Patent Application
20140259397
The present invention relates generally to methods and apparatus for securing actuators to structures, and more specifically to methods and apparatus for attaching linear actuators to articulated furniture.
Actuators have been used for decades to move or control mechanisms or systems. For example, linear actuators have been used to create articulating furniture such as moving chairs, couches and beds (or movable foundations for same). U.S. Pat. No. 4,678,231 issued to Chizek on Jul. 7, 1987, U.S. Pat. No. 5,094,508 issued to Bathrick et al. on Mar. 10, 1992, and U.S. Pat. No. 5,219,204 issued to Bathrick et al. on Jun. 15, 1993 illustrate linear actuators that are used in adjustable chairs. U.S. Pat. No. 3,921,230 issued to Hanning et al. on Nov. 25, 1975, U.S. Pat. No. 4,381,571 issued to Elliott on May 3, 1983, U.S. Pat. No. 4,928,332 issued to Ogden et al. on May 29, 1990, U.S. Pat. No. 5,063,623 issued to Bathrick et al. on Nov. 12, 1991, U.S. Pat. No. 5,438,723 issued to Carroll on Aug. 8, 1995, U.S. Pat. No. 5,579,550 issued to Bathrick et al. on Dec. 3, 1996, and U.S. Pat. No. 6,061,852 issued to Bathrick et al. on May 16, 2000 illustrate linear actuators that are used in adjustable beds.
Over the years, improvements have been made to the designs of these systems and to the linear actuators themselves. For example, U.S. Pat. No. 5,542,744 issued to Bathrick on Aug. 6, 1996 illustrates a linear actuator or drive having pre-determined “extended” and “retracted” positions to assist in the repair or replacement of linear drives in the field. However, as can be seen in viewing any of these references, little to no effort has been made to improve and simplify the way in which such actuators are connected to their respective furniture frames or foundations (both during initial installation and/or during repair or replacement). Rather, the actuators are normally connected to furniture frames or foundations via brackets and pins or brackets and bolts that allow the actuator to pivot throughout its operation.
One problem with conventional mounting means for linear actuators is that their assembly requires the bolting or pinning of the actuator to the furniture via a bracket or clamp. These configurations add time to the assembly and/or repair of the furniture because the bolting or pinning steps are not easy to do and often require the person assigned with such tasks to work in tight spaces that do not lend themselves well to the use of tools or even movement of ones' arms, hands or fingers to complete the bolting or pinning action. For example, conventional actuator mounts for articulated beds are illustrated in
As is best illustrated in
As
Other problems associated with conventional actuator mounts are that current designs require additional material and parts, which in turn drives up cost and the amount of time it takes to assemble or repair conventional actuators. For example, in actuators that are connected using the clevis pin configuration discussed above, the extra costs associated with the pin and the means for securing the pin (e.g., cotter pin or nut) are incurred. In addition, the extra time it takes to insert the pin and secure the pin are incurred during installation and the extra time it takes to unsecure and remove the pin and then replace and re-secure the pin are incurred during repair.
An attempt has been made to make an actuator that connects without the need for a pin as illustrated in U.S. Pat. No. 7,900,302 issued to Long on Mar. 8, 2011, however, this actuator connection (152) requires the installer and/or repairer to exert an excessive amount of force on the actuator in order to make a proper connection to the bed frame. Specifically, the actuator mount or connector (152) has a C-shape that's opening is smaller than the diameter of the frame tube it is connected to and requires the installer or repairer to push hard enough to flex the ends of the C shape to open wide enough to fit the frame tube. The ends of the C shape then return to their normal position thereby securing the actuator to the bed frame member. Another problem with this design (152) is that it can be hard to tell if the actuator has been fully installed or re-connected properly due to the mount design being open on one end and not connecting all the way around the bed frame tube that the actuator connects to as illustrated in the drawings. An actuator that is not fully installed on the bed frame member may slip off due to the cam action of the flexing ends of the C shape mount or connector. Still another problem with such an open actuator mount (152) is that the actuator can be left slightly askew when connected to the bed frame tube (rather than being perfectly square or normal to the tube) which can prove problematic when the actuator is put into operation and is exposed to the forces that the actuator is subject to when moving portions of the furniture. For example, if left askew, the actuator may continue to move further away from the desired position of being normal to the bed frame tube and can prevent the actuator from moving portions of the furniture as far as intended and/or, in worst case scenarios, can lead to the actuator snapping off the bed frame tube to which it is connected or bending or denting portions of the actuator and/or bed frame tube due to the irregular positioning of the actuator.
