Patent Application
20180116419
This invention relates to vibration, and more particularly to vibration isolators for use in air controllers of air beds.
People have traditionally used beds that come in many shapes, sizes, and styles. Such beds can range from extremely simple designs to rather complex designs that include a variety of features. For example, some beds can have one or more inflatable air chambers. Some of such beds can include an inflation system including a number of mechanical and electrical components. For example, some beds can include one or more pumps with one or more valves for inflating the air chambers.
Some embodiments of an air controller pump system can include one or more of the features and functions disclosed herein. Some embodiments can include vibration isolators for dampening vibration of a flow control assembly to achieve quieter operation. The vibration isolators can have certain features allowing for ease of assembly and suitable dampening of vibration due to actuation of solenoid valves. This can be desirable, for example, in an air bed system configured for automatically adjusting pressure while a user is asleep, where quiet operation can be particularly desirable.
In one aspect, an air bed system can include a mattress comprising a first inflatable air chamber and an air controller fluidly connected to the first inflatable air chamber of the mattress for inflating and deflating the first inflatable air chamber. The air controller can include an air pump, a flow control assembly fluidly connected between the air pump and the first inflatable air chamber, and first and second supporting structures. The flow control assembly is supported between the first and second supporting structure. A plurality of vibration isolators can include at least a first vibration isolator positioned between the first supporting structure and the flow control assembly and a second vibration isolator positioned between the second supporting structure and the flow control assembly.
Some of the implementations described herein may optionally include one or more of the following features. The air controller includes a housing having a housing top and a housing bottom, wherein the first supporting structure is part of the housing top and the second supporting structure is part of the housing bottom, and wherein the vibration isolators prevent contact between the flow control assembly and the housing top and bottom so as to reduce transmission of vibration from the flow control assembly to the housing. The flow control assembly comprises an air manifold and a plurality of valves connected to the air manifold. The air manifold includes a first vertical post having a first post top and a first post bottom and a second vertical post having a second post top and a second post bottom, wherein the first vibration isolator is positioned between the first post top and the first supporting structure, wherein the second vibration isolator is positioned between the first post bottom and the second supporting structure, wherein a third vibration isolator is positioned between the second post top and the first supporting structure, and wherein a fourth vibration isolator is positioned between the second post bottom and the second supporting structure. The plurality of valves are rigidly mounted to the air manifold along a length of the air manifold between the first vertical post and the second vertical post. The valves comprise solenoid valves rigidly mounted to the air manifold and the air pump comprises a positive displacement pump spaced from the air manifold and connected to the air manifold via a tube. The air controller includes a housing having a housing top and a housing bottom. The first supporting structure is part of the housing top and the second supporting structure is part of the housing bottom. A threaded fastener extends through holes defined by the housing bottom, the first vibration isolator, the flow control assembly, the second vibration isolator, and the housing top to connect the housing top to the housing bottom and to hold the flow control assembly in place within the housing. The vibration isolators each comprise a cylindrical portion extending substantially circumferentially about an axis and an annular portion extending substantially radially with respect to the axis and having an inner rim that defines a hole and an outer rim connected to an end of the cylindrical portion. The annular portion includes a first set of projections extending from a first side of the annular portion and a second set of projections extending from a second side of the annular portion, wherein the second side is positioned opposite the first side. The first set of projections each extend radially from the inner rim to the outer rim and the second set of projections are shaped differently than the first set of projections. The second set of projections are positioned proximate to and spaced from an inner surface of the cylindrical portion. The flow control assembly includes a first vertical post having a first post top and a first post bottom. The first vibration isolator is positioned between the first post top and the first supporting structure with the cylindrical portion wrapped around a circumferential portion of the first post top with the second set of projections abutting an end of the first post top, the first set of projections abutting the first supporting structure, and the inner rim abutting the first supporting structure. The second vibration isolator is positioned between the first post bottom and the second supporting structure with the cylindrical portion of the second vibration isolator wrapped around a circumferential portion of the first post bottom, with the second set of projections of the second supporting structure abutting an end of the first post bottom, the first set of projections of the second vibration isolator abutting a printed circuit board, and the inner rim of the second vibration isolator abutting the second supporting structure. The flow control assembly includes a post having a post end, wherein the first vibration isolator is positioned between the post end and the first supporting structure with the cylindrical portion wrapped around a circumferential portion of the post, with the second set of projections abutting the post end, with the first set of projections abutting the first supporting structure, and with the inner rim abutting the first supporting structure. The flow control assembly includes a post having a post end, wherein the first vibration isolator is positioned between the post end and the first supporting structure with the cylindrical portion wrapped around a circumferential portion of the post, with the annular portion abutting the post end and the first supporting structure. The vibrations isolators comprise an elastomer.
