PNEUMATIC SYSTEM FOR ADJUSTABLE SUPPORT

TECHNICAL FIELD

This invention relates generally to the field of adjustable beds and more particularly a pneumatic adjustment bladder system for localized support adjustment.

BACKGROUND

Articulating beds have long been used in hospital and healthcare facilities to allow positioning of a patient in a reclining position, sitting position, elevated leg position or combinations of these positions. General usage of articulating beds has been rapidly expanding due to the comfort and convenience available from adjusting the bed to desired positions for reading, general relaxation or sleeping.

Additional and/or variable support for the lumbar region of the back and for head angle adjustment for additional comfort in articulating beds has been accomplished with mechanical or electromechanical actuators. However, these devices typically require additional actuators which may be difficult to position with limited space under the articulating platforms. Additionally, beds having adjustable supports are still limited to discreet adjustable support sections or fixed support placements. It is therefore desirable to provide an articulating bed having a pneumatic adjustment system adapted to provide improved support locating options to customize for user preferences and achieve greater adjustability.

SUMMARY

According to the disclosure, a pneumatic adjustment system attachable to a support panel of a bed includes a plurality of pneumatic adjustment modules, and inflation manifold, and a controller. The plurality of pneumatic adjustment modules may have at least one inflatable chamber. The inflation manifold may be in pneumatic communication with each of the plurality of pneumatic adjustment modules. The inflation manifold may have a pump and a plurality of regulating valves. The controller may be in communication with the inflation manifold and arranged to control the operation of the pump and the plurality of regulating valves to selectively inflate at least one inflatable chamber of each of the plurality of pneumatic adjustment modules.

Also according to the disclosure, a bed system may include a mattress, a support panel supporting the mattress, a frame supporting the support panel and a modular pneumatic adjustment system. The modular pneumatic adjustment system may have a plurality of pneumatic adjustment modules, an inflation manifold, a flexible conduit, and a controller. The plurality of pneumatic adjustment modules may be adjustably positioned on the support panel and disposed between the mattress and the support panel, each of the pneumatic adjustment modules comprising a base and a bladder. The inflation manifold may include a pneumatic pump and a plurality of regulating valves. The pneumatic pump may be configured to provide pressurized air to the plurality of regulating valves. The flexible conduit may interconnect each respective one of the plurality of regulating valves to the bladders of respective ones of the plurality of pneumatic adjustment modules. The controller may be operably connected to the pneumatic pump and the plurality of regulating valves and configured to provide open and close commands to each of the regulating valves for providing a flow of pressurized air from the pneumatic pump to the respective bladders.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention will be better understood by reference to the following detailed description of exemplary implementations when considered in connection with the accompanying drawings wherein:

FIG. 1 is a side view representation of a first exemplary embodiment of an adjustable bed supporting a mattress in an inflated state.

FIG. 2 is a side view of the adjustable bed of FIG. 1 in a deflated state.

FIG. 3 is a side view of a bed frame of the adjustable bed of FIG. 1.

FIG. 4 is a top view of the bed frame of FIG. 3.

FIG. 5 is a perspective view of the bed frame of FIG. 3.

FIG. 6 is a perspective view of the bed frame of FIG. 3.

FIG. 7 is a schematic diagram of the pneumatic adjustment system components of the adjustable bed of FIG. 1.

FIG. 8A is a perspective view of a second embodiment of an adjustable bed employed in an actuated position.

FIG. 8B is a perspective view of the adjustable bed of FIG. 8A with an upper body support in the articulated position.

FIG. 8C is a side view of the adjustable bed of FIG. 8A with an upper body support in the articulated position.

FIG. 9A is a top perspective view of a support panel of an adjustable bed in a fully actuated position.

FIG. 9B is a bottom perspective view of the support panel of FIG. 9A.

FIG. 10 is a block diagram of the pneumatic actuation system components of the adjustable bed of FIG. 8A.

FIG. 11 is a side view of an adjustable bed supporting a mattress in an inflated state.

FIG. 12 is a side view of an adjustable bed supporting a mattress in an inflated state.

FIG. 13 is a top schematic view of a bed having modular pneumatic adjustment modules.

FIG. 14 is a side schematic view of a bed having modular pneumatic adjustment modules supporting a user on a mattress.

DETAILED DESCRIPTION

Embodiments shown in the drawings and described herein provide a modular pneumatic adjustment system that allows users to personalize comfort of a bed by changing a level of support underlying a mattress. Referring to the drawings, FIG. 1 illustrates an exemplary embodiment of an adjustable bed 102 incorporating a pneumatic adjustment system 104 (described in greater detail subsequently), with the actuation system in a fully inflated, or actuated, state. Referring to FIG. 2, the adjustable bed 102 is illustrated with the pneumatic adjustment system in a deflated state. As seen in FIGS. 1 and 2, the bed 102 may include a frame 106 having a supporting panel 110 for supporting a mattress 108. The frame 106 may include the modular pneumatic adjustment system 104 disposed on the supporting panel 110 for providing individual, localized adjustment of various areas along the mattress 108, and further allowing a user to finely adjust a perceived firmness or angle of the mattress 108 overlying the pneumatic adjustment system 104 and the support panel 110. The modular pneumatic adjustment system 104 may include a plurality of pneumatic adjustment modules for adjusting different areas along the mattress 108.

