is a fragmentary, exploded perspective view of one mold utilized in vacuum forming the sheets of the air mattress of Figure 3.
• Figure 6 is a partially diagrammatic illustration of the airflow control system utilized in the air bed of Figure 1.
• Figure 7 is a cross-sectional view of a pressure regulator and surge check valve used in the airflow control system of Figure 6.
• Figure 8 is a cross-sectional view similar to Figure 7 but illustrating the surge check valve in the closed position of the valve.
• Figure 9 is an exploded perspective view of the novel air pump and airflow control system housing of the invention.
• Figure 10 is a partially diagrammatic illustration of a modified airflow control system operable to achieve adjustable firmness of the air mattress.
• FIG 11 is a cross-sectional view of a modified pressure regulator utilized in the air control system of Figure 10.
• an air bed 10 incorporat ⁇ ing the novel airflow control system housing 90 of this invention.
• This air bed comprises an air supply pu p and airflow control system 15. contained within the housing 90 and operable to supply, air pressure to and exhaust air pressure from an air mattress 25.
• the air bed 10 includes a unique cover 30 encasing and surrounding the air mattress 25.
• the mattress 25 is formed from three separate individual sections 25a, 25b, 25c which, when placed end to end as illustrated in Figure 3, form a complete mattress. As illustrated in Figure 3, each section comprises five rows 26 of cells 35, each row 26 of which in the illustrated embodiment is seven cells wide.
• Each mattress section 25a, 25b, 25c is formed from two sheets of 50 mil (0.050 inches) vinyl. Each sheet is heated and vacuum formed to provide a series of recesses or pockets 28 ( Figures 3A, 3B) . The two sheets overlie each other with the pockets facing each other. The sheets are sealed around the edges 29 and between adjoining pockets 28 except at the intersecting corners of the pockets.
• the pockets are square in cross section with the seals 29 being formed between adjacent pockets in order to form the cells 35. As best shown in Figures
• the seals 29 between adjoining cells 35 are not completely formed within any zone. Rather, a channel or groove 27 of between 1/4 inch to 1/2 inch in width is provided at the corners between adjacent cells. These grooves are formed in the manner described hereinbelow with vertical walls between adjacent cells.
• the gap or width of the grooves 27 between adjacent cells within any zone is sufficient to permit a uniform distribution of air among all the cells of a zone and permits a shifting of air from cell to cell as a sleeper shifts his position on the mattress.
• the vertical walls of the grooves 27 prevent collapse of the grooves as a sleeper shifts on the mattress.
• Each pocket 28 is approximately four inches deep so that each cell 35 is about eight inches in height.
• Each square is about five inches across opposed sides.
• the square cells, when inflated, have semi-spherical ends which may be drawn with a minimum thinning of the wall thickness.
• Zone 1 formed by two rows a and b and indicated at 41, is a head zone which extends from the upper end of the bed to about the neck area of a person reclining atop the bed.
• Zone 2 formed by rows c-e and indicated at 42, is a shoulder zone which underlies the shoulder area from the waist to the neck of the person reclining atop the sleeper.
• Zone 3 formed by a single row f and indicated at 43, is a waist zone which underlies the waist of a person reclining atop the mattress.
• Zone 4 formed by rows g, h, i and j and indicated at 44 is a hip zone which receives the hips and pelvic area of a person reclining atop the mattress.
• Zone 5 formed by rows k-o and indicated at 45, is a foot zone which receives the legs and feet of the person reclining atop the sleeper.
• Zone 4 has an air connection or hose, indicated at 50, which connects the zone to the air supply pump and housing 90.
• This source of pressurized air supplies air to each of the zones to maintain those zones at predetermined pressure levels.
• a pressure regulator R 1 -R ( Figure 6) operatively associated with the zone through the connecting hose 50 opens to permit air to bleed out of the zone to atmosphere.
• the pressure regulator associated with the zone opens to connect the air pump to the hose 50 associated with that zone so as to introduce air into the zone.
• Each zone, the respective rows and cells comprising it, and the preferred air pressure in it, are set forth in the chart below.
• Zones 1 and 5 By combining Zones 1 and 5, the head and foot zones, a minimum of four different pressures can be employed in the five zones. To that end, the head and foot zones are connected to a common pressure regulator R., .