In another aspect, an air controller includes an air pump, a flow control assembly having an air manifold fluidly connected to the air pump and a plurality of valves mounted to the air manifold, and a housing including a housing top having a first supporting structure and a housing bottom having a second supporting structure. The flow control assembly is supported between the first and second supporting structures. A plurality of vibration isolators include at least a first vibration isolator positioned between the first supporting structure and the flow control assembly and a second vibration isolator positioned between the second supporting structure and the flow control assembly.
Some of the implementations described herein may optionally include one or more of the following features. The vibration isolators each comprise a cylindrical portion extending substantially circumferentially about an axis and an annular portion extending substantially radially with respect to the axis. The annular portion has an inner rim that defines a hole and an outer rim connected to an end of the cylindrical portion. The annular portion includes a first set of projections extending from a first side of the annular portion and a second set of projections extending from a second side of the annular portion. The second side is positioned opposite the first side.
In another aspect, an air controller includes an air pump, a flow control assembly having an air manifold fluidly connected to the air pump and a plurality of valves mounted to the air manifold, a housing, and means for mounting the flow control assembly in the housing and dampening transmission of vibration from the flow control assembly to the housing.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
An air controller, such as for inflatable air beds, can both inflate and deflate air chambers of a mattress. In applications in which the air bed is configured for inflation and/or deflation while a user is sleeping on the air bed, quiet operation can be particularly desirable. An air control system can include vibration isolators connected to a flow control assembly having one or more valves to dampen vibration of the flow control assembly. This can reduce transmission of vibration from the valves to a housing of the air control system, and consequently, allow the air control system to operate more quietly.
As illustrated in
The remote control 122 can include a display 126, an output selecting mechanism 128, a pressure increase button 129, and a pressure decrease button 130. The output selecting mechanism 128 can allow the user to switch air flow generated by the pump 120 between the first and second air chambers 114A and 114B, thus enabling control of multiple air chambers with a single remote control 122 and a single pump 120. For example, the output selecting mechanism 128 can by a physical control (e.g., switch or button) or an input control displayed on display 126. Alternatively, separate remote control units can be provided for each air chamber and can each include the ability to control multiple air chambers. Pressure increase and decrease buttons 129 and 130 can allow a user to increase or decrease the pressure, respectively, in the air chamber selected with the output selecting mechanism 128. Adjusting the pressure within the selected air chamber can cause a corresponding adjustment to the firmness of the respective air chamber. In some embodiments, the remote control 122 can be omitted or modified as appropriate for an application. For example, in some embodiments the bed 112 can be controlled by a computer, tablet, smart phone, or other device in wired or wireless communication with the bed 112.
The pump 120 can include a motor 142. The pump 120 can be fluidly connected to the pump manifold, which is fluidically connected with the first air chamber 114A and the second air chamber 114B via a first tube 148A and a second tube 148B, respectively. The first and second control valves 145A and 145B can be controlled by switching mechanism 138, and are operable to regulate the flow of fluid between the pump 120 and first and second air chambers 114A and 114B, respectively.
In some implementations, the pump 120 and the air controller 124 can be provided and packaged as a single unit. In some alternative implementations, the pump 120 and the air controller 124 can be provided as physically separate units. In some implementations, the air controller 124, the pump 120, or both are integrated within or otherwise contained within a bed frame or bed support structure that supports the bed 112. In some implementations, the air controller 124, the pump 120, or both are located outside of a bed frame or bed support structure (as shown in the example in
In some embodiments, the pump 120 can be a positive displacement pump. In some of such embodiments, the pump 120 can reduce or prevent back flow. In other embodiments, the pump 120 can be of another type suitable for the application.