Thus, a need exists for improved methods and apparatus for fastening actuators to structures and, more particularly, for fastening linear actuators to articulated furniture.
The above and other aspects, features and advantages of exemplary embodiments of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings.
Corresponding reference characters indicate corresponding components throughout the several views of the drawings. Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present invention.
The following description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of the invention and the exemplary embodiments discussed herein. The scope of the invention should be determined with reference to the claims.
Reference throughout this specification to “one embodiment,” “an embodiment,” “some embodiments” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” “some embodiments”, “in one form”, “in another form”, and similar language throughout this specification may refer to the same embodiment and/or may refer to separate or alternate embodiments as well. Furthermore, the described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description and the materials incorporated by reference, numerous specific details are provided to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.
Turning now to
Unlike the prior art illustrated in
Unlike the '302 patent however (as well as other conventional actuators and actuator driven articulated furniture), the embodiments disclosed herein depict a completely different snap-fit clamp structure that is used to secure the actuators 140 to the torque tubes 122, 124. More particularly and as best illustrated in
In a preferred form, the internal radius of curvature of the snap-fit clevis clamp member 150 matches the internal radius of curvature of the clevis bushing 152 so that when the clamp member 150 is secured to the actuator 140 as illustrated in
In the form illustrated in
In the form illustrated in
It should be understood that in alternate embodiments, other cooperating or mating structures may be used to secure the snap-fit clamp member 150 to the mount 160a (e.g., different sizes, shapes, locations or positioning, etc.). For example, different types of tongue and groove, mortise and tenon, ball and detent or dowel and jig type structures may be used to achieve such a mating configuration. In one form the clamp member arms 150a, 150b may define hooks that engage a shoulder formed on the mount 160a (e.g., shoulders formed by a raised lip, shoulders formed by notches defined by the mount 160a, etc.) to secure the clamp member 150 to the mount 160a and bushing 152. In such other embodiments, the distal ends of clamp arms 150a, 150b may have gripping structures, such as the raised flanges 150e, 150f discussed above, which an installer or repair person can grasp to easily disconnect the bosses 150c, 150d from their mating recesses or notches located in the actuator mount 160a. Alternatively, other embodiments may be provided with alternate gripping structures or even without such gripping structures if desired.
In other forms, the projection defined by the clamp member arms 150a, 150b may be positioned on the opposite side of each arm so that the projections or protrusions extend out and/or away from one another rather than pointing in and/or toward one another as illustrated in FIGS. 3A and 4B-C. For example, in one form, the mount 160a and/or bushing 152 may define a socket into which the arms 150a, 150b are disposed to mate and secure the clamp member 150 to the actuator 140. In other forms, the clamp member 150 and bushing 152 or mount 160a may be designed so that the arms 150a, 150b are inserted into the inner side of the bushing and mount. For example, the channel 152c of bushing 152 may be formed on the inner surface of the bushing 152 or mount 160a and the structures may be designed so that the projections 150c, 150d mate with recesses defined by the inner surfaces of the bushing 152 or mount 160a. In a preferred version of such forms, the bushing 152 or mount 160a would be structured so that when the clevis clamp member 150 is connected to the bushing 152 or mount 160a, the structures collectively would continue to define an opening with a uniform inner diameter like that shown in the embodiment of
In
In a preferred form, the guide channels 260d, 260e will be used in conjunction with channels 152c of clevis bushing 152 to guide the projections 150c, 150d from the moment the clamp member arms 150a, 150b are inserted over the clevis bushing 152 and mount 260a. This allows for controlled movement of the clamp member 150 from start to finish. In other forms, the first guide 152c may guide the projections 150c, 150d for a portion of the clamp member's travel as it is inserted onto the mount 160a and the second guide channels 260d, 260e may be used to guide the projections 150c, 150d for a second portion of the clamp member's travel. These guides may be configured to provide back-to-back alignment and guidance without a gap so that the projections 150c, 150d movement is continuously guided. Alternatively, a gap may be provided between the guides so that a first and second stage of guidance is provided, if desired (e.g., a two-stage guiding member or guide).
