.. .
`~-
`:1 E =
`E i EPatterson :1: 11121111311, en.
`- E 3 =12“) Rand Tower
`”i fi 3;— i525“ Marquette Avenue South
`5 E3. :Minnemneapofis Minnesota 55402-1314
`3 i 3 Telephone:
`[6121349—55'40
`E;
`facsimile:
`[61‘2} 349-926-151
`
`'
`
`55153”
`
`is
`
`Wimp” fl
`111111
`@fljflflfl
`Attorney Docket No. tsetse-user
`
`APPLICATIUN TRANSMITTAL
`
`Box PATENT APPLICATION
`
`Assistant Commissioner for Patents
`
`Washington, 11C. 2111231
`
`for:
`
`Transmitted herewith for filingis the patent application of
`
`INEFENTDMS}: James Edwin Gift-t Paul James leflahonetF
`
`FDR: MPEDVED VALVE ENCLOSURE ASSEMBLY
`
`Enclosed are:
`
`{X}
`
`[X]
`[
`1
`[
`I
`
`[
`
`]
`
`Seven 6’} sheets of drawings (Figs. 1-11}.
`
`An assignment of the invention to Select Comfort Corporation.
`Certified cop-flies} of a
`application.
`_An Information Disclosure Statement.
`
`A verified statement to establish small entity status under 3? C.F.R.
`
`gs 1.9 and 1.2a.
`
`[fl
`
`Declaration for United States Patent Application.
`
`-__-
`
`fl
`
`1
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`i=5-
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`The Efling fee has beencalculated as shown below:
`
`FOR:
`
`3.1:. Fl! .1-‘1 1
`
`H11. l-‘E'l'ltfl
`
`135:5
`
`BASIC FEE
`
`TOTAL (:1 AIMS
`
`_
`
`3-2-20 =
`
`lNlJIliP Cl AIMS
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`12
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`ll Ihe difference is less than zero. enter ”CI”.
`
`Presence of Multiple
`Dependent Claim
`
`TOTAL
`
`DR
`
`TOTAL
`
`5L1?
`
`+260
`
`Petitioner Tempur Sealy — E11. 1002, p. 1
`
`
`~-
`:1 E =
`E i EPatterson :1: 11121111311, en.
`- E 3 =12“) Rand Tower
`”i fi 3;— i525“ Marquette Avenue South
`5 E3. :Minnemneapofis Minnesota 55402-1314
`3 i 3 Telephone:
`[6121349—55'40
`E;
`facsimile:
`[61‘2} 349-926-151
`
`'
`
`55153”
`
`is
`
`Wimp” fl
`111111
`@fljflflfl
`Attorney Docket No. tsetse-user
`
`APPLICATIUN TRANSMITTAL
`
`Box PATENT APPLICATION
`
`Assistant Commissioner for Patents
`
`Washington, 11C. 2111231
`
`for:
`
`Transmitted herewith for filingis the patent application of
`
`INEFENTDMS}: James Edwin Gift-t Paul James leflahonetF
`
`FDR: MPEDVED VALVE ENCLOSURE ASSEMBLY
`
`Enclosed are:
`
`{X}
`
`[X]
`[
`1
`[
`I
`
`[
`
`]
`
`Seven 6’} sheets of drawings (Figs. 1-11}.
`
`An assignment of the invention to Select Comfort Corporation.
`Certified cop-flies} of a
`application.
`_An Information Disclosure Statement.
`
`A verified statement to establish small entity status under 3? C.F.R.
`
`gs 1.9 and 1.2a.
`
`[fl
`
`Declaration for United States Patent Application.
`
`-__-
`
`fl
`
`1
`
`i=5-
`"'33
`;
`
`t
`
`The Efling fee has beencalculated as shown below:
`
`FOR:
`
`3.1:. Fl! .1-‘1 1
`
`H11. l-‘E'l'ltfl
`
`135:5
`
`BASIC FEE
`
`TOTAL (:1 AIMS
`
`_
`
`3-2-20 =
`
`lNlJIliP Cl AIMS
`
`so -_
`
`12
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`OTHER THAN A
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`ll Ihe difference is less than zero. enter ”CI”.
`
`Presence of Multiple
`Dependent Claim
`
`TOTAL
`
`DR
`
`TOTAL
`
`5L1?
