Recessed air pump

Abstract

A pump is disposed within an inflatable chamber of an inflatable bed. The pump is recessed within the inflatable chamber and is offset from a faceplate, which in turn is connected to a portion of the inflatable bed. This arrangement results in less strain applied onto a peripheral panel of the inflatable chamber thereby maintaining the structural integrity of the inflatable bed.

Claims

1. An inflatable product assembly comprising: an inflatable product having a pair of spaced-apart panels and a peripheral panel joining the spaced-apart panels; an assembly comprising: an inflation pump recessed within the inflatable product, the inflation pump including a housing containing a motor and a fan, wherein the entire housing of the inflation pump is spaced inwardly away from the peripheral panel; and a connecting assembly coupled to the inflation pump at a location inward of the peripheral panel and to the peripheral panel, the connecting assembly defining an air pathway between the inflation pump and a vent in communication with the surrounding environment; and a support device coupled to one of the pair of spaced-apart panels and coupled to the inflation pump, the support device configured to support at least a portion of the weight of the inflation pump.

2. The inflatable product assembly of claim 1, wherein the pair of spaced-apart panels comprise upper and lower sheets, and the support device is a tension belt having a pair of ends fixed to the upper sheet and a body wrapped around the inflation pump in a U-shaped configuration.

3. The inflatable product assembly of claim 1, wherein the pair of spaced-apart panels comprises upper and lower sheets, and the support device is a tension rope coupled to the upper sheet and the inflation pump.

4. The inflatable product assembly of claim 1, wherein the pair of spaced-apart panels of the inflatable product comprise: an upper sheet including an upper layer, a lower layer and an air chamber defined between the upper layer and the lower layer; and a lower sheet spaced from the upper sheet and joined to the upper sheet via the peripheral panel.

5. The inflatable product assembly of claim 4, wherein the inflation pump is supported by the lower layer of the upper sheet via the support device.

6. The inflatable product assembly of claim 5, wherein the support device is a tension belt having a pair of ends fixed to the upper sheet and a body wrapped around the inflation pump in a U-shaped configuration.

7. The inflatable product assembly of claim 5, wherein the support device is a tension rope coupled to the upper sheet and the inflation pump.

8. The inflatable product assembly of claim 1, wherein the inflatable product assembly is an inflatable bed.

9. An inflatable product assembly comprising: an inflatable product comprising a lower sheet, an upper sheet spaced from the lower sheet, and a peripheral panel joining the upper and lower sheets to define a main air chamber, the lower sheet including an upper layer, a lower layer, and a secondary air chamber defined between the upper layer and the lower layer; an assembly comprising: an inflation pump coupled to the upper layer of the lower sheet and recessed within the main air chamber, the inflation pump including a housing containing a motor and a fan, wherein the entire housing of the inflation pump is spaced inwardly away from the peripheral panel; and a bent connecting assembly coupled to the inflation pump at a first end located inward of the peripheral panel and extending outwardly toward the peripheral panel at a second end opposite the first end, the bent connecting assembly defining an air pathway between the inflation pump and a vent in communication with the surrounding environment.

10. The inflatable product assembly of claim 9, wherein the bent connecting assembly comprises a spacer tube having a 90 degree bend.

11. The inflatable product assembly of claim 9, wherein the upper sheet comprises an upper layer, a lower layer and an additional secondary air chamber positioned between the upper layer and the lower layer.

12. The inflatable product assembly of claim 11, wherein the bent connecting assembly is coupled to a user interface, and the user interface is coupled to the peripheral panel.

13. The inflatable product assembly of claim 9, wherein the inflatable product assembly is an inflatable bed.

14. An inflatable product assembly, comprising: an inflatable product including: an upper sheet; a lower sheet; and a peripheral panel coupling the upper sheet and the lower sheet and defining an inflatable chamber; an assembly comprising: an inflation pump recessed within the inflatable chamber, the inflation pump including a housing containing a motor and a fan, wherein the entire housing of the inflation pump is spaced inwardly away from the peripheral panel; and a connecting assembly coupled to the inflation pump at a location inward of the peripheral panel and coupled to the peripheral panel of the inflatable product, the connecting assembly defining an air pathway between the inflation pump and a vent in communication with the surrounding environment.

15. The inflatable product assembly of claim 14, wherein the upper sheet includes an upper layer, a lower layer, and a secondary air chamber positioned between the upper layer and the lower layer.