In still other forms, and as mentioned above, it should be understood that the cooperating structures of the clamp member 150 and mount 160a may be reversed if desired. For example, in one form, the projections may extend from opposite sides of mount 160a and engage mating recesses defined by the arms 150a, 150b of clamp member 150. In such alternate forms, the projections defined by the mount 160a would preferably be tapered from a smaller height near the opening of the mount 160a or bushing 152 to a larger height away from the opening of the mount 160a or bushing 152. This would continue to allow the clamp member 150 to be installed easily on the mount 160a, but securely mate the projections and corresponding recesses so that the clamp member 150 cannot be removed unless desired.
An exemplary embodiment of such an alternate snap-fit clamp design is illustrated in
As can best be seen in the cross-sectional view of
In addition to the above, the snap-fit clamp member 350 further includes a tongue member 350m which cooperates with channels 350i, 350j to form mating recesses for receiving the distal ends of the U-shaped mount 360a as illustrated in
In the form illustrated in
In the exemplary embodiments of the invention disclosed herein, the snap-fit clamp provides a three-hundred sixty degree (360°) boltless or pinless (fastenerless) clamp that secures the actuator to the frame and prevents removal of the actuator in all three-hundred sixty degrees (360°) around the frame to prevent accidental or inadvertent removal. In other words, a self-contained 360° clamp is provided to secure the actuator without the need for additional pins, bolts or fasteners. The clamp member is formed with integral securing structures that mate with corresponding securing structures on the actuator mount or bushing without requiring excessive force applied to the actuator 140. In alternate forms, the clamping structures may be designed to secure an amount of the frame less than 360°, but more than the friction fit structure of the '302 patent. For example, clamp member 150 and bushing or mount could be designed to encircle between 200°-360° of the frame, and preferably, 270°-360° of the outer circumference or periphery of the frame portion to which the actuator is connected. It should also be understood that many of these embodiments may be used with different types of articulating furniture designs, such as the four point articulated bed system of
It should also be understood that in addition to the various snap-fit clamp embodiments disclosed herein, there have also been disclosed numerous methods relating to apparatus for securing actuators to structures. For example, a new method for securing an actuator to a structure, such as a frame of articulated furniture, has been disclosed comprising providing a first clamp member connected to an actuator and having a first mating structure, and a second snap-fit clamp member having a second mating structure that engages and mates with the first mating structure when the second clamp member is snapped onto the first clamp member. This design forms a clamp that secures the actuator to a structure such as the frame of articulated furniture and encloses at least 200° of the outer circumference or periphery of the structure so that the actuator is easily and properly connected to the structure. More preferably, the first and second clamp members mate to secure the first end 142 or motor end of the actuator 140 to a part such as a frame member. As explained above, the second snap-fit clamp member (e.g., 150) is movable between a first position wherein the second snap-fit clamp member is spaced apart from the first clamp member (e.g., 152) and a second position wherein the second snap-fit clamp member is snapped onto the first clamp structure. The method further comprising securing the actuator to the structure by enclosing a portion of the structure between the first and second clamp members via the snap-fit connection made between the first and second clamp members when the second clamp member is in the second position.
Another method disclosed herein is a method for moving articulated furniture comprising providing an actuator having a motor coupled to a transmission and a power supply, the transmission driving a drive tube that is connected to a structure for moving articulated furniture and having a housing for covering the transmission, and a clamp for connecting the actuator to the articulated furniture. The clamp preferably having a first clamp member that is connected to the actuator, such as being coupled to the transmission housing, and a second clamp member that is movable between a first position wherein the second clamp member is spaced apart from the first clamp member and a second position wherein the second clamp member is snap-fit onto the first clamp member to form a clamp that encloses a portion of the articulated furniture and secures the actuator to the articulated furniture so that the actuator is easily and properly connected to the articulated furniture. The method further comprises securing the actuator to the articulated furniture via the clamp and operating the actuator to move at least a portion of the articulated furniture.