`
`+260
`
`Petitioner Tempur Sealy — E11. 1002, p. 1
`
`
`
`
`
`aEili‘ii1:53.-iiiiii..2r.
`
`
`
`
`
`
`
`.'.'...|i.'..ui
`
`iflittorne}r Docket No. 13D453—US-D1
`
`A check in the amount of $lfiflzgflfl to cover the filing fee and Assignment
`recording fee is attached. The Commissioner is herein},F authorized to grant
`an}:r extensions of time and to charge any fees under 37' CPR. §§ 1.16 and 1.1?
`that ma}.r be required during the entire pendency of this application to Deposit
`Account No. 16-13631.
`.
`
`R
`
`esthtll},r submitted,
`
` gistration No. 29,595
`
`CERTLFICATE OF EHRESS MAIL
`
`I'J'ate of Deposit_.. _ JulyEBJL—.—.__
`
`[hereinr Dainty that this paper is bein deposited with the United States Postal
`Sendce "Etc fess Mail Post Office to ddnessee" service under 3'? ill-ER. E3110 0n
`the date ' mated above and is addresses! to the Assistant Commissioner
`r
`Patenls. Washington, DC. 20231.
`
`
`
`Petitioner Tempur Seely — Ex. 1002, p. 2
`
`
`
`Attorney Docket No. 13fl4.58-US-fl1
`
`i
`
`E
`
`SSEMBLY
`
`Ieghnigal Field
`
`The present invention relates to an electric pump for use with an
`
`inflatable mattress. More particularly, the present invention relates to an improved
`
`valve enclosure assembly used to control the pressure in the inflatable mattress and
`
`method to inflate the mattress.
`
`Background of the Invention
`
`A prior art valve enclosure assembly is shown generally at 1C! in Figure
`
`1. Valve enclosure assembly III] is preferably coupled to a pump 12. The pump 12 is
`
`preferably electrically powered by common household current through cord 13. The
`
`pump 12 is mounted on a base 14. An air inlet if: defined in the base 14 provides
`
`inlet air to the pump 12. Pressurized air is discharged from the pump 12 into the
`
`valve enclosure assembly it} through an air outlet 13 defined in the rear face of the
`
`valve enclosure assembly 1i]. A processor board 2i] is mounted on the upper surface
`
`of the pump 12. A loft pressure sensor 22 and a right pressure sensor 24 are
`
`mounted on the processor board 21'].
`
`The prior art valve enclosure assembly to is formed of two major
`
`subcomponents; enclosure 2+5 and front face 28. The enclosure 26 has four sides and
`
`a rear face. After the various valve components have been mounted within the
`
`enclosure 26, the front face 28 is chemically bonded to the enclosure 2s.
`
`Petitioner Tempur Sealy — Ex. 1002, p. 3
`
`
`
`iii
`Fin-l“1|.
`
`ii..il
`
`III.it's‘ll'ila:i-
`
`'Fi
`
`A right air outlet 3!] is defined within outlet sleeve 32. A left air outlet
`
`34 is defined within the left outlet sleeve 35. The outlet sleeves 32, 35 are formed
`
`integral with the front face 28 and project outward therefrom such that an air hose
`
`may be slipped over the outer surfaee of the outlet sleeves 32, 36. A monitor port 38
`
`may be formed on the outlet sleeve 32. The monitor port 33 is fluidly coupled to the
`
`right air outlet 3f]. Likewise, a monitor port 40 is formed on the outlet sleeve 36 and
`
`is fluidly coupled to the left air outlet 34. Pressure monitor tubes 42 couple the
`
`outlet sleeves 32, 36 to the right pressure sensor as and the left pressure sensor 22,
`
`respectively.
`
`A right and left solenoid {not shown) are mounted within the prior art
`
`valve enclosure assembly ill. Each solenoid has a shiftable plunger [not shown}
`
`coupled thereto. A sealing disk [not shown} is mounted on the end of the plunger.
`
`In the closed configuration, the sealing disks close the right air outlet 3C! and the left
`
`air outlet 34 by sealingly engaging the inner peripheral surface of the respective
`
`outlet sleeves 32, 36. A coil spring {not shown} is mounted concentric with the
`
`plunger between solenoid and the sealing disk to bias the sealing disk to the closed
`
`configuration, thereby fluidly sealing the mattress off from the prior art valve
`
`enclosure assembly 10.