Referring to FIGS. 1 and 3, the exemplary frame 106 includes a pneumatic adjustment system 104 comprising of at least one pneumatic adjustment module, and in particular five pneumatic adjustment modules. For example, the pneumatic adjustment system 104 may include a head pneumatic adjustment module 112, a neck pneumatic adjustment module 124, a lumbar pneumatic adjustment module 114, a hip pneumatic adjustment module 126, and a knee pneumatic adjustment module 128. In other examples, more or less pneumatic adjustment modules may be included.

Each of the pneumatic adjustment modules includes at least one bladder 118. The bladders 118 may be filled with pressurized air to provide pressure to the underside of the overlying mattress 108 in localized areas to create a desired effect to a user on the mattress 108. In some examples, the bladders 118 may include more than one expandable chamber. The expandable chambers may be in fluid communication with each other such that as pressurized air is input into the bladder 118, all of the expandable chambers are connected and are gradually inflated. The continued input of air may displace air from a chamber closest to the air input to the further chambers, until the bladders reach a maximum inflation or until a user stops an input at a desired inflation less than the maximum inflation.

The bladders 118 may be arranged in varying configurations to achieve different effects on the overlying mattress 108. The varying configuration of bladders 118 allow for more precise control at desired locations which may result in certain desired pressures or positions of the overlying mattress 108. When the bladders 118 are inflated, the overlying mattress 108 experiences the bladders 118 pushing into the lower surface of the mattress 108. Based on the configuration and inflation levels of the bladders 118, the mattress 108 may experience an effect that then provides a desired effect to a user on the mattress 108. In some examples, the configuration and inflation levels of the bladders 118 may raise the mattress 108 with the bladders 118 to change the position of the mattress 108, having a desired effect of raising a localized area of the mattress and a desired effect to a user of angling a portion of their body at the localized area. In other examples, the configuration and inflation levels of the bladders 118 may push upward on a lower surface of the mattress 108, having a desired effect of applying pressure to a localized area of the mattress 108 and a desired effect to a user of providing an increase firmness at the localized area.

In some examples, as shown with the head pneumatic adjustment module 112 and the hip pneumatic adjustment module 126, the bladders 118 may comprise at least three expandable chambers configured in a fan shape when inflated. The fan configuration may be provided to raise a localized area of the mattress above the bladders 118. For example, when all bladders 118 in the fan configuration are inflated, the bladders 118 may raise the lower surface of the mattress 108 in that localized area to provide a desired effect to a user. The desired effect to a user may, for example, include inflating the bladders 118 of the head pneumatic adjustment module 112 to raise the mattress 108 at the head location and thus raise a user's head at an angle higher than the rest of the mattress 108. In other examples, as shown with the lumbar pneumatic adjustment module 114 and the knee pneumatic adjustment module 128, the bladders 118 may comprise of one or more expandable chambers in a stacked configuration when inflated. The stacked configuration may be provided to increase the firmness of a localized area of the mattress above the bladders 118. When all bladders 118 in the stacked configuration are inflated, the bladders 118 may push against the lower surface of the mattress 108 in that localized area to provide a desired effect to a user of feeling an increased firmness in that area. For example, inflating the bladders 118 of the lumbar pneumatic adjustment module 114 may assist in providing added pressure to the mattress 108 at the lumbar location and thus providing a feeling of increased firmness to a user at the lumbar location. In further examples, as shown with the neck pneumatic adjustment module 124, the bladders 118 may be configured in a single horizontal row when inflated. The single row of bladders 118 may be provided to raise a localized area of the mattress above the bladders 118 at a more precise or in a generally smaller increment than the fan configuration. For example, when the bladder 118 in the single configuration is inflated, the bladder 118 may raise the lower surface of the mattress 108 in a smaller localized area to provide a desired effect to a user. The desired effect to a user may, for example, include providing the neck pneumatic adjustment module 124 with a minute adjustment to assist a user in controlling snoring behavior due to the angle at which the inflated neck pneumatic adjustment module 124 affects an overlying mattress at that precise location. In a deflated state as illustrated in FIG. 2, the pneumatic adjustment modules are generally flat, allowing the mattress 108 to rest flat along the support panel 110. Each of the pneumatic adjustment modules may be independently controlled. For example, as illustrated in FIGS. 1 and 3, all five pneumatic adjustment modules are fully inflated. In other exemplary positions, a user may actuate only one or any number of the pneumatic adjustment modules to a customized preference.

Further referring to FIGS. 1 and 3, the pneumatic adjustment system 104 may be covered in a sheath 120. In some examples, the sheath 120 may be a fabric covering extending over the plurality of pneumatic adjustment modules. The sheath 120 may be attached to the frame 1016 or the support panel 110 and configured to move with the actuation of each of the plurality of pneumatic adjustment modules. For example, the sheath 120 may be flexible or extendable in a direction of the headboard and footboard of the frame 106 such that the sheath 120 can lay flat when the pneumatic adjustment modules are in a deflated state, and such that the sheath 120 can extend when one or any number of the pneumatic adjustment modules inflates in an actuated state. The sheath 120 is provided as a protective covering to the bladders 118 to prevent or reduce puncturing of the bladders. The sheath 120 may also prevent or reduce undesired movement of the bladders 118 when the mattress 108 experiences movement. Moreover, the sheath 120 also acts as a smooth, consistent layer between the mattress 108 and the pneumatic adjustment modules.

