MODULAR PNEUMATIC ACTUATION SYSTEM FOR ADJUSTABLE SUPPORT

Abstract

A pneumatic adjustment module is attachable to a support panel of a bed. The module has a base received on a support panel of the bed and a tilt panel attached to the base with a vertex hinge. A bladder is positioned between the base and tilt panel. The bladder may have a plurality of expansion segments. The bladder is pneumatically expandable from a deflated condition to an inflated condition. The tilt panel is substantially parallel to the base in the deflated condition and in the inflated condition has an effectively triangular expanded cross section with a vertex proximate the vertex hinge providing the tilt panel with a tilt angle with respect to the base.

Claims

1. A pneumatic adjustment module configured to removably attach to a mattress support panel of an adjustable bed, the pneumatic adjustment module comprising: a base configured to be received on the mattress support panel of the adjustable bed; a tilt panel attached to the base with a vertex hinge; a bladder positioned between the base and tilt panel, the bladder pneumatically expandable from a deflated condition to an inflated condition, wherein when the bladder is in the deflated condition, the tilt panel is substantially parallel to the base, and wherein when the bladder is in the inflated condition, the bladder has an effectively triangular cross section having a vertex proximate the vertex hinge and the tilt panel has a tilt angle with respect to the base.

2. The pneumatic adjustment module of claim 1, wherein the bladder comprises multiple expansion segments.

3. The pneumatic adjustment module of claim 2, wherein each one of the multiple expansion segments includes lobes interconnected for inflation of the one expansion segment.

4. The pneumatic adjustment module of claim 3, wherein the lobes of each one of the multiple expansion segments are interconnected by molded or bonded seams.

5. The pneumatic adjustment module of claim 1, wherein the tilt angle has a range from substantially 0 with the bladder in the deflated condition to a maximum angle, between 20 and 30 with the bladder in the inflated condition.

6. The pneumatic adjustment module of claim 1, wherein the tilt panel is flexible to allow contouring between the pneumatic adjustment module and an overlying mattress.

7. The pneumatic adjustment module of claim 6, wherein the tilt panel, the base, and the vertex hinge are formed of fiber reinforced plastic (FRP).

8. The pneumatic adjustment module of claim 6, wherein the vertex hinge is a living hinge joining the tilt panel to the base.

9. A pneumatic adjustment module configured to removably attach to a mattress support panel of an adjustable bed, the pneumatic adjustment module comprising: a base configured to be received on the mattress support panel of the adjustable bed; a tilt panel having a rectangular planar structure that defines an upper edge and a lower edge at opposing sides of the rectangular planar structure, the lower edge of the tilt panel attached along a corresponding portion of the base with a vertex hinge; and a bladder positioned between the base and the tilt panel, the bladder having a plurality of separate expansion segments overlapping between the base and the tilt panel, wherein the bladder is pneumatically expandable from a deflated condition with the tilt panel substantially parallel to the base in an inflated condition with the tilt panel positioned at a tilt angle with respect to the base.

10. The pneumatic adjustment module of claim 9, wherein with the bladder in the inflated condition, the bladder has a triangular cross section.

11. The pneumatic adjustment module of claim 9, wherein with the bladder in the inflated condition, the bladder has a vertex proximate and is spaced from the vertex hinge.

12. The pneumatic adjustment module of claim 9, wherein the base includes corresponding upper and lower edges that substantially align with the upper and lower edges of the tilt panel in the deflated condition, the upper and lower edges configured to extend laterally relative to the adjustable bed.

13. The pneumatic adjustment module of claim 9, wherein each one of the plurality of expansion segments includes lobes interconnected for inflation of the one expansion segment.

14. The pneumatic adjustment module of claim 13, wherein the lobes of each one of the multiple expansion segments are interconnected by molded or bonded seams.

15. The pneumatic adjustment module of claim 9, wherein the tilt angle has a range from substantially 0 with the bladder in the deflated condition to a maximum angle, between 20 and 30 with the bladder in the inflated condition.

16. The pneumatic adjustment module of claim 9, wherein the tilt panel is flexible to allow contouring between the pneumatic adjustment module and an overlying mattress.

17. The pneumatic adjustment module of claim 16, wherein the tilt panel, the base, and the vertex hinge are formed of fiber reinforced plastic (FRP).

18. The pneumatic adjustment module of claim 16, wherein the vertex hinge is a living hinge joining the tilt panel to the base.

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 implementations when considered in connection with the accompanying drawings wherein:

[0010] FIG. 1A is a pictorial representations of an embodiment of an adjustable bed employing implementations of modular pneumatic adjustment modules as lumbar supports and head tilt actuators with the pneumatic adjustment modules in the fully actuated position.