`
`In operation of the prior art device, a command is received by the
`
`processor board if} to inflate either the right or the left bladder of the mattress. as
`
`selected. The pump 12 is energized, drawing air in through air inlet 16, compressing
`
`the air, and discharging the compressed air into the valve enclosure assembly in
`
`Petitioner Tempur Sealy — Ex. 1002, p. 4
`
`
`
`through air outlet 13. The pressure differential between the commanded pressure
`
`and the existing pressure in either the right or left bladder is determined by the
`
`processor board 2t} using inputs from either the left pressure sensor 22 or the right
`
`pressure sensor 24. The left or right solenoid is actuated opening the sealing disk on
`
`the right air outlet 3D or left air outlet 34, as selected, to inflate the desired bladder of
`
`the air mattress.
`
`1it"lfhile the bladder is being inflated,
`
`the solenoid must be
`
`periodically disengaged so that the sealing disk seats closing off the air outlet 3f], 34
`
`in order to provide to the processor board 2i] a reading of the existing pressure in the
`
`bladder.
`
`While the prior art valve enclosure assembly It) has proved to be a
`
`useful device, certain problems existed. The sealing disk on the solenoid has a
`
`considerable area. The pressure in the bladder of the air mattress constantly acts
`
`upon the area of the sealing disk, generating a significant
`
`force thereon.
`
`Accordingly, the coil spring biasing the sealing disk into the closed configuration
`
`must have substantiai strength in order to counteract the force exerted by the
`
`pressure in the bladder of the air mattress. This further necessitated having a very
`
`large solenoid to overcome the bias of the coil spring in order for the solenoid to
`
`unseat the sealing disk and open the valve.
`
`Such solenoids were prone to
`
`overheating. Additionally, with the need to periodically seat the sealing disk in
`
`order to monitor the pressure in the bladder the solenoid needed to be actuated
`
`many times while a bladder was being inflated, further adding to the heat buildup.
`
`
`
`ii.iiilamidi.-..EEis
`
`Petitioner Tempur Sealy — Ex. 1002, p. 5
`
`
`
`A further problem was that, since the pressure in the bladder was
`
`constantly acting on the sealing disk, the sealing disks tended to develop leaks
`
`around the periphery resulting in the slow deflation of the bladder. Over time. the
`
`sealing disks acquired a layer of dust that contributed to the leaky condition.
`
`Accordingly, there is a need in the industry to minimize bladder leaks,
`
`to provide for continuous monitoring of existing pressure in a bladder of the
`
`mattress. and to provide for increased production efficiencies. Such production
`
`efficiencies include reducing assembly time and eliminating chemical sealants on
`
`the valve air enclosure.
`
`iiii
`
`lib-i=il..':
`
`urnm
`
`Inv .ntion
`
`The present invention substantially meets the aforementioned needs
`
`of the industry. A new valve design is incorporated in which the pressure in the
`
`respective bladders acts to hold the valve in a closed disposition. The area of the
`
`valve that is subject to the pressure from the bladder has been substantially reduced.
`
`As
`
`result of the aforementioned improvements, the actuating solenoids now have
`
`to merely unseat the valve against the force of a small spring in combination with a
`
`reduced force generated by the pressure in the bladder acting on the valve. Much
`
`smaller solenoids are required for this function, thereby reducing the amount of
`
`heat generated in the improved valve enclosure assembly.
`
`Additionally,
`
`the pressure in the bladders may be continuously
`
`monitored by means of a tap on the improved valve enclosure assembly. The now
`
`Petitioner Tempur Sealy — Ex. 1002, p. 6
`
`
`
`
`
`;its:li.;.'§:
`
`E-L'II
`
`-_-_r
`
`
`
`I.I.J.-II"I.--:5..Jim!Ii.:iI"
`
`
`
`
`
`valve design minimizes leaks from the bladders. Further, assembly time for
`
`assembling the improved valve enclosure assembly has been substantially reduced
`
`with respect
`
`to the prior art valve enclosure assembly and chemical sealants
`
`formerly used in the assembly have been eliminated.