To further improve the level of adjustment of the bed, the plurality of pneumatic adjustment modules can further be repositionable along the support panel. One example implementation of the repositionable pneumatic adjustment modules may be seen in U.S. patent application Ser. No. 17/539,999, entitled Modular Pneumatic adjustment System For Head Tilt And Lumbar Supports In An Adjustable Bed, filed Dec. 1, 2021, the entirety of which is incorporated by reference herein.

Referring to FIGS. 4-6, another example implementation of the repositionable pneumatic adjustment modules is illustrated. Each of the pneumatic adjustment modules may be secured to a module base 430 to be received on a support panel 410 of a frame 406. Each of the module bases 430 may be mounted to the frame 406 through convention bolt fasteners 432 extending through the base 430 and into slots in the upper surface of the frame 406 and secured with adjustable nuts on a lower surface of the frame 406. In other examples, the module bases 430 may be removeable and adjustable through the use of an attachment mechanism such as hook and loop fasteners 434. The added adjustment provided by repositionable modules allows the pneumatic adjustment modules to be positioned for users of different heights and sizes. For example, a user of one height may require a lumbar support 414 to be a first distance from a head support 412. A user of a different height, perhaps a shorter height, may require the lumbar support 414 to be a second distance from the head support 412, perhaps closer to the head support 412, to align the supports with the correct location on their body.

Also referring to FIGS. 4 and 5, providing individual, localized adjustment in the different pneumatic adjustment modules allows the support to change from one side of a dual-occupant bed to the other side and increase a level of personalization of comfort among different users. For example, the plurality of pneumatic adjustment modules may include a first set of pneumatic adjustment modules 404 disposed on a first side of the of the frame 406 and a second set of pneumatic adjustment modules 406 disposed on a second side of the frame 406. The first set of pneumatic adjustment modules 404 and the second set of pneumatic adjustment modules 406 may be physically separate such that the modules may be repositioned separately for personalized comfort on the two sides of the dual-occupant bed 402. The first set of pneumatic adjustment modules 404 and the second set of pneumatic adjustment modules 406 may be configured for selective simultaneous inflation. In other examples, the first set of pneumatic adjustment modules 404 and the second set of pneumatic adjustment modules 406 may be configured for selective independent inflation. For example, the first set of pneumatic adjustment modules 404 and the second set of pneumatic adjustment modules 406 may be configured to be actuated simultaneously to inflate corresponding bladders on both sides of the bed at a same rate. In other examples, the first set of pneumatic adjustment modules 404 and the second set of pneumatic adjustment modules 406 may be configured to be actuated independently. For example, a first set of pneumatic adjustment modules 404 may be configured to be actuated by an input from a first user while the second set of pneumatic adjustment modules 406 may be configured to be actuated by an input from a second user. Further description of the actuation of the pneumatic adjustment modules is described below.

Referring to FIG. 6, the bladders 618 of each pneumatic adjustment module are attached to the module bases 430. The bladders 618 may be attached to the module base 430 via a flexible hinge. The flexible hinge is configured to allow the bladders 618 to lay generally flat in a deflated position and to inflate in a desired direction and angle. In examples where the bladders 618 are vertically stacked, such as with the lumbar support 414 and the leg support 428, the bladders 618 may be mounted to the base 430 in a central location. In a deflated state, the bladders 618 may remain stacked and lay generally flat. In examples where the bladders 618 are configured to inflate in a fanned configuration, such as with the head support 412, the neck support 424, and the hip support 426, the bladders 618 may be mounted to the base 430 towards one of the longitudinal sides of the base 430. Thus, as the bladders 618 are inflated, the bladders 618 are inflated from one of the upper or lower sides of the base based on the preferred inflation direction and angle. For example, the head support 412 may include bladders 618 mounted and inflating from a lower side of the base 430. Thus, as the bladders 618 inflate, the bladders 618 achieve the correct inflated position to raise the head of user from the upper side of the base 430.

Referring to FIG. 7, a schematic diagram of the pneumatic adjustment system 704 of an adjustable bed is illustrated. The pneumatic adjustment system 704 includes an inflation manifold 740 in fluid communication with each of the pneumatic adjustment modules. The inflation manifold may be in electronic communication with a pneumatic pump 742 for provided pressurized air to the pneumatic adjustment modules. An inflation conduit 744 may connect the pneumatic pump 742 to each of the pneumatic adjustment modules such that the pressurized air can be delivered to the bladders 718 of each of the adjustment modules. The inflation conduits 744 may be flexible to allow routing from the inflation manifold to the respective bladders 718 regardless of repositioning of the adjustment modules. Each of the pneumatic adjustment modules may have a regulating valve 746 positioned between the pneumatic pump 742 and the respective bladders 718. The regulating valves 746 are electronically controlled with a controller 754 configured to provide inflation or deflation commands, responsive to user input, for example on a remote or in a connected application, to each regulator valve 746 for flow of pressurized air from the pneumatic pump 742 to the bladder 718 in each of the respective adjustment modules to increase the tilt angle or relief of pressure from the bladder 718 to reduce the tilt angle. A remote may be wirelessly connected to the controller 754 with WiFi or Bluetooth®, or hardwired. The remote may be a software application housed on and executed by a smart phone, a smart home hub device, or other personal computing device.