• the mattress is encased within a cover 30 which includes a top pad 65 and a denim covering material 66.
• the top pad comprises two plies 68, 69 of woven, eight-way stretch fabric between which there is sandwiched a non-woven, crimped batting 70.
• the batting is preferably formed of crimped polyester fibers and in its uncompressed condition, is approximately one-inch thick.
• the woven, eight-way stretch fabric allows shoulders or any other body prominences to penetrate into the mattress and not be restrained by the material so as to have a minimal effect on maintaining ischemic pressures against the body prominences.
• the batting 70 functions to permit the free flow of air between the body and the top of the vinyl mattress.
• the batting is encased between the two plies of eight-way stretch fabric 68, 69, which is in turn sewn together at the edge as indicated at 71. This edge is also sewn to the denim covering material 66 which surrounds the sides and bottom of the mattress.
• the method of forming the mattress 25 is illustrated in Figure 5.
• the mattress is made in three separate sections of five rows each.
• the sections are not identical, though, because the seals between adjacent zones within the mattress sections differ.
• the middle section 25b has one transverse seal 46 extending the length of the row and located between one endmost row and the next adjacent row, i.e., between rows f and g of the overall mattress.
• the third mattress section 25c has a single transverse seal 46 extending the length of the row between rows b and c.
• all three sections may be manufactured utilizing a single die or forming tool 75.
• This tool 75 is illustrated in Figure 5. It has a plurality of pockets 76 for forming the pockets 28 in the mattress. In the preferred embodiment of the tool, it has 35 pockets 76 arranged in 5 rows of 7 pockets each.
• the bottom wall 77 of the tool is foraminous as is conventional in vacuum forming machinery such that a vacuum may be drawn through the bottom wall.
• the side walls 78 of each pocket 76 terminate in an upper flat or planar section 79 of the die. At the intersection of the pockets 76, this upper planar section 79 is recessed as indicated at 80 to form a recessed intersection at every intersection except at the outer sides of the die.
• inserts are placed in these recesses 80. These inserts 81, 82 take one of two forms.
• the passages 81a in the insert 81 form parallel airflow passages in the formed half of the mattress. This insert is used at a site where a continuous seal 46 is located.
• the resulting formed half of the mattress section has intersecting passageways formed therein so as to form a four-way airflow passage between all four pockets formed at this intersection.
• the sheet of vinyl is laid across the tool and is heated by conventional apparatus until it becomes formable.
• the vacuum is then applied to stretch the material and draw it into the pockets 76 of the forming tool 75.
• the vinyl is drawn into the rectangular-shaped grooves or channels 81a of the insert 81 or the rectangular- shaped channels 82a, 82b of the insert 82.
• the airflow passages 27 ( Figures 3A and 3B) between adjacent pockets are formed.
• the two sheets are placed one atop the other with the pockets opposed.
• An electronic sealing die is then applied to the juxtapositioned sheets so as to form seals 29, 46 between the pockets approximately 1/4 inch in width.
• the seals 29 are not formed at the location of the channels 81a, 82a and 82b between adjacent cells or pockets so that those channels remain open to form grooves or flow paths 27 for air between the adjacent pockets.
• the mattress is inflated approximately to the pressure referred to in the chart hereinabove.
• the person reclining atop the mattress positions their waist to overlie the sixth row f of cells. This row, which occupies the waist zone, is inflated to a pressure greater than that of the other zones. Thereby, the waist of a person reclining atop the mattress is retained in a relatively elevated position for good spinal alignment, as well as total body alignment, of the person reclining atop the mattress from head to toe.
• spinal alignment it is meant that alignment of the spine which the spine maintains when that same person is standing in a relaxed attitude with their feet approximately 12 inches apart.
• the mattress of this invention is operative to maintain that spinal alignment while the person reclines either on their side or on their back atop of the mattress.
• the normalized pressures in the zones maintain those zones in a condition so as to achieve this spinal alignment.
• the mattress is operative, via the air pump and flow control 15, to readjust the pressure so as to maintain the pressure set forth hereinabove within those zones.
• the air from the cells shifts to bleed air from the newly occupied cells into the cells previously occupied.