`
`The improved valve enclosure assembly of the present invention
`
`includes at least one air bladder, a pump fluidly coupled to the at least one air
`
`bladder for providing compressed air thereto, and a processor for providing
`
`commands to the improved valve enclosure assembly during an inflatef deflate
`
`cycle. The improved valve enclosure assembly is fluidly coupled intermediate the
`
`pump and the at least one air bladder for controlling the inflation of the at least one
`
`air bladder. An enclosure defines a substantially fluidly sealed air chamber and has
`
`at least one air inlet to the air chamber being fluidly coupled to the pump. A
`
`pressure monitor
`
`is operably coupled to the processor and is in fluid
`
`communication with the at least one bladder for continuously monitoring the
`
`pressure in the at least one bladder.
`
`The method of the present invention for effecting a desired pressure in
`
`a bladder of an air inflatable mattress is also disclosed. The method includes the
`
`steps of:
`
`providing a commanded desired pressure of the bladder;
`
`opening a valve fluid coupled to the bladder;
`
`continuously monitoring the existing pressure in the bladder;
`
`Petitioner Tempur Sealy — Ex. 1002, p. T!"
`
`
`
`determining the differential between the existing pressure in the
`
`bladder and the desired pressure in the bladder;
`
`exhausting air
`
`from the bladder
`
`through the valve when the
`
`differential indicates that the existing pressure in the bladder is greater than
`
`the desired pressure;
`
`energizing a pump fluidly coupled to the valve for providing
`
`compressed air to the bladder when the differential indicates that the desired
`
`pressure in the bladder is greater than the existing pressure in the bladder to
`
`inflate the bladder; and
`
`closing said valve when the existing pressure in the bladder
`
`substantially equals the desired pressure in the bladder.
`
`madam
`
`Figure 1 is a front elevational view of a prior art valve enclosure
`
`assembly coupled to a pump; _
`
`Figure 2 is an air inflatable mattress system having right and left
`
`inflatable bladders;
`
`Figure 3 is a perspective view of the improved valve enclosure
`
`assembly of the present invention;
`
`Figure 4 is an exploded perspective viev.r of the
`
`improved valve
`
`enclosure assembly;
`
`Petitioner Tempur Sealy — Ex. 1002, p. 3
`
`
`
`Figure 5 is a sectioned side elevational view of the interface of the
`
`enclosure, rear cover and the gasket of the improved valve enclosure assembly;
`
`Figure 6 is a perspective view of the
`
`improved valve enclosure
`
`assembly with a corner broken out to reveal the solenoid and valve;
`
`Figure 5" is a side elevational view of_the
`
`improved valve enclosure
`
`assembly with a portion broken out to reveal the solenoid and valve, with the valve
`
`being sectioned and depicted in the sealed disposition;
`
`Figure 8 is a side elevational view of the improved valve enclosure
`
`assembly with a portion broken out to reveal the solenoid and valve, with the valve
`
`being sectioned and depicted in the open disposition;
`
`Figure '9
`
`is an exploded perspective view of the
`
`improved valve
`
`enclosure assembly having two valves with pressure taps;
`
`Figure 10 is perspective view of the inner face of the rear cover of the
`
`improved valve enclosure; and
`
`Figure 11 is a perspective view of the enclosure of the improved valve
`
`enclosure.
`
`Detailed Description of the Drawings
`
`The improved valve enclosure assembly of the present invention is
`
`shown generally at too in the Figures. Referring to Figure 2, improved valve
`
`enclosure assembly 1131] is preferably incorporated into the air mattress system
`
`depicted therein. The improved valve enclosure asflmbly lfll] is incorporated into
`
`Petitioner Tempur Sealy — Ex. 1002, p. 9
`
`
`
`the housing of the pump 112. Pump 112 may be made substantiatly in accordance
`
`with the pump 12 of Figure 1. Other types of pumps are also suitable for use 1with
`
`the improved valve enclosure assembly 10E]. Accordingly, pump 112 is electrically
`
`powered from household current via cord 114. The pump 112 has an air inlet, an air
`
`outlet that is fluidly coupled to the improved valve enclosure assembly 1t111, and a
`
`processor board similar in function to the processor board 20 of prior art Figure 1.