The example air bed system 100 depicted in
In use, the processor 136 can, for example, send a decrease pressure command for one of the air chambers 114A or 114B, and the switching mechanism 138 can be used to convert the low voltage command signals sent by the processor 136 to higher operating voltages sufficient to operate the relief valve 144 of the pump 120 and open the control valve 145A or 145B. Opening the relief valve 144 can allow air to escape from the air chamber 114A or 114B through the respective air tube 148A or 148B. During deflation, the pressure transducer 146 can send pressure readings to the processor 136 via the A/D converter 140. The A/D converter 140 can receive analog information from pressure transducer 146 and can convert the analog information to digital information useable by the processor 136. The processor 136 can send the digital signal to the remote control 122 to update the display 126 in order to convey the pressure information to the user. Alternatively, one or more of the air chambers 114A and 114B can be deflated without opening the relief valve 144 as further described below.
As another example, the processor 136 can send an increase pressure command. The pump motor 142 can be energized in response to the increase pressure command and send air to the designated one of the air chambers 114A or 114B through the air tube 148A or 148B via electronically operating the corresponding valve 145A or 145B. While air is being delivered to the designated air chamber 114A or 114B in order to increase the firmness of the chamber, the pressure transducer 146 can sense pressure within the air manifold 143. Again, the pressure transducer 146 can send pressure readings to the processor 136 via the A/D converter 140. The processor 136 can use the information received from the A/D converter 140 to determine the difference between the actual pressure in air chamber 114A or 114B and the desired pressure. The processor 136 can send the digital signal to the remote control 122 to update display 126 in order to convey the pressure information to the user.
The air manifold 143 and the valves 144, 145A, and 145B can combine to form a flow control assembly 161. The flow control assembly 161 can selectively control flow from the pump 120 to the air chambers 114A and 114B. A tube 162 can extend from a outlet 164 of the pump 120 to an inlet 165 of the air manifold 143 for fluidly connecting the pump 120 to the air manifold 143. One or more additional tubes 166 and 168 can extend from the air manifold 143 to one or more pressure transducers 146 (shown in
As shown in
The air manifold 143 can also include one or more vents 170 and 171. The vents 170 and 171 can connect a manifold interior to atmosphere. The vents 170 and 171 can be non-valved and can remain open during substantially all operating conditions. This can allow for relatively slow deflation of one or more of the air chambers 114A and 114B by opening their corresponding valve 145A or 145B, without necessitating opening of the valve 144.
Vibration isolators 172 can be used to dampen transmission of vibration from the flow control assembly 161 to the housing 150. For example, the valves 144, 145A, and 145B can be rigidly mounted to the air manifold 143 along a length of the air manifold 143. When one or more of the valves 144, 145A, and 145B opens or closes, such movement can cause the flow control assembly 161 to vibrate. Dampening vibration via the vibration isolators 172 at the flow control assembly 161 can allow for the air controller 124 to operate more quietly.
In some embodiments, the flow control assembly 161 can include posts 174 and 176 configured for mounting the flow control assembly 161 within the housing 150. In the illustrated embodiment, the posts 174 and 176 are substantially vertical posts of the air manifold 143. The post 174 has a vibration isolator 172 on its top and another vibration isolator 172 on its bottom. The post 176 also has a vibration isolator 172 on its top and another vibration isolator 172 (not shown) on its bottom. The flow control assembly 161 can be sandwiched between the housing top 152 (shown in
The air controller 124 can included threaded fasteners 178 (such as screws or bolts) for connecting the housing top 152 to the housing bottom 154. One of the threaded fasteners 178 can extend through holes defined by the housing bottom 154, the post 176 of the air manifold 143, vibration isolators 172 at the top and bottom of the post 176, and the housing top 152. Another of the threaded fasteners 178 can extend through holes defined by the housing bottom 154, the post 178 of the air manifold 143, vibration isolators 172 at the top and bottom of the post 178, and the housing top 152. These threaded fasteners 178 can connect the housing top 152 to the housing bottom 154 in a manner that also holds the flow control assembly 161 in place within the housing 150.