• the air may also pass to or from the regulator valves R. to R..
• both the size and shape of the grooves 27 between adjoining cells and the flow rate through the regulator valves R 1 to R. are critical to the performance of the bed.
• Air Pump and Airflow Control System The air pressure within each of the cells is controlled by the air pump and airflow control system 15 contained within the housing 90. As a consequence of the construction of the pump and flow control 15, there is only an electrical cord 91 and four air supply lines extending from the housing 90.
• the air pressure regulators R ⁇ ⁇ R 4 for controlling the pressure in each of the five zones of the mattress, as well as the pump for supplying pressurized air to the pressure regulators, and the surge check valves CV -CV are all contained within this housing 90. Additionally, this housing 90 contains the electric motor for driving the pump, as well as the solenoids and timers for controlling airflow from the pump to the mattress as described hereinbelow.
• This pump and control circuit is schematically illustrated in Figure 6 and is physically illustrated in Figure 9.
• the airflow control system for supplying air from the air supply pump to the mattress 25 via the air supply lines or conduits 50a, 50b, 50c, 50d and 50e is diagrammatically illustrated in Figure 6.
• this system includes a constantly driven electric motor 97 for driving a reciprocating piston pump 100.
• This pump is operative to supply air to the zones 41-45 of the mattress via the air lines 50a-50e.
• a pressure regulator R- R 4 for maintaining the pressures set forth in the chart hereinabove in each of the zones.
• the pressure regulator R- supplies air at the desired and preset pressure to both the foot and head zones 45, 41 as a consequence of the two air lines 50a, 50e to those zones being interconnected via a common line 101.
• each pressure regulator for supplying air at the preset pressure to the zones and the air lines to that zone, there is a surge check valve CV1.-CV4..
• the function of these check valves is to prevent air from being bled off of any zone in the event that an excessively high pressure is applied to that zone.
• Such excessively high pressures are applied, for example, whenever a person sits on the edge of the bed, or sits up in bed, as for example, to watch TV on the bed, or even if two persons applied their weight to the same zone.
• the air in any one zone could be bled off so as to bottom the mattress in that zone.
• the connection and the construction of the surge check valves is such that those valves close and prevent any bleeding of air from the zone in the event that the air pressure in a particular zone exceeds some multiple, as for example, 1.7, of the preset pressure at which the regulator R- j -R * is set to bleed pressure from that zone.
• the airflow control system 15 contained within the housing 90 includes two solenoid operated valves, SOL-1 and SOL-2, operable between the pump and the pressure regulators R -R . Additionally, the system 15 includes a timer T operable to control electrical actuation of the solenoid SOL-2.
• the first solenoid, SOL-1 functions to prevent the flow of air from the zones 41-45 of the mattress 25 whenever there is a loss of electrical power to- the system.
• the second solenoid SOL-2 cooperates with the timer and with the pressure regulators to periodically and regularly supply a high pressure pulse of air or boost to the shoulder and hip zones of the mattress so as to prevent a person reclining atop the bed from slowly sinking into the mattress below the normalized position over a long period of time, as for example, over the course of a complete night's sleep. Sometimes it is found that the sleeper sinks further into the bed than the normalized position.
• the purpose of the boost system is to lift the sleeper back to the normalized position.
• the airflow control system of Figure 6 periodically operates to inject a pulse of air into the shoulder zone 42 and the hip zone 44 of the mattress.
• This pressure pulse which may be on for a period of six seconds, followed by sixty seconds off, is not so great when applied to the volume of the full zones as to increase the measured pressures in the zones to a level such that a person reclining upon the mattress feels the pressure increase, but it is sufficient to return a person to the normalized height of the mattress after sinking below that height.
• Each is a diaphragm-type pressure regulator operative to maintain relatively low air pressures in the air mattress within narrow parameters as air is bled off of a zone or supplied to it.
• Each regulator R -R is a diaphragm-type pressure regulator operative to maintain relatively low air pressures in the air mattress within narrow parameters as air is bled off of a zone or supplied to it.
• Each regulator R -R is a diaphragm-type pressure regulator operative to maintain relatively low air pressures in the air mattress within narrow parameters as air is bled off of a zone or supplied to it.