`
`Left and right air hoses 116, 113 are fluidly coupled to the improved valve enclosure
`
`assembly too. The left and right air hoses 116, 115 are fluidly coupled to the left and
`
`right bladders 122, 124 respectively of the air inflatable bed 1211'. A manually operated
`
`controller 126 may be utilized to communicate with the processor board 20 to
`
`command either increased or decreased pressure in either the left bladder or right
`
`bladder 122, 124 as desired, by transmitting a signal to the processor 211. A controller
`
`that is wired to the pump 112 may also be used.
`
`The improved valve enclosure assembly 1111] has two major structural
`
`components; enclosure 13121 and rear cover 132.
`
`lr'ifhen mated together, the enclosure
`
`131.] and rear cover 132 define an air chamber 133 internal thereto. Referring to
`
`Figures 3, 4, 5 and 111, the rear cover 132 is a generally rectangular-shaped device
`
`having an outer face 134 and an inner face 136 [Figure 111]. The outer face 134 has a
`
`periphery 133 that extends substantially around a recessed portion 141]. The
`
`periphery 138 includes a plurality of screw bores 142 at the outer margin thereof. A
`
`mounting tab 144 is formed at an edge thereof to facilitate coupling the improved
`
`valve enclosure assembly 1111.1 to a particular configuration of the pump 112.
`
`itsatll'i'i
`
`14'1":.'.
`
`Ii..."
`
`
`
`ail.iiiiilIi
`
`Petitioner Tempur Sealy — Ex. 1002, p. 10
`
`
`
`The recessed portion 141] has three air ports defined therein; pressure
`
`monitoring port 146. first inlet port 148, and second inlet port 151}. The pressure
`
`monitoring port 146 is fluidly coupled to the interior of the improved valve
`
`enclosure assembly 11:11] and has an outwardly directed portion designed to receive a
`
`small tube thereover for conveying pressure to a pressure sensor.
`
`The first inlet port 148 and second inlet port 15tl| are used in the
`
`alternate depending upon the configuration of the pump 112 that the improved
`
`valve enclosure assembly is mated to. The first inlet port 148 has an outwardly
`
`directed projecting portion for receiving an air tube thereover. Such air tube may
`
`have an inside diameter of approximately five-sixteenths of an inch. A second inlet
`
`port 151.] is designed to mate flush with a similarly sized outlet port from the pump
`
`112. Depending upon the configuration of the pump 112, either the first inlet port
`
`148 or the second inlet port 1511 is formed in a sealed configuration when the rear
`
`cover 132 is formed and another inlet port is used with the particular configuration
`
`of the pump 112.
`
`Referring to Figure 1D, the inner face 13E of the rear cover 132 is formed
`
`in substantially mirror image to the outer face 134. Accordingly, the periphery 152 is
`
`recessed with respect to the projected portion 154. The projected portion 154 has
`
`four side walls 156 and a beveled upper margin 158. Three inwardly directed gasket
`
`hangers 161) are formed on the surface of the inner face 136.
`
`Referring now to Figures 3, 4. b, and 11, the enclosure 13D that is the
`
`second of the two main structural components of the improved valve enclosure
`
`:rfli
`
`
`
`tillal::.:-'
`
`I'l
`
`riffs"=:'-'-..-
`
`
`
`rail:lil'li6:11:.:5:
`
`Petitioner Tempur Sealy — Ex. 1002, p. 11
`
`
`
`assemlalj.F 111D is generally box-shaped having two opposed sides 162, 164, a top 168, a
`
`bottom lift] and a front face IFE, evident in Figure 11. A rear cover opening W4 is
`
`defined opposite the front face 1'?2.
`
`In a preferred embodiment, the top 1458 has an
`
`inclined portion we that inclines downward toward the front face 1'32. For some
`
`applications of the improved valve enclosure assemhlj,r 1G0, the inclined portion 11-76
`
`accommodates disposing the improved valve enclosure assernbl],r Iflfl next to the
`
`generally circular fan housing of the pump 112.
`
`A plurality of screw receivers IFS are disposed peripheral to the rear
`
`cover opening 1.751 of the enclosure 1311 The home 1313 defined in the screw receivers
`
`HS are disposed such that the bores 1811 will he in registry with the screw bores 142 of
`
`the rear cover 132 when the rear cover 132 is positioned over the rear cover opening
`
`1?4.