Similarly, the supporting structure 182 can include a projection 190 and a stop 192. The projection 190 can define a hole 194 for receiving and connecting to the threaded fastener 178. One of the vibration isolators 172 can abut the projection 190 and/or the stop 192 to dampen transmission of vibration between the flow control assembly 161 and the housing top 152.
Similarly, the supporting structure 198 can include a projection 206 and a stop 208. The projection 206 can define a hole 210 for receiving and connecting to the threaded fastener 178. One of the vibration isolators 172 can abut the projection 206 and/or the stop 208 to dampen transmission of vibration between the flow control assembly 161 and the housing bottom 154.
The vibration isolator 172 can be formed of an elastomer material suitable for dampening vibration. The cylindrical portion 212 can be integrally formed with the annular portion 214 as a single structure. In other embodiments, one or more portions of the vibration isolator 172 can be separately formed.
The vibration isolator 172 can include projections 220 and 222. The annular portion 214 can include the projections 220 extending from a first side of the annular portion 214 and can include the projections 222 extending from a second side of the annular portion 214. Accordingly, the projections 220 and 222 can be positioned on opposite sides, with the projections 222 positioned substantially interior of the cylindrical portion 212 in a cavity defined by the vibration isolator 172.
In some embodiments, the projections 220 can be shaped differently than the projections 222. For example, the projections 220 can extend substantially radially outward with respect to the centerline axis CL along a surface of the annular portion 214. The projections 220 can be shaped as ribs that extend radially from the inner rim 216 to the outer rim 218. The projections 220 can be positioned in an array, substantially equally spaced circumferentially about the centerline axis CL.
The projections 222 can be positioned opposite of the projections 220. The projections 222 can be positioned near an inner surface 224 of the cylindrical portion 212 but slightly spaced from the inner surface 224 by a gap 226. The projections 222 can be positioned in an array, substantially equally spaced circumferentially about the centerline axis CL.
The vibration isolator 172 can be sized and configured to connect to a mounting structure of the flow control assembly 161, such as the posts 174 and 176 (shown in
The inner rim 216 of the annular portion 214 can abut the projection 184 of the supporting structure 180. The projection 184 can extend into a hole defined by the post 174, with the vibration isolator 172 holding the projection 184 substantially centrally in that hole to reduce or prevent contact between the post 174 and the projection 184. This can allow the annular portion 214 of the vibration isolator 172 to dampen vibration of the flow control assembly 161 in directions radial to the centerline axis CL.
The vibration isolators 172 can also be positioned on a bottom end of the post 174 and/or either or both ends of the post 176. For example, the vibration isolator 172 can be positioned on a bottom end of the post 174, with the circumferential portion 212 wrapped around a circumferential portion of the post 174, the projections 222 abutting the bottom end of the post 174, and the projections 220 abutting the printed circuit board 160 (shown in
By positioning the vibration isolators 172 between the posts 174 and 176 of the flow control assembly 161 and each of the supporting structures 180, 182, 196, and 198, the flow control assembly 161 can be mounted in the housing 150 while reducing noise caused by vibration of the flow control assembly 161. In some cases, the configuration of the vibration isolators 172 can allow for relatively easy assembly, as the vibration isolators 172 can be slipped over the ends of the supporting structures 180, 182, 196, and 198 and hold the flow control assembly 161 in place without requiring additional fasteners other than the those already being used to secure the housing top 152 to the housing bottom 154.
A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, in some cases the manifold 143 need not include the posts as illustrated, but rather, the flow control assembly can include other mounting structures suitable for the application. Moreover, one or more features present on one or more of the various embodiments can be considered optional, and need not necessarily be included in all embodiments. Accordingly, other embodiments are within the scope of the following claims.
