UNDER BASE INTEGRAL CLIMATE CONTROL FOR AN ARTICULATING BED

Abstract

An environmental control assembly has a case configured for attachment to a bottom surface of an articulation assembly. One or more inlet fans is attached to a first wall of the case. An inlet plenum receives air provided by the one or more fans and extends from the first wall to a central chamber. An outlet plenum extends from the central chamber to a second wall of the case. A first pair of outlet ports extends from the outlet plenum proximate the central chamber through side walls of the case and a second pair of outlet ports extends from the outlet plenum distal the central chamber through side walls of the case. A cylindrical flow diffuser is positioned in the outlet plenum between the side walls and controls airflow into the first pair of ports and second pair of ports, each of said outlet ports configured for attachment to one of a plurality of flexible air conduits.

Claims

1. An environmental control assembly comprising: a case configured for attachment to a bottom surface of an articulation assembly; one or more inlet fans attached to a first wall of the case, an inlet plenum receiving air provided by the one or more fans and extending from the first wall to a central chamber; an outlet plenum extending from the central chamber to a second wall of the case, and at least one first outlet port extending from the outlet plenum proximate the central chamber through side walls of the case; and, at least one second outlet port extending from the outlet plenum distal the central chamber through side walls of the case.

2. The environmental control assembly as defined in claim 2 wherein the at least one first outlet port comprises a first pair of outlet ports and the at least on second outlet port comprises a second pair of outlet ports; and, a cylindrical flow diffuser positioned in the outlet plenum between the side walls and controlling airflow into the first pair of ports and second pair of ports, each of said outlet ports configured for attachment to one of a plurality of flexible air conduits.

3. The environmental control assembly as defined in claim 2 wherein longitudinal positioning of the cylindrical airflow diffuser for equal flow into the proximate ports and distal ports is accomplished with a center axis of the cylindrical air diffuser at a first distance.

4. The environmental control assembly as defined in claim 3 wherein the first distance is between 30% and 45% of a distance between an axis of the proximate ports and an axis of the distal ports.

5. The environmental control assembly as defined in claim 1 further comprising a heating element supported in the central chamber between the inlet plenum and outlet plenum.

6. The environmental control assembly as defined in claim 5 wherein an upper cover and a lower cover of the case converge vertically between the inlet plenum and central chamber to further increase flow velocity of air provided by the one or more fans over the heating element.

7. The environmental control assembly as defined in claim 5 wherein the side walls of the case converge in the inlet plenum from the first end wall to the central chamber thereby increasing effective flow velocity of air provided by the one or more fans.

8. The environmental control assembly as defined in claim 5 wherein the heating element comprises a metal support folded with a curved leading edge, the heating element mounted to the upper cover with standoffs and a laminated copper heater circuit adhered to the metal support.

9. The environmental control assembly as defined in claim 8 wherein the radius of curvature of the leading edge spaces an upper flange and lower flange from the upper cover and lower cover forming an upper flow channel and a lower flow channel and the curvature of the leading edge is configured to smoothly transition flow of incoming air from the inlet plenum into the upper and lower flow channels.

10. The environmental control assembly as defined in claim 8 wherein the copper heater circuit is laminated inside a Kapton-Polyimide film sandwich.

11. The environmental control assembly as defined in claim 1 further comprising: at least one cooling unit having a thermoelectric device with an array of thermoelectric plates supported by a frame, a finned heatsink mounted to the frame contact with a hot side of the thermoelectric plates, said finned heatsink extending outward from a side wall of the case, a finned coldsink mounted to the frame in contact with a cold side of the thermoelectric plates, the coldsink extending into the inlet plenum in flow contact with air provide by the one or more inlet fans whereby in operation the thermoelectric device cools the coldsink thereby cooling the airflow in the inlet plenum.

12. The environmental control assembly as defined in claim 11 wherein the at least one cooling unit further comprises a heatsink fan mounted to a channel cover surrounding the finned heatsink, said channel cover attached to one of said side walls, said heatsink fan providing cooling air for efficiency of the thermoelectric device during operation.

13. The environmental control assembly as defined in claim 12 wherein the heatsink fan is angularly mounted to the channel cover to provide airflow with a longitudinal component across the finned heat sink.