`
`A plurality.F of lead grooves 182 are defined in the top 168 of the
`
`enclosure 13f] intersecting the rear cover opening 114. A third inlet port 18:“;E is
`
`defined in the side 162. Like the second inlet port 159, third inlet port 184 is
`
`designed to mate with an outlet port in the fan housing. The third inlet port 134 is
`
`an alternate inlet and is formed sealed off if either the first or second inlet ports 148,
`
`15121 are to be utilized in the particular application of the improved valve enclosure
`
`assembly 1 as.
`
`For use with a particular configuration of the pump 112, the improved
`
`valve enclosure asserrtl:ilj-.»r IUD has an upwardly.Ir directed flange 136 formed on the
`
`side 164. The flange 136 has a screw slot 138 defined therein for coupling to the fan
`
`iii9il:'._
`
`‘t‘ait?
`
`
`
`3.5:.c:....--Ha
`
`rd.
`
`1D
`
`Petitioner Tempur Seslv — Ex. 1002, p. 12
`
`
`
`1'12 by means of a screw inserted therein and threaded into a bore defined in the
`
`housing of the fan 112.
`
`Referring to Figure 11, the front face NE of the enclosure 13f] preferably
`
`has three valve openings 193 formed therein. Certain applications of the improved
`
`valve enclosure assembly lfli] require the use of either one, two or three valves.
`
`In
`
`applications where fewer than three valves are needed, one or two of the valve
`
`openings may be formed sealed when the enclosure 13D is made. Each of the valve
`
`apertures 190 has a circumferential beveled face 192 to assist in the insertion of the
`
`valve into the valve aperture 190, as will be later described.
`
`Referring to Figure 4, the inner surface 194 of the bottom 137i] has two
`
`solenoid guides 196 formed therein,
`
`the solenoid guides 19d laterally position
`
`solenoids within the improved valve enclosure assembly 1m], as will be later
`
`described. Additionally, toward the front face 1?2 of the enclosure 13D, solenoid
`
`stops 193 are formed on the inner surface of the bottom Hi]. The solenoid stops 198
`
`act to limit
`
`the travel of a solenoid motor in relation to the front face 1?2. A
`
`plurality of screw bores zoo are Formed in the bottom iTii through which screws may
`
`be passed to affix. a solenoid to the bottom Hi}.
`
`As depicted in Figure 4, a deformable gasket 202 is interposed benveen
`
`the rear cover 132 and the enclosure 13!]. The deformable gasket 2132 has a plurality
`
`of port bores Zfls defined therein. The port bores 2B4 are designed to be in registry
`
`with the pressure monitoring port 146, the first inlet port 148, and the second inlet
`
`port 15!}. Additionally, three hanger bores ass are formed in the deformable gasket
`
`1]
`
`Petitioner Tempur Sealy — Ex. 1002, p. 13
`
`
`
`ti..iiisul:::.~;
`"'i-u'ia'.ati"
`
`262.
`
`1Wilhen the deformable gasket 262 is mated to the rear cover 132, the hanger
`
`bores 266 are positioned over the gasket hangers 1613 to properly position the
`
`deformable gasket 262 with respect to the rear cover 132.
`It should be noted that the
`outer margin 263 of the deformable gasket 202 has substantially the same
`
`dimensions as the margin of the periphery 152 of the rear cover 132.
`
`At least one paired solenoid 216 and valve 218 are disposed within the
`
`improved valve enclosure assembly lflll. Each solenoid 210 has a solenoid coil 212
`
`and an axially translatable plunger 214, as depicted in Figures 4 and 6—3. A pair of
`
`electrical leads 216 are connected to the solenoid coil 212. Application of electrical
`
`power to the solenoid coil 212 causes the tip of the translatable plunger :14 to extend
`
`from the solenoid 216. Figure 6 depicts the extended disposition of the plunger 214.
`
`1Each of the valves 213 has a valve body 221}. An axial air passageway
`222 is defined through the valve body 226, as depicted in Figures 2 and 8. The air
`
`passageway 222 has an air outlet 224. A valve member 226 is disposed at the
`
`opposite end of the air passageway 222 from the air outlet 22:1.
`
`The valve member 226 is biased in the closed disposition depicted in
`
`Figure '2' by a valve spring 28. Preferably, the valve spring 228 exerts about a quarter
`
`of a pound of force on the valve member 226. The valve member 226 is biased into
`
`contact with a valve seat 236 formed peripheral to the air inlet 232.