The controller 754 is also in electronic communication with a sensor 748 in each of the pneumatic adjustment modules for receiving signals regarding the inflation conditions of the bladders 718 and signals regarding a user's conditions. The sensor 748 may be a sensor array and may be arranged to sense one or more parameters associated with the inflation of the pneumatic adjustment modules, or with the user, such as a user position. The sensor 748 may include an accelerometer for determining how much the bladders 718 have been inflated or deflated to determine ideal positions or heights of the adjustment modules based on the level of inflation. The sensor 748 may also include a pressure sensor for signaling a pressure provided to the mattress surface in various locations which may be correlated to a user's condition, including, but not limited to, conditions such as determining when a user rests on the mattress, what position the user is in, and when a user changes positions or moves to a different location on the bed. The sensor 748 may include various other types of sensors for receiving signals and information, for example a user's temperature or a noise sensor to determine if a user is snoring. Each type of sensor in the sensor array 748 may send signals independently. The signals may be used collectively to determine ideal bladder inflation conditions across the bed to meet a user's desired adjustments.

Each pneumatic adjustment module may be attached to a different regulating valve 746 in the example shown. This allows separate actuation/regulation of each of the plurality of adjustment modules. Moreover, each of the first set of pneumatic adjustment modules 704 and the second set of pneumatic adjustment modules 706 may each include a respective inflation manifold 740 and pneumatic pump 742 to provide separate positioning and adjustment to two separate users on opposite side of the bed. Thus, the pneumatic adjustment system 704 may include a first inflation manifold 7401 and a first pneumatic pump 7421 in fluid communication with the first set of pneumatic adjustment modules 704 and a second inflation manifold 7402 and a second pneumatic pump 7422 in fluid communication with the second set of pneumatic adjustment modules 706. In an example operation, the remote and controller 754 may be configured to provide independent control of the two regulating valves for corresponding adjustment modules on the first and second side to allow for independent control. For example, the controller 754 may be configured to provide a first control to the first pneumatic pump 7421 and the regulating valve 746 of the head support module 712 of the first set of pneumatic adjustment modules 704, and a second control to the second pneumatic pump 7422 and the regulating valve 746 of the head support module 712 of the second set of pneumatic adjustment modules 706. In other examples, the remote and controller 754 may be configured to provide synchronized control of the two regulating valves for corresponding adjustment modules on the first and second side to allow for simultaneous tandem operation. For example, the controller 754 may be configured to provide synchronized control of the first and second pneumatic pumps 742 and the regulating valves 746 of both the head support module 712 of the first set of pneumatic adjustment modules 704 and the head support module 712 of the second set of pneumatic adjustment modules 706 to provide synchronized tandem operation of both head supports 712 across the width of the bed.

The pneumatic adjustment modules may be biased toward the deflated condition. In one example, the inflation manifold 740 may be arranged to reverse the air flow to the pneumatic adjustment module to evacuate the air from the bladder 718 and return the pneumatic adjustment module to the deflated condition more quickly and completely. In the alternative, or in addition, the bladder 718 may work against a biasing force toward the deflated condition. For example, the weight of the mattress and the hinge of the bladders 718 at the base 730 may bias the bladders 718 toward the support panel when pressurized air is not being actively pumped into the bladders 718 from the pneumatic pump 742. The regulating valves 746 may be biased towards a closed state. The valves 746 may require an input from the controller 754 to open to either receive pressurized air from the pneumatic pump 742 to inflate or to open to allow pressurized air to exit from the bladders 718 to deflate. Thus, active current is not provided to the regulating valves 746 unless an input is received or pre-set to be received at a particular time. Each of the first set of pneumatic adjustment modules 704 and the second set of pneumatic adjustment modules 706 may be in fluid communication with a respective exhaust valve 750 and a respective exhaust muffler 752. When the exhaust valve 750 is open, the weight of the mattress biases the air to exhaust out of the exhaust muffler 752 to the atmosphere. Thus, the pneumatic adjustment system 704 may include a first exhaust valve 7501 and a first exhaust muffler 7521 in fluid communication with the first set of pneumatic adjustment modules 704 and a second exhaust valve 7502 and a second exhaust muffler 7522 in fluid communication with the second set of pneumatic adjustment modules 706. In an example operation, the remote and controller 754 may be configured to provide independent control of the two exhaust valves and the two exhaust mufflers to allow for independent control. For example, the controller 754 may be configured to provide a first control to the first exhaust valve 7501 and the first exhaust muffler 7521 of the first set of pneumatic adjustment modules 704, and a second control to the second exhaust valve 7502 and the second exhaust muffler 7522 of the second set of pneumatic adjustment modules 706. In this example, the two sides of the bed may receive commands to deflate and exhaust air independently at different rates or where one side deflates and the other does not. In other examples, the remote and controller 754 may be configured to provide synchronized control of the two exhaust valves and the two exhaust mufflers to allow for simultaneous tandem operation. For example, the controller 754 may be configured to provide synchronized control of the first exhaust valve 7501 and the first exhaust muffler 7521 of the first set of pneumatic adjustment modules 704 and the second exhaust valve 7502 and the second exhaust muffler 7522 of the second set of pneumatic adjustment modules 706 to provide synchronized tandem operation of both exhaust valves across the width of the bed. In this example, the two sides of the bed may receive commands to deflate together.