14. The environmental control assembly as defined in claim 1 further comprising: a heating element having a metal support folded with a curved leading edge, the heating element mounted to the upper cover with standoffs and a laminated copper heater circuit adhered to the metal support, said heating element supported in the central chamber between the inlet plenum and outlet plenum; at least one cooling unit having a thermoelectric device with an array of thermoelectric plates supported by a frame, a finned heatsink mounted to the frame contact with a hot side of the thermoelectric plates, said finned heatsink extending outward from a side wall of the case, a finned coldsink mounted to the frame in contact with a cold side of the thermoelectric plates, the coldsink extending into the inlet plenum in flow contact with air provide by the one or more inlet fans whereby in operation the thermoelectric device cools the coldsink thereby cooling the airflow in the inlet plenum; a heatsink fan mounted to a channel cover surrounding the finned heatsink, said channel cover attached to one of said side walls; a control electronics printed circuit board (PCB) mounted in a compartment in the case, the PCB receiving AC power at an input and having a regulator circuit providing AC to DC power conversion and regulation of power ; a controller receiving temperature signals from an outlet plenum temperature sensor and user desired controls for ventilation and temperature on an input; a heater drive circuit receiving a heater element temperature and a heater control signal from the controller and providing a heater control output to the heater circuit; a cooling unit drive circuit receiving a cooler temperature from the cooling units and a cooler control signal from the controller and providing a cold plate power output to the thermoelectric device and heatsink fan; a fan control output provided by the controller through the regulator circuit to power the one or more inlet fans responsive to a user desired ventilation input.

15. An under base integral climate control system for an articulating bed, the system comprising: an environmental control assembly attached to a bottom surface of an articulation assembly and having a case; one or more inlet fans attached to a first wall of the case, an inlet plenum extending from the first wall to a central chamber; an outlet plenum extending from the central chamber to a second wall of the case, and a plurality of outlet ports extending from the outlet plenum through side walls of the case; a plurality of flexible air conduits extending from the plurality of outlet ports to connection flanges on bottom surfaces of support panels of the articulation assembly; a plurality of mattress feeder hoses in flow communication with the plurality of flexible air conduits, said mattress feeder hoses extending through tube channels in a mattress supported on the articulation assembly; an air distribution mesh layer supported in a relief in an upper surface of the mattress, said relief surrounded by a barrier preventing peripheral flow out of the mesh layer to enhance the desired mattress surface ventilating, heating and cooling effects.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] These and other features and advantages of the present invention will be better understood by reference to the following detailed description of exemplary embodiments when considered in connection with the accompanying drawings wherein:

[0010] FIG. 1 is a pictorial representation of an articulating bed in which the presently described implementations may be employed;

[0011] FIG. 2 is a bottom pictorial view of the articulation assembly and the environmental control assembly;

[0012] FIG. 3 is a pictorial view of the environmental control assembly

[0013] FIG. 4 is a pictorial view of the environmental control assembly with the lower cover removed;

[0014] FIG. 5 is a bottom view of the environmental control assembly with the lower cover removed;

[0015] FIG. 6 is a side section view of the environmental control assembly;

[0016] FIG. 7 is a detailed pictorial view of the heating element;

[0017] FIG. 8 is a detailed pictorial view of a cooling unit;

[0018] FIG. 9 is a detailed exploded pictorial view of the thermoelectric device with associated heat sink and cold sink

[0019] FIG. 10 is a block diagram representation of a control electronics printed circuit board for the system;

[0020] FIG. 11 is a detailed pictorial view of a flexible conduit connection flange for use in the exemplary implementation;

[0021] FIG. 12 is a detailed pictorial view of a mattress feeder hose connection flange;

[0022] FIG. 13 is an exploded pictorial view of the articulation assembly, mattress and mesh insert demonstrating air distribution from the environmental control assembly; and,

[0023] FIG. 14 is a detailed section pictorial view showing the ovaloid reliefs in the mattress for the mattress feeder hoses.

DETAILED DESCRIPTION

[0024] Implementations shown in the drawings and described herein provide selectable environmental control for an articulating bed with air circulation, heating and cooling capability. Referring to the drawings, FIG. 1 shows an exemplary articulating bed in which an implementation of the under base integral climate control system may be employed. A mattress 10 is supported on an articulating assembly 12. A base 14 includes a frame and articulating actuators for the articulating assembly 12. The articulating assembly 12 has a seat section 16 which remains substantially horizontal, an upper body support panel 18 hinged to the seat section which articulates over a range of motion from a horizontal position to an elevated position, as shown, a thigh support panel 20 hinged to the seat section which articulates over a range of motion from a horizontal position to an elevated position, as shown, and a lower leg support panel 22 attached to the thigh support panel.