16. The inflatable product assembly of claim 15, wherein the connecting assembly further includes a support device coupled to the lower layer of the upper sheet and configured to support at least a portion of the weight of the inflation pump.

17. The inflatable product assembly of claim 16, wherein the support device is a tension belt having a pair of ends fixed to the upper sheet and a body wrapped around the inflation pump in a U-shaped configuration.

18. The inflatable product assembly of claim 16, wherein the support device is a tension rope coupled to the upper sheet and the inflation pump.

19. The inflatable product assembly of claim 14, wherein the connecting assembly comprises a spacer tube having a 90 degree bend.

20. The inflatable product assembly of claim 14, wherein the inflatable product is an inflatable bed.

21. The inflatable product assembly of claim 14, further comprising a user interface coupled to the peripheral panel and having a grille over the vent, the inflatable product assembly having: an inflate mode in which air is directed through the grille of the user interface, through the air pathway of the connecting assembly, and through the pump to inflate the inflatable product; and a deflate mode in which air is discharged from the pump, through the air pathway of the connecting assembly, and through the grille of the user interface to deflate the inflatable product.

22. The inflatable product assembly of claim 14, wherein an actuator is positioned within the connecting assembly and extends to an airflow selector to direct airflow through the inflatable product assembly.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:

(2) FIG. 1 is a perspective view of an inflatable bed with a portion of the inflatable bed cut away;

(3) FIG. 2 is a perspective view of an alternate embodiment of the inflatable bed of FIG. 1 with a portion of the inflatable bed cut away;

(4) FIG. 3 is a perspective view of an inflation pump suitable for use in the inflatable beds of FIGS. 1 and 2;

(5) FIG. 4 is a cross sectional view of the inflation pump of FIG. 3;

(6) FIG. 5 is an exploded view of inflation pump of FIG. 3;

(7) FIG. 6 is a perspective view of an alternate embodiment of the inflation pump of FIG. 3;

(8) FIG. 7 is a cross sectional view of the inflation pump of FIG. 6;

(9) FIG. 8 is an exploded view of inflation pump of FIG. 6;

(10) FIG. 9 is a perspective view of an alternate embodiment of the inflatable bed of FIG. 1 with a portion of the inflatable bed cut away;

(11) FIG. 10 is a perspective view of an alternate embodiment of the inflation pump of FIG. 3 suitable for use in the inflatable bed of FIG. 9;

(12) FIG. 11 is a cross sectional view of the inflation pump of FIG. 10; and

(13) FIG. 12 is an exploded view of inflation pump of FIG. 10.

(14) Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate exemplary embodiments of the invention and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION

(15) The present disclosure provides an assembly 4 (with alternative embodiments also shown as 4 and 4) having a pump 2 that is disposed within a main inflatable air chamber 14 of an inflatable bed 1. The pump 2 is recessed within the inflatable chamber 14 and is coupled a connecting assembly 3, which in turn is connected to a user interface 23 welded or otherwise fixed to peripheral panel 13 of inflatable bed 1. The connecting assembly 3 is configured to convey air to and from pump 2 and exterior user interface 32, and also includes support device 7 which transfers the weight of pump 2 to portions of the inflatable bed 1 other than the peripheral panel 13, such as the upper or lower sheets 11, 12. In this way, connecting assembly 3 reduces the strain applied to the peripheral panel 13 of the inflatable chamber 14. This promotes the structural integrity and longevity of the inflatable bed 1.

(16) Referring first to FIGS. 1 and 2, an inflatable bed 1 is shown. The inflatable bed 1 comprises an upper sheet 11, a lower sheet 12 spaced from the upper sheet 11 to form a gap therebetween, and a side wall or peripheral panel 13 coupling upper sheet 11 and lower sheet 12 and spanning the gap. Upper sheet 11, lower sheet 12, and peripheral panel 13 cooperate to define an inflatable chamber 14. Inflatable bed 1 further comprises an inflation pump 2 recessed within inflatable chamber 14 of inflatable bed 1 and a connecting assembly 3 that connects to inflatable bed 1 and to inflation pump 2, as further described below.