The controller 754 may include or may be in electronic communication with one or more memory devices storing machine executable instructions that when executed cause the controller to operate the pneumatic pump 742 and regulating valves 746. The controller 754 may be operated in response to a user's input entered on the remote, or may be operated automatically in certain operating modes or based on sensor values. The sensor values may be used to represent the inflation condition between a minimum, deflated condition, and a maximum fully inflated condition. The maximum fully inflated condition may be defined as less than the maximum burst strength of the bladder of the pneumatic adjustment module. The maximum fully inflated condition may also or alternatively be limited by the valves 746 or pump 742 parameters. The inflation manifold 740 may be equipped with a pressure release valve to relieve excess pressure in the event of an overpressure condition, for example, if the bed experiences unanticipated excess user weight. Inflation condition of the pneumatic adjustment modules may be indicated based on air pressure, inflation volume, displacement of the tilt panel away from the base panel or other component displacement within the pneumatic adjustment module, other physical parameters, and combinations thereof.

In one example, the controller 754 may be arranged to inflate or deflate the pneumatic adjustment modules to certain inflation conditions based on a time of day. Specifically, the controller 754 may inflate a head support 712 to a maximum inflation condition as a preset wake-up time. In another example, the controller 754 may place the pneumatic adjustment modules in a preset inflation condition suitable for a side-sleeping at a preset sleep time. The preset inflation condition suitable for side-sleeping may include an intermediate inflation condition to provide tailored support levels at a user's hips, shoulders, and head to maintain a substantially straight spine of the user. The intermediate inflation condition may be individually set for different users through a manual adjustment process. The intermediate inflation condition may be automatically set by the controller 754 in cooperation with one or more sensors 748 arranged to sense a user's posture. The controller 754 may automatically transition inflation conditions in response to a user's condition on the mattress, such as a changing position or pose. For example, if a user transitions from a first position over a first set of pneumatic adjustment modules 704 to a second position over the same first set of pneumatic adjustment modules 704 or a different second set of pneumatic adjustment modules 706, the controller 754 may receive sensor 748 input in response to the user's repositioning. In response, the controller 754 may change an inflation condition from one suitable for side sleeping to one suitable for back sleeping when the sensor 748 information indicates the user has repositioned from their side to their back. Similarly, if the sensor 748 information indicates the user has transitioned from a location over a first set of pneumatic adjustment modules 704 to a second location over a second set of pneumatic adjustment modules 706, such as when moving from a side of a bed to the other side of the bed, the controller 754 may return the first set of adjustment modules 704 to a default inflation condition, such as a deflated condition, and change the inflation condition of the second set of adjustment modules 706 to an inflation condition suitable for the sleeper's new pose and position.

Referring to FIG. 8A, a second embodiment of an adjustable bed 802 is illustrated. The adjustable bed 802 includes a pneumatic adjustment system (described in greater detail subsequently) with pneumatic adjustment modules 803, employed as lumbar support modules 804, head tilt modules 806, and lower support modules 808. The support panel may include an upper body support panel 812 and a seat support section 814 separating the support panel into an upper section and a lower section for articulating. FIG. 8A illustrates an unarticulated position of the upper body support panel 812 such that the bed 802 is generally flat. FIG. 8B illustrates an articulated position of the upper body support panel 812 such that the bed 802 is provided with the upper body support panel 812 at raised angle. The bed 802 may include a frame 810 having side rails 811A, 811B and end rails 813A, 813B that carry the upper body support panel 812 and a seat support section 814. The upper body support panel 812 may be attached to the seat support section 814 with hinges 815 for rotation. A thigh support panel 816 may also be attached with hinges 817 to the seat support section and a lower leg support panel 818 attached with hinges 819 to the thigh support panel 816. The frame 810 may be supported by legs 820. Structure and actuation of the adjustable bed 802 may be implemented in one example shown herein as disclosed in U.S. Pat. No. 10,932,583, entitled Electric Adjustable Bed. The contouring effect of the inflated pneumatic support modules on an overlying mattress 808 is represented in FIG. 8C.

An example implementation of the pneumatic adjustment modules 803 may be seen in U.S. patent application Ser. No. 17/539,999, entitled Modular Pneumatic Actuation System For Head Tilt And Lumbar Supports In An Adjustable Bed, filed Dec. 1, 2021, the entirety of which is incorporated by reference herein. Each pneumatic adjustment module has a base 822 that may be received on a support panel of the bed 802, such as the upper body support panel 812. A tilt panel 814 is attached to the base 822 with a vertex hinge 826. The tilt panel 824 and the base 822 may be rigid, and may be formed of a fiber reinforced plastic, or other suitable material. The vertex hinge 826 may be formed integrally with the tilt panel 824 and base 822 as a living hinge, for example, formed of fiber reinforced plastic. A bladder 828 is positioned between the base 822 and tilt panel 824. The bladder 829 may include a single or a plurality of expansion segments. In one example, the bladder 828 may provide an effectively triangular expanded cross section, in an inflated condition, having a vertex proximate the vertex hinge 826. In another example, the bladder 828 may include a plurality of interconnected lobes, a single chamber, a series of interconnected chambers, or other designs. The chamber may include a series of baffles segmenting the air chamber or chambers. The interconnected surfaces of the bladder 828 may be interconnected by molded or bonded seams. In other examples, the pneumatic adjustment modules 803 may be configured as described above in the first exemplary embodiment of the adjustable bed 102 where the bladders are attached to base which are repositionable secured to the support panels and which extend in an upward manner such as in a stacked configuration or a fanned configuration, when inflated.