[0025] FIG. 2 shows the articulating assembly 12 in an unarticulated position with the base 14 and all associated actuation elements removed for clarity. An environmental control assembly 24 is attached to a bottom surface 26 of the seat section 16. Flexible air conduits 28 (represented in phantom) extend from outlet ports, generally designated as element 30, on the environmental control assembly 24 to connection flanges 32 for air distribution. In the exemplary implementation, two connection flanges are located in the upper body support panel and two connection flanges are located in the thigh support panel. In alternative implementations, locations of the connection flanges may be altered to the seat section 16 or lower leg support panel 22.

[0026] Details of the environmental control assembly 24 are seen in FIGS. 3-6. The environmental control assembly 24 includes a case 34 having an inlet plenum 36 and an outlet plenum 38. The case 34 is attached to the bottom surface 26 of the seat section 16 with flanges or tabs 35 using suitable fasteners. A heating element 40 is supported in a central chamber 42 between the inlet plenum 36 and outlet plenum 38. One or more inlet fans 44 are positioned in a first end wall 46 to direct airflow into the inlet plenum 36. For the exemplary implementation, two cooling units 48, to be described in greater detail subsequently, extend through side walls 50 of the inlet plenum 36.

[0027] As best seen in FIG. 5, the side walls 50 converge laterally in the inlet plenum 36 from the first end wall 46 to the central chamber 42 thereby increasing effective flow velocity of air provided by the one or more fans 44 through the inlet plenum 36 and into the central chamber 42. As best seen in FIG. 5, an upper cover 52 and lower cover 54 of the case 34 converge vertically between the inlet plenum 36 and central chamber 42 to further increase flow velocity over the heating element 40. The upper cover 52 and lower cover 54 further converge vertically between the central chamber 42 and second end wall 56. The second end wall 56 is convex with respect to the outlet plenum 38 for enhanced flow distribution into the ports 30. Each of the ports 30 has an extending neck 31 with a bead 33 configured to be received in corrugations of the flexible conduit 28 to allow connection with out supplemental fasteners.

[0028] A cylindrical flow diffuser 58 is positioned in the outlet plenum 38 between the side walls 50 to control airflow into ports 30a proximate to the central chamber 42 and ports 30b distal from the central chamber 42. Longitudinal (in the flow direction from the central chamber to the outlet plenum) positioning of the cylindrical airflow diffuser 58 for equal flow into the proximate ports 30a and distal ports 30b is accomplished with a center axis 60 of the cylindrical air diffuser 58 at a first distance 62 between 30% and 45% of the distance 64 between axis 66 of the proximate ports 30a and the axis 68 of the distal ports 30b. For the exemplary implementation, the proximate ports 30a provide airflow to the connection flanges 32 on the left side of the bed while the distal ports 30b provide airflow to the connection flanges 32 on the right side of the bed. Modifying flow between the proximate ports 30a and distal ports 30b (left and right sides of the bed) may be accomplished by longitudinal translation of the cylindrical flow diffuser 58. Modifying flow between connection flanges on the upper body support panel 18 and thigh support panel 20 may be accomplished by lateral translation of the cylindrical flow diffuser 58.

[0029] A control electronics printed circuit board (PCB) 70 is mounted in a compartment 72 in the case 34. For the exemplary implementation, the compartment 72 is formed by the vertical convergence of the lower cover. Side walls 50 incorporate vents 74 for cooling of the PCB 70. PCB70 is interconnected with the one or more fans 44, the cooling units 48, the heating element 40 and temperature sensors as will be described in greater detail subsequently.

[0030] The heating element 40 has a metal support 76 folded with a curved leading edge 78 as seen in FIG. 7. The heating element 40 is mounted to the upper cover 52 with standoffs 80 (seen in FIG. 6). The radius of curvature of the leading edge 78 spaces an upper flange 82 and lower flange 84 from the upper cover 52 and lower cover 54 forming upper flow channel 86 and lower flow channel 88. The curvature of the leading edge is configured to smoothly transition flow of incoming air from the inlet plenum 36 into the upper and lower flow channels 86, 88. The metal support 76 in the exemplary implementation is formed from aluminum and heating element 40 has a copper heater circuit 90 laminated inside a Kapton-Polyimide film sandwich that is adhered to the metal support.