• 1 4 comprises a housing 112 divided into upper and lower chambers 113, 114 (right side and left side, respectively, in Figures 7 and 8) by a flexible diaphragm 115.
• the diaphragm 115 is clamped at its outer periphery between two sections 112a, 112b of the housing which defines the upper and lower chambers of the regulator.
• the inner portion of the diaphragm 115 is secured to a rigid piston 116 movable internally of the regulator housing 112.
• the piston 116 is in turn connected to a piston rod 118 movable within a cylinder 119 contained internally of the upper chamber
• This cylinder has one outlet passage 120 open to the exterior of the housing and a second outlet passage 123 open to the interior of the upper chamber 113.
• the piston rod 118 is stepped such that an enlarged diameter section 121 of the piston rod is movable over the passage 120 to either block it in the position illustrated in Figure 7 or unblock it if the piston 116 is moved into the lower chamber 114 from the position illustrated in Figure 7.
• the passage 120 connects a pump air line inlet 122 of the pressure regulator to atmosphere.
• the second passage 123 through the cylinder connects the pressure regulator inlet 122 from the pump to the upper chamber 113 of the regulator.
• the upper chamber 113 of the pressure regulator has an outlet port 124 connected via a port 125 to the appropriate one of the surge check valves- CV.-CV 4 .
• the lower chamber 114 of the pressure regulator contains a compression spring 117 which extends between an adjustable screw 126 mounted in a threaded bore 127 of the regulator and the piston 116.
• the screw 126 may be threaded into and out of the housing to control the force with which the piston li6 is biased against the end 128 of the cylinder 119. Adjustment of this screw, and thus of the spring pressure applied to the piston 116, determines the force required in the chamber 113, and thus the air pressure in the zone of the mattress to which the regulator is connected to move the piston 116.
• a pressure in chamber 113 which exerts less force on piston 116 than the force of the spring 117, causes the enlarged section 121 of piston 118 to close off exhaust port 120. Pressure through air inlet 122 then flows around piston 118 and exhausts through the outlet port 124 to the surge check valve CV -CV and on to the mattress zone.
• a pressure in chamber 113 which exerts more force on piston 116 than the force of the spring 117 causes the enlarged section 121 of piston 118 to open exhaust port 120 and port 124 to be sealed off by the lower enlarged section of piston 118.
• Pressure through air inlet 122 then flows around piston 118 and exhausts through exhaust port 120 while pressure in the mattress zone is effectively sealed off by the closed outlet port at 124.
• the pressure regulators of these two zones are provided with a port 131 which connects the lower chamber 114 of the pressure regulators (Rani and R ) to the solenoid valve SOL-2 via an air supply line 132.
• the solenoid valve SOL-2 enables the line 132 to, whenever the solenoid 129 of the valve SOL-2 is energized, connect the lower chamber 114 of the regulator to the pump supply line 133 via a surge chamber 162.
• the solenoid 129 of the valve SOL-2 When the solenoid 129 of the valve SOL-2 is energized, high pressure air at pump pressure is connected to the lower chamber 114 of the pressure regulator which, with the assistance of the spring 117, will overcome the pressure in chamber 113.
• this pressure is supplied to the lower chamber 114 via the solenoid valve SOL-2, it results in the piston 116 being moved to the position illustrated in Figure 7 wherein air pressure from the pump at pump pressure is supplied through the air passage 122 and the upper chamber 113 to the air passage 124 and the mattress.
• the solenoid 129 of the valve SOL-2 is controlled by a timer T.
• This timer is operative to cycle energization of the solenoid 129 of the valve SOL-2 through an on cycle of from 1-15 seconds and an off cycle of from 30-180 seconds.
• the timer cycles the solenoid 129 through an on or energized cycle of 6 seconds and an off or deenergized cycle of 60 seconds.
• surge check valves CV ⁇ -CV Located in the airflow path between the outlet 124 of each pressure regulator and the air conduit 50 to each zone 41-45 of the mattress, there is one of the surge check valves CV ⁇ -CV..
• These surge check valves function to close and prevent the egress of air from any zone of the mattress whenever the pressure in a zone exceeds by a predetermined multiple, as for example, 1.7, the normalized pressure preestablished by the regulator to be maintained in that zone.