Inflation of the expansion segments in the bladder 828 adjusts a tilt angle between the base 822 and tilt panel 824. Each expansion segment is pneumatically expandable over a range from a deflated condition in which the expansion segments are substantially flat and the tilt panel 824 is substantially parallel to the base 822 to an inflated condition placing the tilt panel 824 at a desired tilt angle. Use of separate expansion segments in the bladder 828 may allow more precise angular control over a range of tilt angles from substantially 0° with the bladder 828 uninflated to a maximum angle, between 20° and 30°. In certain implementations, the segments may be individually and sequentially inflated to provide incremental predetermined tilt positions within the overall tilt range. For example, a controller may be provided with predetermined tilt positions including 0°, 10°, 20°, and 30°. In other examples, the controller may be provided with other tilt positions that may be customizable to a user based on preferred settings that may be saved to a remote. Each position may be provided with specific expansion segments that are inflated to reach the desired tilt position. In some examples, where the expansion segments are provided in a triangular configuration, each tilt position may employ the use of further expansion segments. At 0°, all of the expansion segments may be deflated. To achieve a tilt position of 10°, the first expansion segments closest to the vertex hinge 826 may be inflated. To achieve a tilt position of 20° or 30°, further expansion segments away from the vertex hinge 826 may also be inflated to create a higher tilt position. Thus, as the segments are sequentially inflated, the degree of tilt position can be varied based on inflation. Additionally, the substantially triangular shapes of the individual segments and overall triangular shape created in the bladder 828 during inflation of the segments provides even pressure over the lower surface of the tilt panel 824 for more stable support of the overlying mattress through the range of tilt angle.

The pneumatic actuation system includes an inflation manifold 840 in fluid communication with the pneumatic adjustment modules 803. The inflation manifold 840 may be mounted on a bottom surface of the seat support section 814. Inflation conduits 842 extend from each of the bladders 828 of the respective lumbar support modules 804 and head tilt actuators 806 through apertures 843 in the seat support section 814 to one of a plurality of regulating valves 844 in the inflation manifold. Alternatively, the apertures 843 may be placed in the upper body support panel 812 proximate the positions of the lumbar support modules 804 and head tilt actuators 806. In example implementations, the inflation conduits are flexible to allow routing from the inflation manifold to the respective bladders 828. A pneumatic pump 846 provides pressurized air to the regulating valves 844. The regulating valves 844 are electronically controlled with a controller 1048, as shown in FIG. 10, configured to provide inflation or deflation commands, responsive to user input on a remote 1049, to each regulator valve for flow of pressurized air from the pneumatic pump 946 to the bladder 828 in the respective lumbar support or head tilt actuator to increase the tilt angle or relief of pressure from the bladder 828 to reduce the tilt angle. The remote 1049 may be wirelessly connected to the controller 1048 with WiFi or Bluetooth®, or hardwired. The remote 1049 may be a software application housed on and executed by a smart phone, a smart home hub device, or other personal computing device. The controller 1048 is also in electronic communication with a sensor 1050. The sensor 1050 may be a sensor array and may be arranged to sense one or more parameters associated with the inflation of the pneumatic adjustment modules 803, or with the user, such as a user position.

Each pneumatic adjustment module 803 may be attached to a different regulating valve 844 in the example shown. This allows separate actuation/regulation of the two lumbar support modules 804 and/or the two head tilt actuators 806 on each side to provide separate positioning for the two separate users. The remote 1049 and controller 1048 may be configured to provide synchronized control of the two regulating valves for the lumbar support modules 804 or the two regulating valves for the head tilt actuators 806 to allow simultaneous tandem operation.

Further referring to FIG. 10, the inflation manifold 840 includes a controller 1048 for controlling the operation of the pneumatic pump 846 and regulating valves 844. The controller 1048 is in electronic communication with a sensor 1050. The manifold 840 may be in fluid communication with a heat exchanger 1051 or other thermal device for increasing or decreasing the temperature of pneumatic fluid used in the pneumatic adjustment modules 803. The heat exchanger 1051 may include a resistive heating element for heating the fluid. The heat exchanger 1051 may include a heatsink and fan for cooling the fluid. The heat exchanger 1051 may include Peltier plates for maintaining a temperature of the fluid. In one example, the pneumatic fluid may be air, and the pneumatic pump 846 may be arranged to take in air from the surrounding environment, and release air externally when the pneumatic adjustment modules are deflated or deactivated. In another example, the pneumatic pump may be arranged in communication with a reservoir or storage chamber for the pneumatic fluid. The pneumatic fluid may be water, a water-based liquid, or other suitable media.