[0031] Each of the two cooling units 48, seen in detail in FIG. 8, incorporates a Peltier thermoelectric device 92 as seen in FIG. 9. The thermoelectric device 92 has an array of thermoelectric plates 94 supported by a frame 96. A finned heatsink 98 is mounted to the frame 96 in contact with a hot side of the thermoelectric plates 94 while a finned coldsink 102 is mounted to the frame in contact with a cold side of the thermoelectric plates. The coldsink 102 extends into the inlet plenum in flow contact with air provide by the one or more inlet fans. In operation the thermoelectric device 92 cools the coldsink 102 thereby cooling the airflow in the inlet plenum 36. A heatsink fan 104 is mounted to a channel cover 106 surrounding the finned heatsink 98 and attached to the side wall 50 to provide cooling air for efficiency of the thermoelectric device during operation. In the exemplary embodiment, the heatsink fan 104 is angularly mounted to the channel cover 106 to provide airflow with a longitudinal component across the finned heat sink 98.

[0032] The PCB 70 receives AC power at an input 108 provides power and control for the one or more inlet fans 44, the heating element 40 and the cooling units as shown in the block diagram of FIG. 10. A regulator circuit 110 provides AC to DC power conversion and regulation for power to the PCB components, fans, heater and Peltier thermoelectric device. A controller 112 which may be a microprocessor or dedicated application-specific integrated circuit (ASIC) or gate array receives temperature signals from an outlet plenum temperature sensor 114 and user desired controls for ventilation and temperature on input 116 which may be hardwired to a hand controller or a wireless receiver from a remote control or cellular phone interface. A heater drive circuit 118 receives a heater element temperature 120 and a heater control signal 122 from the controller 112 and provides an appropriate heater control output 124 to the heater circuit 90. Similarly, a cooling unit drive circuit 126 receives a cooler temperature 128 from the cooling units 48 and a cooler control signal 130 from the controller 112 and provides an appropriate cold plate power output 132 to the Peltier thermoelectric device 92 and heatsink fans 104. A fan control output 134 is provided by the controller 112 through the regulator circuit 110 to power the one or more inlet fans 44 response to a user desired ventilation input.

[0033] A detailed view of an example of one of the plurality of flexible conduit connection flanges 32 of the exemplary implementation is shown in FIG. 11. A central inlet connection neck 140 extends from a circular mounting flange 142 configured to be attached to a bottom surface of a support panel of the articulating assembly 12 to provide a flow aperture 144. Similar to the ports 30, a bead 146 surrounding the circumference of the neck 140 is configured to be received in corrugations of the flexible conduit 28 to allow connection with out supplemental fasteners.

[0034] FIG. 12 shows a detailed view of an example of one of a plurality of mattress feeder hose connection flanges 148 in the exemplary implementation. An outlet connection neck 150 extends from a circular mounting flange 152 configured to be attached to a top surface of a support panel of the articulating assembly 12 concentric at the flow aperture 144 with an adjacent flexible conduit connection flange 32. The outlet connection neck 150 employs dimpled beads 153 on an internal surface to receive and engage corrugations in a mattress feeder hose 154 (seen in FIG. 13). The combined mattress feeder hose connection flange 148 and flexible conduit connection flange 32 provide flow communication from the flexible conduits 32 to the mattress feeder hoses 154.

[0035] As seen in FIGS. 13 and 14, the mattress feeder hose connection flanges 148 (located in the upper body support panel 18 and thigh support panel 20 of the articulating assembly 12 in the exemplary implementation) each receive a mattress feeder hose 154 which extends upward to be received through tube channels 156 in the mattress 10. The mattress 10 includes a relief 158 in a top surface into which an air distribution mesh layer 160 is inserted to distribute air received through the mattress feeder hoses 154. The relief 158 is surrounded by a barrier 162 preventing peripheral flow out of the mesh layer to enhance the desired mattress surface ventilating, heating and cooling effects. The mattress 10 with mesh layer 160 may be inserted in a fabric sock (not shown) to restrain the mesh layer on the mattress.

[0036] To facilitate unhindered articulation of the mattress 10 with articulation of the upper body support panel 18 or thigh support panel 20, the tube channels 156 have an ovaloid cross section as shown in FIG. 13. The ovaloid shape allows translation of the mattress feeder hoses 154 longitudinally in the mattress during articulation to avoid binding.

[0037] Having now described various embodiments of the invention in detail as required by the patent statutes, those skilled in the art will recognize modifications and substitutions to the specific embodiments disclosed herein. Such modifications are within the scope and intent of the present invention as defined in the following claims.