• a predetermined multiple as for example, 1.7
• Such high pressure within the zone would occur, for example, if the person stood on the mattress or kneeled on the mattress or sat on the mattress. If a person remained standing or sitting on the mattress for a long enough time and in the absence of the surge check valve CV.-CV., the mattress would eventually flatten or bottom out in that zone.
• the surge check valves CV..-CV. in response to that high pressure, close and prevent the egress of air from any zone so long as the pressure in the zone exceeds by a preset multiple the preset or predetermined normalized pressure established by the pressure regulator for that zone.
• the multiple is between 1.3 and 2.0 times the preset pressure, depending upon the applied zone.
• the surge check valves CV -CV are . all identical.
• a typical surge check valve CV--CV. is illustrated in Figures 7 and 8.
• This surge check valve comprises a housing 141 within which is a diaphragm 142 and a close valve 143.
• the diaphragm 142 is secured at its periphery to the housing and is secured at the center to a piston 142a of a piston rod 144.
• This piston rod 144 extends downwardly or to the left as viewed in Figures 7 and 8 from the piston 142a.
• the close valve 143 comprises a flat, round plate with segments machined out of the periphery of the plate to allow a controlled flow of air and a flat, circular butile rubber insert fixed to the face of the plate and able to seal on a circular abutment 145 of the housing 141.
• a compression spring 146 exerts an upward force on the close valve plate 143.
• a second compression spring 151 exerts a downward force on piston 142a which, via piston rod 144, normally exerts a greater downward force on plate 143.
• the close valve therefore normally remains open.
• a screw 152 is threaded into housing 141 at 153 and may be screwed in and out of the thread 153 to adjust the compression of spring 151.
• Each surge check valve CV.-CV. has three chambers. A lower chamber 147, a central (sensing) chamber 148 and an upper chamber 149. During normal pumping or idling conditions, pump pressure at port 125 is sensed in chamber 147, close valve 143 is open, pump pressure is sensed in chamber 148 and chamber 149 via channel 150, and the flow from and to the regulator valve passes via port 125 and the chambers 147 and 148 to the mattress zone via connector 154. A surge pressure resulting from a sudden, increased load- on the mattress is sensed in chamber
• the screw 152 is normally adjusted in the threaded portion 153 of housing 141 to permit spring
• Figure 8 illustrates the close valve 147 in the surge or closed condition.
• the pressure in chamber 148 ceases to be sufficient to compress spring 151, and the piston 142a moves upwards, causing piston rod 144 to contact close valve plate 143 and open the seat at 145.
• the close valve then reverts to its open position illustrated in Figure 7.
• the air pump and airflow control system housing 90 (Figure 1) is illustrated in an exploded perspective view in Figure 9.
• the pump housing 90 encases all of the structure illustrated diagrammati- cally in Figure 6 except for the air lines 50 and 101. Those are the air lines which extend between the pump housing 90 and the mattress 25.
• the housing 90 contains the reciprocating diaphragm pump
• the electric motor 97 for driving that pump. It also contains the four pressure regulators R -R. , as well as the surge check valves CV,-CV.
• the housing further contains or houses the two solenoid valves SOL-1, SOL-2, their respective solenoids and the timer T. These components are all interconnected in the manner illustrated in Figure 6 via chambers, air lines, airflow passages and ports contained within the housing.
• the housing 90 is divided by a wall 156 into a front section 90a and a rear section 90b.
• the front section 90a houses the pressure regulators R -R , as well as the surge check valves CV--CV. associated with those pressure regulators.
• the front section also houses the air lines which interconnect those surge check valves and pressure regulators in the manner illustrated in Figure 6.
• the rear section 90b of the housing 90 is divided into upper and lower sections 157, 158, each section of which is formed by a separate die casting. The two sections are divided or pealingly separated by a mounting plate 159, which
• the upper section 157 houses the pump 100, as well as the electric motor 97 for driving that pump, both of which are mounted upon the top of the mounting plate 159.
• the upper section 157 also houses the two solenoid valves SOL-1 and SOL-2 and the timer
• the lower section 158 of the housing 90 is divided into two chambers, a main pressure reservoir chamber 160 and a surge pressure chamber 162.