The controller 1048 may include or may be in electronic communication with one or more memory devices storing machine executable instructions that when executed cause the controller to operate the pneumatic pump 846 and regulating valves 844. The controller 1048 may be operated in response to a user's input entered on the remote 1049, or may be operated automatically in certain operating modes or based on sensor values. The sensor values may be used to represent the inflation condition between a minimum, deflated condition, and a maximum fully inflated condition. The maximum fully inflated condition may be defined as less than the maximum burst strength of the bladder of the pneumatic adjustment module. The maximum fully inflated condition may also or alternatively be limited by the valves 844 or pump 846 parameters. The inflation manifold 840 may be equipped with a pressure release valve to relieve excess pressure in the event of an overpressure condition, for example, if the bed experiences unanticipated excess user weight. Inflation condition of the pneumatic adjustment modules may be indicated based on air pressure, inflation volume, displacement of the tilt panel away from the base panel or other component displacement within the pneumatic adjustment module, other physical parameters, and combinations thereof.

In one example, the controller 1048 may be arranged to inflate or deflate the pneumatic adjustment modules 803 to certain inflation conditions based on a time of day. Specifically, the controller 1048 may inflate a head tilt actuator 806 to a maximum inflation condition as a preset wake-up time. In another example, the controller 1048 may place the pneumatic adjustment modules 803 in a preset inflation condition suitable for a side-sleeping at a preset sleep time. The preset inflation condition suitable for side-sleeping may include an intermediate inflation condition to provide tailored support levels at a user's hips, shoulders, and head to maintain a substantially straight spine of the user. The intermediate inflation condition may be individually set for different users through a manual adjustment process. The intermediate inflation condition may be automatically set by the controller in cooperation with one or more sensors arranged to sense a user's position on the mattress and the user's posture. The controller 1048 may be electronically connected to a sensor for receiving information about the user. In some example, the sensor may be a pressure sensor configured to receive sensor information such as pressure and/or compression levels at varying locations around the mattress which may be correlated to a user laying on a mattress and with specific positions of a user on the mattress. The controller 1048 may automatically transition inflation conditions in response to a user's condition on the mattress, such as a changing position or pose when the pressure sensor determines that compression at different locations has changed. For example, if a user transitions from a first position over a first set of pneumatic adjustment modules to a second position over the same first set of pneumatic adjustment modules or a different second set of pneumatic adjustment modules, the controller 1048 may receive sensor input in response to the user's repositioning based on compression levels. In response, the controller 1048 may change an inflation condition from one suitable for side sleeping to one suitable for back sleeping when the sensor information indicates the user has reposition from their side to their back. Similarly, if the sensor information indicates the user has transitioned from a location over a first set of pneumatic adjustment modules to a second location over a second set of pneumatic adjustment modules, such as when moving from a side of a bed to the other side of the bed, the controller 1048 may return the first set of adjustment modules to a default inflation condition, such as a deflated condition, and change the inflation condition of the second set of adjustment modules to an inflation condition suitable for the sleeper's new pose and position.

The pneumatic adjustment modules 803 may be biased toward the deflated condition. In one example, the inflation manifold 840 may be arranged to reverse the air flow to the pneumatic adjustment module 803 to evacuate the air from the bladder 828 and return the pneumatic adjustment module 803 to the deflated condition more quickly and completely. In the alternative, or in addition, the bladder 828 may work against a resilient bias toward the deflated condition. For example, the vertex hinge 826 may bias the tilt panel 824 toward the base 822. Alternatively, or in addition, a torsion spring 829 may be arranged between base 822 and the tilt panel 824 to supplement a biasing force imparted by the vertex hinge 826. Further alternatively, or additionally, a biasing member 831 may be arranged between the base 822 and the tilt panel 824 opposite the vertex hinge 826. The biasing member 831 may include a spring 833, or other suitable device. The biasing member 831 may include a spandex fabric 835, or other highly elastic fabric, extending between the base and the tilt panel along the width of pneumatic adjustment module opposite the vertex hinge. The elastic fabric may fully enclose the pneumatic adjustment module 803, or may extend only along the edges of the base 822 and the tilt panel 824. Further alternatively, the elastic fabric may extend only along a portion or section of the pneumatic adjustment module 803. For example, the elastic fabric may only enclose the ends of the pneumatic adjustment module, or may only extend along a central portion of the pneumatic adjustment module 803. The structure of the pneumatic adjustment modules 3 allows for micro-adjustment of the head, lumbar and thigh areas, and further allows a user to finely adjust a perceived firmness of a mattress overlying the pneumatic adjustment modules 3. Providing individual, localized adjustment in the different pneumatic adjustment modules 3 also allows the support to change from one side of a dual-occupant bed to the other side and increase a level of personalization of comfort.

To further improve the level of adjustment, the pneumatic adjustment modules may be repositionable along the support panels. One example implementation of the repositionable pneumatic adjustment modules 803 may be seen in U.S. patent application Ser. No. 17/539,999, entitled Modular Pneumatic Actuation System For Head Tilt And Lumbar Supports In An Adjustable Bed, filed Dec. 1, 2021, the entirety of which is incorporated by reference herein.