[0011] FIG. 1B is a pictorial representations of the adjustable bed with the modular pneumatic adjustment modules in the fully actuated position and the upper body support of the bed in the articulated position.

[0012] FIG. 1C is a side view representation of the adjustable bed with an overlying mattress shown in phantom with modular pneumatic adjustment modules as lumbar supports and head tilt actuators in the fully actuated position.

[0013] FIG. 2A is a pictorial representation of a first exemplary implementation of the modular pneumatic adjustment module.

[0014] FIG. 2B is a side view representation of the first exemplary implementation.

[0015] FIG. 2C is a rear pictorial representation of the first exemplary implementation.

[0016] FIG. 3A is a pictorial representation of an upper view of the pneumatic actuation system.

[0017] FIG. 3B is a lower pictorial view of the pneumatic actuation system.

[0018] FIG. 3C is a top view of the pneumatic actuation system and modular adjustment modules in varying longitudinal positions as lumbar support and head tilt actuators for two users.

[0019] FIG. 4 is a block diagram of the pneumatic actuation system components.

[0020] FIG. 5A is a lower pictorial partially exploded representation of first example positioning elements for the lumbar support and head tilt actuators.

[0021] FIG. 5B is an upper pictorial partially exploded representation of a second example positioning elements for the lumbar support and head tilt actuators.

[0022] FIGS. 6A and 6B are pictorial representations of the first exemplary implementation of the bladder segments in the modular pneumatic adjustment module in the inflated and deflated condition.

[0023] FIG. 7A is a pictorial representation of a second exemplary implementation of the modular pneumatic adjustment module.

[0024] FIG. 7B is a side view representation of the second exemplary implementation.

[0025] FIG. 7C is a rear pictorial representation of the second exemplary implementation.

[0026] FIGS. 8A and 8B are pictorial representations of the second exemplary implementation of the bladder segments in the modular pneumatic adjustment module in the inflated and deflated condition.

DETAILED DESCRIPTION

[0027] Embodiments shown in the drawings and described herein provide a modular pneumatic actuation system for lumbar support and head tilt in an articulating bed which may be implemented in a compact vertical space to present a minimum vertical profile for modern bed designs. Referring to the drawings, FIGS. 1A and 1B illustrate an exemplary embodiment of an adjustable bed 2 incorporating a pneumatic actuation system (described in greater detail subsequently) with pneumatic adjustment modules 3, employed as lumbar support modules 4 and head tilt actuators 6, in an actuated position. As seen in FIG. 1A in the unarticulated position of an upper body support panel 12 and FIG. 1B in an articulated position of the upper body support, a frame 10 having side rails 11a, 11b and end rails 13a, 13b carries the upper body support panel 12 and a seat support section 14. The upper body support panel 12 may be attached to the seat support section 14 with hinges 15 for rotation. A thigh support panel 16 may also be attached with hinges 17 to the seat support section and a lower leg support panel 18 attached with hinges 19 to the thigh support panel. The frame 10 may be supported by legs 20. Structure and actuation of the adjustable bed 2 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 8 is represented in FIG. 1C.

[0028] An example implementation of the pneumatic adjustment modules 3, for use as lumbar support modules 4 and head tilt actuators 6, is shown in detail in FIGS. 2A-2C. Each pneumatic adjustment module has a base 22 to be received on a support panel of the bed, the upper body support panel 12 for the example shown. A tilt panel 24 is attached to the base 22 with a vertex hinge 26. A bladder 28 positioned between the base and tilt panel has a plurality of expansion segments 30. Each expansion segment provides an effectively triangular expanded cross section, in an inflated condition, having a vertex 32 proximate the vertex hinge 26. The vertices of the segments may be adhesively joined or mechanically engaged by a spring clamp or similar device. Alternatively, the segments may be molded as a single element with joined seams at the vertices. In the example shown in FIGS. 2A-2C, three expansion segments are employed (FIGS. 2A and 2B are shown with transparent ends on the segments). Each expansion segment 30 is attached to a pneumatic inflation system (to be described in greater detail subsequently). Inflation of the expansion segments in the bladder 28 adjusts a tilt angle 34 between the base and tilt panel. 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 is substantially parallel to the base to an inflated condition placing the tilt panel at a desired tilt angle. Use of separate expansion segments 30 in the bladder 28 allows more precise angular control over a range of tilt angles from substantially 0 with the bladder uninflated to a maximum angle, between 20 and 30. In certain implementations, the segments 30 may be individually and sequentially inflated to provide incremental predetermined tilt positions within the overall tilt range. Additionally, the substantially triangular shapes of the individual segments 30 and overall triangular shape created in the bladder 28 during inflation of the segments provides even pressure over the lower surface of the tilt panel 24 for more stable support of the overlying mattress through the range of tilt angle.