• the two chambers 160, 162 are sealingly separated by a wall 163 of the lower section .158 of the housing.
• a divider wall 164 which is upstanding from the bottom wall of the lower section 158 of the housing. This divider wall, though, has air passageways 165, 166 formed therein through which air may freely pass between opposite sides of the divider wall 164 without any pressure differential on opposite sides of the divider wall 164.
• an air filter and muffler 167 Mounted on the rear side of the lower ' section 158 of the housing 90 there is an air filter and muffler 167.
• This filter and muffler combination is operative to filter air before it enters the pump.
• the filter also acts as a muffler to quiet operation of the pump and control system. Air passing through the filter flows through a passage 168 formed in the lower section 158 of the housing upwardly through an air intake line 169 into the pump 100.
• the solenoid valve SOL-2 in turn, when open, supplies the air from the pump through a sealed fitting 183 into the surge pressure chamber 162 ( Figure 9) .
• the air at full pump pressure is supplied via lines 132 and 186 to the intake ports 131 of the pressure regulators R- and R., respectively.
• the air from the pump to the main pressure reservoir chamber 160 is supplied from that reservoir to an air line 187, which in turn distributes it via passages 188, 189, 190 and 191 internally of the pump housing to the air intake ports 122 ( Figure 6) of the pressure regulators R.-R., respectively.
• the pressure in the upper chamber 113 of the pressure regulator associated with that zone will be sufficient to overcome the spring pressure in the lower chamber 114 so as to force the piston 116 downwardly to a position wherein the inlet port 122 of the regulator is closed.
• This closing of the port 122 internally of the pressure regulator prevents air from entering the upper chamber from the inlet port 122 so that the pressure then obtaining in the zone with which that regulator is connected is maintained.
• the reciprocating diaphragm pump 100 will continue to operate with a resulting pressure buildup in the lines 188-191 to the pressure regulators.
• This buildup in pressure to the pressure regulators causes the piston rods 118 to move downwardly and uncover the exhaust ports 120 such that there is leakage airflow through the regulators via the exhaust ports 120 so long as the zones of the mattress are all at the preset normalized pressures of the regulator valves.
• the pressure buildup to the pressure regulators also causes the volume of air delivered by the pump to be reduced. The leakage airflow just balances the flow from the pump without causing any changes of pressure in the zones of the mattress to which the regulators supply air.
• the timer T While the mattress is inflating, and after full inflation of the mattress zone, the timer T will periodically be actuated, as for example, for 6 seconds of a 66-second total cycle.
• the timer When the timer is actuated or on, it causes the solenoid valve SOL-2 to open, thereby permitting air to flow at pump pressure from line 133, through the surge pressure chamber 162 and lines 132, 186, to the lower pressure chamber 114 of the pressure regulators R_ and R..
• This air from the pump flowing through the solenoid valve SOL-2 is at full pump pressure, a pressure sufficient- to overcome the springs 117 of the pressure regulators and thereby lift the diaphragm pistons 116 of these valves to a position whereat the regulator valve is open between the inlet port 122 and the outlet port 124 irrespective of the pressure in the mattress zone with which the regulator is associated. For so long as the solenoid valve SOL-2 remains open, this air at pump pressure will be supplied to the hip and shoulder zones of the mattress. When the solenoid closes, as determined by the timer T, high pressure air in the lower chamber of the regulator bleeds to atmosphere via the small leakage port 130 in the housing 112b.
• the airflow control system of this invention could operate to permit the bleeding off of air from the mattress via the pressure regulator, but there would be no pump pressure or airflow to replenish that air. Eventually, the mattress could lose substantially all of its air pressure.
• the airflow control system of this invention includes the solenoid valve SOL-1, which is normally closed when the solenoid is energized and opens when there is a loss of power and the solenoid is deenergized. As may be seen in Figure 6, the loss of electrical power from the source is operative to deenergize solenoid valve SOL-1 and thereby open the air reservoir 160 to atmospheric pressure via the airflow line 200.
• Figures 1-9 of the air bed the capability of regulating or adjusting the firmness of the mattress.