(17) In the illustrated embodiment, upper sheet 11 includes an upper layer 11A, a lower layer 11B, and an air chamber 11C disposed between upper layer 11A and lower layer 11B. Upper layer 11A, lower layer 11B, and air chamber 11C enhance the comfort level of the inflatable bed 1 by providing additional cushioning to a user that is positioned on top of upper sheet 11. Lower sheet 12 may have the same structure as upper sheet 11 (i.e., panels with an air chamber disposed between the panels). In alternative embodiments, both upper sheet 11 and lower sheet 12 may be single-layer structures or may have other multilayer constructions, as required or desired for a particular application.

(18) FIGS. 1 to 5 disclose a first embodiment of assembly 4 comprising an inflation pump 2 coupled to connecting assembly 3. Inflation pump 2 includes a housing 21 and an upper cover 22 coupled to housing 21. Housing 21 contains the components of pump 2, including motor 6 and fan 5, which is selectively driven by motor 6 to convey air between the ambient area outside inflatable bed 1 and the interior of inflatable chamber 14. As best seen in FIG. 5, fan 5 may be supported within a fan housing 5A and substantially enclosed by fan housing cover 5B.

(19) Connecting assembly 3 shown in FIGS. 3-5 includes a straight spacer tube 31 and a support device 7 (FIGS. 1 and 2), which interface with user interface 32 as described herein. Together, these structures act to substantially isolate the weight of assembly 4 from peripheral panel 13, shifting such weight onto support device 7 and upper sheet 11, as described in further detail below. Connecting assembly 3 may further include components which enable the use of pump 2 by operation of user interface 32, such as switch 321, corded plug 323, and inflate/deflate control knob 23 (FIG. 6), as also described below.

(20) As best shown in FIGS. 1 and 2, spacer tube 31 provides a gap between the pump 2 and user interface 32. An outer end of straight spacer tube 31 is threadably connected to user interface 32, while the inner end of straight spacer tube 31 is threadably connected to upper pump cover 22 of inflation pump 2. However, it is within the scope of the present disclosure that other suitable connections between straight spacer tube 31 and user interface 32 and upper pump cover 22 may be used (e.g., fasteners, welding, adhesives, collars, clamps, gaskets, or any other substantially fluid-tight attachment).

(21) Spacer tube 31 also provides an air pathway between pump 2 and the ambient air around inflatable bed 1. Further, spacer tube 31 has an inflate/deflate control knob 23 connected thereto, which extends into the interior of housing 21 of inflation pump 2. Knob 23 may be rotated to impart a corresponding rotation to airflow selector 24 (FIG. 7), which may selectively align airflow selector 24 with one of two apertures formed in fan housing cover 5B (FIG. 5). This alignment configures pump 2 into inflate or deflate modes by shifting the air pathway engaged by fan 5. Spacer tube 31 may also provide a pathway for a portion of the cord of corded plug 323 (FIGS. 5 and 6).

(22) User interface 32 is welded or otherwise fused in a fluid-tight manner (e.g., fasteners, clips, etc.) to peripheral panel 13 of inflatable bed 1. User interface 32 includes switch 321, which is electrically connected to motor 6 of pump 2 and operable to switch fan 5 into an on configuration to thereby activate inflation pump 2, and an off configuration in which fan 5 does not rotate and inflation pump 2 is thereby inactive. An air grille is formed in user interface 32, as shown, in order to allow air to be drawn inwardly through spacer tube 31 and pump 2 to inflatable chamber 14 when pump 2 is on and inflate/deflate control knob 23 is in inflate mode. Similarly, air discharges from inflatable chamber 14 via grille in user interface 32 when pump 2 is on and inflate/deflate control knob 23 is in deflate mode.

(23) User interface further includes the outer, user-operable portion of inflate/deflate control knob 23, which can be rotated by the user to switch between configurations of inflate/deflate control knob 23 as described herein. A power connector, in the form of a corded plug 323 adapted to be connected to an external power source, passes through a fluid-tight clamp 322 connected to user interface 32.