When considering the material incorporated by reference from the '302 patent in combination with the material disclosed herein, another method for moving an adjustable bed is disclosed comprising providing a stationary base having a pair of opposed side rails, a head end rail and a foot end rail, a frame spaced above said stationary base and movable relative to said stationary base and an articulated deck comprising a head deck board, a seat deck board, a leg deck board and a foot deck board hingedly joined to each other, said seat deck board being fixedly secured to said frame. The method further comprising providing head links of a fixed length pivotally secured to said side rails of said base and pivotally secured to brackets secured to said head deck board, and a pair of motorized linear actuator assemblies for moving said frame relative to said stationary base. Each of said motorized linear actuator assemblies comprising a linear actuator having one end connected by a first snap-fit connector to a cross member of said movable frame and an opposite end connected by a second connector to a component operative when moved to effect movement of at least one of said head, leg and foot deck boards between said horizontal position and said inclined position wherein said second connector is a snap-fit connector (see the '302 patent) that has a slot adapted to receive a pin extending between a pair of link arms operatively coupled to a rotatable torque tube of said frame and said first snap-fit connector having a first clamp member fixed to a portion of the actuator and a second clamp member movable between a first position wherein the second clamp member is spaced apart from the first clamp member so that the actuator may be removed from the cross member of said movable frame and a second position wherein the second clamp member is snap-fit to the cross member of said movable frame in order to secure the actuator to the movable frame, the first and second clamp members enclosing the cross member of said movable frame to ensure the actuator (and particularly the first end or motor end of the actuator) is properly secured to the cross member of said movable frame. In such other embodiments, the method may further comprise securing both ends of the linear actuators to the cross members of the movable frame via the first and second clamp members of the snap-fit connectors disclosed herein, and operating the linear actuators to move portions of the adjustable bed. In other words, both ends of the actuator may be secured to articulated furniture using 360° clamps like those disclosed in
In summary, many different embodiments and methods have been disclosed herein and even more embodiments and methods are contemplated by the disclosure set forth herein. It should be understood that changes may be made to the embodiments disclosed herein while still operating within the concepts contemplated as the invention. For example, parts of different size, shape, location or number may be used in keeping with the invention and/or various parts of one embodiment may be combined with other embodiments to come-up with a variety of different embodiments in keeping with the invention disclosed herein. For example, although some embodiments discussed herein mention using a snap-fit clamp having first and second clamp members each with first and second mating structures, it should be understood that in alternate embodiments any number of mating structures may be used as is desired for a particular application. Similarly, additional clamp members may be used to make-up the clamp that encloses the structure for anchoring the actuator to the articulated furniture. As also mentioned above, numerous patents cover alternate apparatus and methods for securing actuators to structures such as articulated furniture. These disclosures detail various alternate types of furniture, furniture construction and actuator systems that can be used with same. Rather than repeating all of these different embodiments in this disclosure, Applicants hereby incorporate by reference U.S. Pat. No. 3,921,230 issued to Hanning et al. on Nov. 25, 1975, U.S. Pat. No. 4,381,571 issued to Elliott on May 3, 1983, U.S. Pat. No. 4,678,231 issued to Chizek on Jul. 7, 1987, U.S. Pat. No. 4,928,332 issued to Ogden et al. on May 29, 1990, U.S. Pat. No. 5,063,623 issued to Bathrick et al. on Nov. 12, 1991, U.S. Pat. No. 5,094,508 issued to Bathrick et al. on Mar. 10, 1992, U.S. Pat. No. 5,219,204 issued to Bathrick et al. on Jun. 15, 1993, U.S. Pat. No. 5,438,723 issued to Carroll on Aug. 8, 1995, U.S. Pat. No. 5,542,744 issued to Bathrick on Aug. 6, 1996, U.S. Pat. No. 5,579,550 issued to Bathrick et al. on Dec. 3, 1996, U.S. Pat. No. 6,061,852 issued to Bathrick et al. on May 16, 2000 and U.S. Pat. No. 7,900,302 issued to Long on Mar. 8, 2011 (hereinafter collectively referred to as “the incorporated patents”), to keep the size of this application reasonable, but it should be understood that the snap-fit clamp disclosed herein may be used with any of the apparatus, methods or systems disclosed in the incorporated patents to secure either or both ends of the actuator (e.g., 142, 144) and the claims presented herein are intended to cover same.
The application claims the benefit of U.S. Provisional Application No. 61/798,472, filed Mar. 15, 2013, and is hereby incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61798472 | Mar 2013 | US |