[0029] The tilt panel 24 may be flexible as opposed to a rigid structure to allow contouring between the module and the overlying mattress for greater comfort. Fiber reinforced plastic (FRP) is employed in exemplary implementations. Additionally, the tilt panel 24 and base 22 may both be FRP and the vertex hinge 26 may be a living hinge of flexible FRP joining the tilt panel to the base. The bladder 28 may be adhesively bonded to the tilt panel and/or base or may be removably attached with hook and loop fasteners or comparable devices to allow for replacement or adjustment.

[0030] FIGS. 3A and 3B demonstrate and example inflation manifold 40 which is mounted on a bottom surface of the seat support section 14. Inflation conduits 42 extend from each of the bladders 28 of the respective lumbar support modules 4 and head tilt actuators 6 through apertures 43 in the seat support section 14 to one of a plurality of regulating valves 44 in the inflation manifold. Alternatively, the apertures 43 may be placed in the upper body support panel 12 proximate the positions of the lumbar support modules 4 and head tilt actuators 6. In example implementations, the inflation conduits are flexible to allow routing from the inflation manifold to the respective bladders 28. A pneumatic pump 46 provides pressurized air to the regulating valves 44. The regulating valves 44 are electronically controlled with a controller 48, as shown in FIG. 4, configured to provide inflation or deflation commands, responsive to user input on a remote 49, to each regulator valve for flow of pressurized air from the pneumatic pump 46 to the bladder in the respective lumbar support or head tilt actuator to increase the tilt angle or relief of pressure from the bladder to reduce the tilt angle. The remote 49 may be wirelessly connected to the controller 48 with WiFi or Bluetooth, or hardwired.

[0031] Each pneumatic adjustment module 3 is attached to a different regulating valve 44 in the example shown. This allows separate actuation/regulation of the two lumbar support modules 4 and/or the two head tilt actuators 6 on each side to provide separate positioning for the two separate users. The remote 49 and controller 48 may be configured to provide synchronized control of the two regulating valves for the lumbar support modules 4 or the two regulating valves for the head tilt actuators 6 to allow simultaneous tandem operation.

[0032] The structure of the pneumatic adjustment modules 3 allows attachment of the base 22 of the module to be positioned on the upper body support panel 12 as either a lumbar support module 4 or a head tilt actuator 6. Further, as seen in FIG. 3, the longitudinal position L1 and L2 (relative distance from the edge of the panel hinged at the seat support) of each of the lumbar support modules 4 or longitudinal position L3 and L4 of head tilt actuators 6 may be adjusted to match the height or torso length of an individual user for greatest comfort. In a dual configuration as shown in FIGS. 1A, 1B and 3C, placement of each set of modules, a lumbar support module 4 and a head tilt actuator 6, may be customized for the user on each side of the bed. In example implementations, the modules may be removable and adjustable through the use of an attachment mechanism such as hook and loop fasteners having lower moiety 21a mounted to the upper body support panel and upper moiety 21b mounted to a lower surface 23 of the module base 22 as seen in FIG. 5A or conventional bolt fasteners 27a extending from tabs 25 on the module base 22 through slots 29 in the upper body support panel 12 secured by adjustable nuts 27b on a lower surface of the upper body support panel as seen in FIG. 5B.

[0033] The segments 30 of the bladder 28 are shown in the inflated or expanded condition in FIG. 6A and in the deflated or contracted condition in FIG. 6B.

[0034] The modular form of the pneumatic adjustment modules 3 additionally allows use of the modules to provide thigh support or elevation without the thigh support panel being rotatable from the seat support section 14. A thigh elevation module 7 as represented in FIG. 4 elevates an overlying mattress providing the desired knee elevation without the necessity for rotatable hinges thigh support and foot panels. Additionally, in specific implementations, a pneumatic adjustment module 3 may be placed longitudinally aligned to provide elevation of the mattress to form a side pillow for comfort of side sleepers. The modular form of the pneumatic adjustment modules allows placement on a support panel for curved displacement of an overlying mattress at any desired position.

[0035] The individual segments in the plurality of segments 30 forming the bladder 28 may also include a plurality of lobes 50 interconnected for inflation of the segment as seen in FIGS. 7A-7C. The lobes 50 may be interconnected by molded or bonded seams 52. As in the initially described implementation, the vertices 32 of the segments may be adhesively joined or mechanically engaged by a spring clamp.

[0036] Alternatively, the segments may be molded as a single element with joined seams at the vertices. An example segment with the lobed configuration is shown in the inflated or expanded condition in FIG. 8A and in the deflated or contracted condition in 8B.

[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.