(24) Turning to FIGS. 1 and 2, support device 7 of connector assembly 3 is coupled at its upper end to upper sheet 11 and at its lower end to inflation pump 2. Exemplary support devices 7 include a tension belt 34 as shown in FIG. 1 (e.g., made of PVC) and a tension rope 35 as shown in FIG. 2. Tension belt 34 (FIG. 1) has opposing ends that are coupled (e.g., by welding) to upper sheet 11, with a body of belt 34 forming a U-shaped structure between the opposing ends which wraps around housing 21 and thereby functions to hold inflation pump 2 in a substantially fixed position within inflatable chamber 14 when inflatable mattress 1 is inflated. Tension rope 35 (FIG. 2) is similarly coupled to upper sheet 11 at its upper end (e.g., via a connection point welded or otherwise attached to upper sheet 11) and to housing 21 at its lower end, such that pump 2 is similarly held in a substantially fixed position within inflatable chamber 14 when inflatable mattress 1 is inflated.

(25) In an exemplary embodiment, support device 7 (e.g., tension belt 34 or tension rope 35) is connected to the lower layer 11B of the upper sheet 11. In use, the multilayer structure of upper sheet 11 provides additional support to support device 7 such that when the weight of inflation pump 2 is transferred to lower layer 11B via support device 7, upper sheet 11 and the support device will not collapse or form a concavity in the sleeping surface of upper layer 11A. Moreover, air chamber 11C provides a buffer between the sleeping surface of upper layer 11A and the attachment point on lower layer 11B, such that the presence of support device 7 will not be detectable to a user of inflatable bed 1.

(26) Thus, support device 7 supports the weight of inflation pump 2 primarily via upper sheet 11, rather than peripheral panel 13 and inflatable bed 1. This support provided by support device 7 assists in preventing undue stress or damage to peripheral panel 13 caused by the weight of inflation pump 2, while still allowing the user interface 32 and air intake to be applied to peripheral panel 13. That is, the weight of inflation pump 2 is distributed on support device 7 which transfers the weight to upper sheet 11, such that support device 7 reduces the amount of strain applied onto peripheral panel 13 thereby reducing stresses at the interface between peripheral panel 13 and user interface 32. In this way, damage or separation at such interface is prevented. A potential source of leak development in inflatable beds with integrated pumps is thereby eliminated, such that the service life of inflatable bed 1 can effectively be extended. In addition, distribution of the weight of inflation pump 2 on support device 7, and the location of pump 2 within air chamber 14 and spaced away from user interface 32, reduces the noise of inflation pump 2 during inflation or deflation operations.

(27) Referring now to FIGS. 6-8, an alternate embodiment of assembly 4 is shown and includes inflation pump 2 and connecting assembly 3. Assembly 4 has a similar structure as assembly 4, and analogous structures used in both designs have common functions and common reference numbers, except as otherwise specifically designated herein.

(28) However, assembly 4 differs from assembly 4 in that connecting assembly 3 comprises a nut 31 in place of spacer tube 31. As best shown in FIG. 7, user interface 32 has an inner flange engaged by a corresponding flange formed on an outer end of nut 31. The inner portion of nut 31 is threadably engaged with the correspondingly threaded male extension formed in cover 22. As nut 31 is tightened into cover 22, the inner surface of user interface 32 is drawn tight against the abutting outer surface of the extension formed on cover 22 (as shown in FIG. 7), such that user interface 32 forms a fluid-tight connection with upper pump cover 22 via nut 31. As compared to spacer tube 31, nut 31 is shorter and uses less material, such that nut 31 can be employed to provide a more compact assembly 4, which in turn, reduces its weight and any associated strain applied onto peripheral panel 13.

(29) Referring now to FIGS. 9-12, a further alternate embodiment of inflatable bed 1 is shown including assembly 4. Assembly 4 has similar structures and functions as assemblies 4, 4, and analogous structures used in both designs have common functions and common reference numbers, except as otherwise specifically designated herein.

(30) Assembly 4 includes inflation pump 2 threadably coupled to bent spacer tube 33 of connecting assembly 3 via pump cover 22, in a similar fashion to assembly 4 described in detail above with respect to straight spacer tube 31. A user interface 32, also described above, is threadably coupled to a bent spacer tube 33. In the illustrated embodiment, bent spacer tube 33 forms a 90 degree bend such that the longitudinal axis of the inner end (i.e., the end attached to pump cover 22) is perpendicular to the longitudinal axis of the outer end (i.e., the end attached to user interface 32). However, it is contemplated that in alternate embodiments, other suitable degree turns may be used. Although threaded engagement is used to create a fluid tight connection between the respective ends of spacer tube 33 and user interface 32 and upper pump cover 22 of inflation pump 2, it is within the scope of the present disclosure that alternate coupling methods and structures may be used as required or desired, as discussed above with respect to assembly 4.