• Figures 10 and 11 is that this second embodiment air bed adds an adjustable pressure regulator S in line 133, and it utilizes four pneumatically adjusted pressure regulators R ⁇ ""R fi to replace the screw and spring adjusted pressure regulators R..-R.. It also utilizes three additional check valves C. , C 2 and C..
• the pressure regulator S. is identical to the pressure regulator R. or R- of Figure 7.
• the pressure regulators R c -R 0 are substantially identical to the pressure regulators 110 of Figure 7 except that a pneumatic pressure chamber 301 replaces the screw 126 and spring 130 adjustment of the regulators R.-R..
• a pressure adjustment chamber 301 located within a cap 302 secured on to the lower end of the pressure regulators R 5 -R g .
• the outer periphery of a diaphragm 303 is secured or sandwiched between this cap and the bottom surface of the regulator.
• the central portion of this diaphragm 303 is secured to a second piston 304 of a piston rod 305, which piston rod also is connected to the piston 116 of the diaphragm 115.
• the air system is arranged to sustain an adjusted low air pressure in chambers 301 of pressure regulators R ⁇ and R and to provide either an adjusted low air pressure in chambers 301 of pressure regulators R,. and R Q or a high air pressure in the
• Solenoid valve SOL-3 cooperates with the timer T to periodically and regularly supply a high pressure pulse of air or boost to the shoulder and hip zones of the mattress so as to prevent a person reclining and moving on the bed from slowly sinking into the mattress below the normalized position over a long period of time.
• solenoid SOL-3 When solenoid SOL-3 is energized, pump pressure in line 133 passes through the solenoid valve into line 134 and through the check valve C_. The flow is checked at C_ but passes through check valve
• Line 136 carries the reduced pressure air to pressure regulators R_ and R_, while line 135 carries the full pump pressure air to pressure regulators R ⁇ and RRON causing the main pressure in the shoulder and hip zones to be boosted while maintaining the normalized pressure in the foot, head and waist zones.
• D 8 reduces to the lower pressure determined by the setting of regulator S.. Any overpressure of the hip and shoulder zones which occurred while solenoid valve SOL-3 was energized is then allowed to flow from that zone back to the pressure regulator as a consequence of that overpressure until such time as the overpressure is reduced to the selected zone pressure.
• the cross-sectional areas 301a of the chambers 301 of the regulators _ r - R o differ between the regulators R_-R fate.
• the area 301a of the pressure regulator R_ is 4/11 of the area 301a of regulator R_
• the area 301a of the regulator R g is 8/11 of the area 301a of regulator R_
• the area 301a of regulator Rg is 6/11 of the area 301a of regulator R ? .
• the pressures in the hip and shoulder zones will be 4 inches of water.
• the pressures in the hip and shoulder zones will be 8 inches of water and 6 inches of water when the pressure in the waist zone is 11 inches of water.
• the regulated pressure on the output side of pressure regulator S will be increased until the pressure in the waist zone 43 is 13 inches of water. This increase of pressure in . the waist zone will simultaneously result in the pressure in the hip zone being increased to 8/11 x 13 or 9.45 inches of water.
• the pressure in the shoulder zone will be increased to 7.09 inches of water (6/11 x 13), and the pressure in the foot and head zones will be increased to 4.73 inches (4/11 x 13) of water.
• the relationship between zone pressures is maintained at a constant ratio, which ratio is established by the relative areas 301a of the pressure regulators R -Ro_, and spinal alignment of a person reclining atop the mattress is maintained, even though firmness of the mattress is increased.
• the pressure regulator S. would differ in the embodiment of Figures 10 and 11 from the pressure regulators R 1 and R- of Figure 7 in that the slotted adjustment screw 126 would be replaced by a more easily maneuverable adjusting knob (not shown) attached to the lower end of the screw. In all other respects, the regulator S. would be identical to the pressure regulators R.. and R,.

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• 1990
  • 1990-02-02 DE DE69009781T patent/DE69009781T2/de not_active Expired - Fee Related
  • 1990-02-02 EP EP90907581A patent/EP0512983B1/de not_active Expired - Lifetime
  • 1990-02-02 WO PCT/US1989/005326 patent/WO1991011617A1/en active IP Right Grant
  • 1990-02-02 JP JP50744790A patent/JPH04504372A/ja active Pending

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