In other alternatives, the pneumatic adjustment module 803 may be reversible. That is, the vertex hinge of the pneumatic adjustment module 803 may be placed toward the head-end or the foot-end of the bed. Reversing the direction of the vertex hinge changes the concentration of support located away from the vertex hinge, and also the slope of increasing support away from the vertex hinge 826. The air connection between the bladder 828 and conduits 842 may be located at the vertex hinge 826 so repositioning support by flipping the pneumatic adjustment module 803 may be easier than by sliding the pneumatic adjustment module 803 along the support to a new position. In one example, the lower supports 808 are arranged with the vertex hinge oriented toward the foot-end of the bend in FIG. 8A. In FIG. 8B, the lower support 808 are reversed and the vertex hinge is oriented toward the head end. Additionally, the lower support 808 is moved from the thigh support panel to the 816 to the lower leg support panel 818. However, this is not limiting and the pneumatic support modules 803 may be reversed while maintaining the same positioning on the respective support panel.

Referring to FIG. 11, in one implementation of the pneumatic actuation system, the pneumatic adjustment modules are inflated to achieve an inclined sleeping position for a user. For example, a lower support 1108 may be inflated a first, small amount, a lumbar support module 1104 may be inflated a second amount, greater than the first amount, and a head tilt actuator 1106 may be inflated a third amount, greater than the first amount, and potentially greater than the second amount of the lumbar support module 1104. The result of the varying inflation amount increasing from the foot-end to the head-end results in the overlying mattress 1121 adopting an incline, for example between about 1° and about 15°. In another example, the incline may be between about 5° to about 10°. FIG. 11 illustrates one example of the pneumatic adjustment system where the mattress 1121 is oriented at an incline of 5° from the foot-end to the head-end.

Referring to FIG. 12, where the pneumatic adjustment modules 803 incline the mattress 1221 relative to the frame 1210, gaps may be present between the mattress 1221 and the frame 1210. This may be present in particular where the frame 1210 is a solid foundation and does not include adjustable support panels. To minimize the appearance of these gaps, the frame 1210 may include a shroud, cover or other enclosure to span the gap, such as fabric skirt 1235 that extends from the frame 1210 to the mattress 1221. The fabric skirt 1235 may comprise a highly elastic fabric, such as a spandex fabric. The fabric skirt 1235 may include an elastic band 1237, draw string, or other cinch at a top end to tension the skirt around a bottom of the mattress. Alternatively, the fabric skirt 1235 may connect to the mattress 1221 via zipper, hook-and-look fastener, snaps, buttons, toggles, clips or other suitable joining mechanism. The fabric skirt 1235 may include a similar joining mechanism to join the fabric skirt 1235 to the frame 1210 as to the mattress 1221. Alternatively, the fabric skirt 1235 may extend from a fabric cover component of frame 1210, being stitched, sewn, or woven to the fabric of a frame cover. FIG. 12 illustrates one example of the bed 1202 including a fabric skirt 1235 extending between the mattress 1221 and the frame 1210. The fabric skirt 1235 is illustrated to include the elastic band 1237 securing the fabric skirt 1235 to the mattress 1221, and where the fabric skirt extends from a fabric cover of the frame 1210.

Referring generally to FIGS. 13 and 14, a bed 1302 may include modular pneumatic adjustment modules 1303 positioned to support various locations of a user including, but not limited to, a user's head, shoulders, and hips. The head, shoulder, and hips are pressure points for a user whether positioned on their back, side or stomach and thus may contribute to accelerated wear of mattress 1321 support materials proximate to those points, including for example, foam or coil springs. Providing the modular pneumatic adjustment modules 1303 in these locations can provide customizable support assistance that aids in supporting in these specific areas and allows the user to perceive firmer support. An adjustable bed 1302 may include any or both of the disclosed pneumatic adjustment modules disclosed in FIG. 1 or 8A and operated under controls as disclosed in either or both of FIGS. 7 and 10.

Thus, according to the disclosure, a pneumatic adjustment system attachable to a support panel of a bed including a plurality of pneumatic adjustment modules, and inflation manifold, and a controller. The inflation manifold may be in pneumatic communication with each of the plurality of pneumatic adjustment modules. The inflation manifold may have a pump and a plurality of regulating valves. The controller may be in communication with the inflation manifold and arranged to control the operation of the pump and the plurality of regulating valves to selectively inflate the plurality of pneumatic adjustment modules.

For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature; may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components; and may be permanent in nature or may be removable or releasable in nature, unless otherwise stated. Similarly, the terms “supported,” “joined,” “mounted,” in all their forms, should be understood similarly to include directly or indirectly, permanently or impermanently, rigidly or resiliently, unless stated otherwise.

The articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements in the preceding descriptions. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional implementations that also incorporate the recited features. Furthermore, the terms “first,” “second,” and the like, as used herein do not denote any order, quantity, or importance, but rather are used to denote element from another.

Numbers, percentages, ratios, or other values stated herein are intended to include that value, and also other values that are “about” or “approximately” the stated value, as would be appreciated by one of ordinary skill in the art encompassed by implementations of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. For example, the terms “approximately,” “about,” and “substantially” may refer to an amount that is within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of a stated amount.

Further, it should be understood that any directions or reference frames in the preceding description are merely relative directions or movements. For example, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the orientation shown in FIG. 1. However, it is to be understood that various alternative orientations may be provided, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in this specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

Changes and modifications in the specifically described embodiments may be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims as interpreted according to the principles of patent law. The disclosure has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present disclosure are possible in light of the above teachings, and the disclosure may be practiced otherwise than as specifically described.

PNEUMATIC SYSTEM FOR ADJUSTABLE SUPPORT

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