(31) Referring to FIG. 11, spacer tube 33 contains inflate/deflate control knob 23 which is operably connected to airflow selector 24 via a connecting rod 26 and a conical gear 25. Inflate/deflate control knob 23 is coupled to user interface 32 and can be rotated by the user of the inflatable bed 1, similar to inflate/deflate control knob 23 described above with respect to assembly 4 (FIG. 3). As inflate/deflate control knob 23 is rotated, connecting rod 26 transmits the rotation to conical gear 25, which in turn transmits the rotation to airflow selector 24. In this manner, inflate/deflate control knob 23 can be used to switch pump 2 between inflation and deflation modes as described above with respect to inflate/deflate control knob 23, even though the axis of rotation of inflate/deflate control knob 23 is skewed with respect to the axis of rotation of airflow selector 24.

(32) As shown in FIG. 9, inflation pump 2 is disposed on lower sheet 12. Similar to upper sheet 11 as previously described, lower sheet 12 of the inflatable bed 1 can have a double-layer structure. That is, lower sheet 12 comprises an upper layer 12A and a lower layer 12B with an air chamber 12C between the upper and lower layers 12A, B.

(33) Inflation pump 2 is flexibly but firmly coupled to upper layer 12A of lower sheet 12 so that inflation pump 2 is supported from underneath within air chamber 14 of inflatable bed 1. In one embodiment, inflation pump 2 is fixed to lower sheet 12 via an adhesive 36 (e.g., tape), which ensures the stability of the connection between inflation pump 2 and inflatable bed 1 during use, transport and storage. However, it is within the scope of the present disclosure that other coupling means may be used, such as fasteners, couplers, etc. Similar to assemblies 4, 4 described above, supporting the weight of pump 2 on lower sheet 12 avoids undue stress upon, and potential damage to, peripheral panel 13. Further, the fixed connection between pump 2 and lower sheet 12 avoids relative movement therebetween, thereby avoiding damage to lower sheet 12 due to the friction between inflation pump 2 and lower sheet 12. In this way the arrangement of assembly 4 extends the service life of inflatable bed 1. Furthermore, the weight of inflation pump 2 is distributed about lower sheet 12, and pump 2 is disposed within air chamber 14, such that noise during inflation or deflation of inflatable bed 1 is reduced.

(34) For all three assemblies 4, 4, 4, user interface 32 is welded on to peripheral panel 13 of inflatable bed 1 and includes switch 321 to activate inflation pump 2, and includes corded plug 323 and an air grille as also described above with respect to assembly 4. In this way, assemblies 4, 4 and 4 are visually indistinguishable from the user's perspective when inflatable bed 1 is inflated.

(35) To produce inflatable bed 1 with assembly 4, 4, or 4, user interface 32 is welded to peripheral panel 13, and inflation pump 2 is then connected to user interface 32 through spacer tubes 31 or 33, or through nut 31. Advantageously, this production modality simplifies the process since welding user interface 32 to the adjacent peripheral panel is simpler than welding an entire pump assembly to such peripheral panel. Once the user interface 32 is in place, inflation pump 2 is connected to connecting assembly 3, which in turn is connected to peripheral panel 13 of inflatable bed 1 as described in detail herein with respect to the various embodiments of FIGS. 1-12. To disassemble assembly 4, 4, or 4, inflation pump 2 can be detached from the connection point between spacer tube 31 or 33 (or nut 31) and upper pump cover 22, or at the connection point between spacer tube 31 or 33 (or nut 31) and user interface 32, and then removed from the inflatable chamber 14 of inflatable bed 1. Thus, if problems are detected in inflation pump 2 after assembly and connection of inflation pump 2 to peripheral panel 13, a user can easily remove, disassemble, and replace inflation pump 2. This is a simpler remedy than removing a welded-on pump assembly.

(36) Although the present disclosure is made in the context of inflatable bed 1, it is contemplated that other inflatable structures may also be used in conjunction with assemblies 4, 4 and 4. Any inflatable product with a pump integrated into the inflatable chamber thereof may benefit from the present designs. Examples of such products include inflatable spas, inflatable furniture items such as chairs and sofas, and the like.

(37) While this invention has been described as having exemplary designs, the present disclosure can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.