`
`It should be
`
`noted that the Bering seal 231 of the valve member 226 is substantially smaller in
`
`area than the area of the prior art plunger in order to minimize the force necessarin
`
`12
`
`Petitioner Tempur Sealy — Ex. 1002, p. 14
`
`
`
`i3
`1"”1':1
`
`.-’-aIi-
`
`exerted by the valve spring 228 acting on the [Ii-ring seal 231 of the valve member
`
`226.
`
`The valve body 22E! has a ramped snap fit ring 234 formed slightly
`
`spaced apart from an expanded diameter portion 24s of the valve body 22f]. an O-
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`ring 236 is preferably disposed between the ramped snap fit ring 234 and the
`
`expanded diameter portion 240.
`
`In an alternative preferred embodiment depicted in Figure 9, a pressure
`
`monitor tab 24D is disposed on the valve body 22D of two of the valves 213. The
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`pressure monitor tab 240 has an air passageway 222 defined therein that is fluidly
`
`coupled to the air passagmvay 222 of the valve body 2213.
`
`In assembly, the valves 218 are press fit into the valve openings 19G.
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`Preferably a small press is utilized to insert the valves 218 into the valve openings
`
`19a. The ramped snap—fit ring 234 of the valve 218 rides up the beveled face 192 of
`
`the valve opening 1% as the valve 218 is pressed into the valve opening 15”.]. As
`
`the ramped snap—fit
`
`ring 234 passes through the valve opening 19D and
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`compressively engages the inner peripheral surface of the valve opening 19D, this
`
`disposition puts the D-ring 236 into a compressive sealed engagement between the
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`expanded diameter portion 240 of the valve 218 and the beveled face 192 of the
`
`valve opening 191:}.
`
`A solenoid 210 is paired with each valve 218. Solenoid 2lfl.is slidably
`
`positioned by the solenoid guides 196 and slid into the enclosure 13o. Travel into
`
`the enclosure 13!} is arrested by the solenoid 21!] coming into contact with the
`
`'13
`
`Petitioner Tempur Sealy — Ex. 1002, p. 15
`
`
`
`solenoid stops 198. The solenoid 2112} is then held in position by screws passing
`
`through the screw bores Elli] into the underside of the solenoid 211]. The leads 216 of
`
`the solenoid 21121 are passed out of the enclosure 1312) through the lead grooves 132.
`
`Plunger 214 is inserted into an axial bore 211 defined in the coil 212. The plunger
`
`214 is free to translate in the bore. At its right-most disposition, as depicted in Figure
`
`2', the plunger 214 is stopped by the gasket hanger 15o. At its left—most disposition, as
`
`depicted in Figure 8, the plunger 214 acts to open the valve 218.
`
`The gasket 2112 is then positioned on the inner face 136 of the rear cover
`
`132 by means of the gasket hangers lot}. The rear cover 132 and the gasket 2D2 are
`
`then positioned in registry.r with the rear cover opening 124 of the enclosure 13f].
`
`The rear cover 132 is affixed to the enclosure 130 bv screws 143 passed through the
`
`.11.";:.|”r'::'-'-
`
`
`-i.-:.:5..sl'
`
`screw hores 142 and engaging the screw receivers 128 of the enclosure 130. As the
`
`screws are drawn up, the periphery of the deformable gasket 2132 is compressed
`
`between the margin of the rear cover opening 124 and the side walls 15s of the
`
`projected portion 154 of the rear cover 132, as depicted in Figure 5. The compression
`
`of the deformable gasket therein fluidly seals the rear cover 132 and the enclosure
`
`131], including sealing around the solenoid leads 216 that are passed out of the
`
`enclosure 134:] through the lead grooves 132.
`
`The improved valve enclosure assemblyr IUD is designed to be utilized
`
`with a number of different pump types, pump configurations, and air inflatable beds
`
`12E]. accordingly, some inflatable beds 120 have onlyr a single bladder. In such case, a
`
`single solenoid 21D and valve 218 is utilized with the improved valve enclosure
`
`14
`
`Petitioner Tempur Sealv — Ex. 1002, p. 16
`
`
`
`assembly lilfl. With the single bladder inflated to a given pressure, that pressure
`
`bears on the back side of the valve member 225, thereby assisting the valve spring
`
`228 in biasing the valve member 226 against the valve seat 230. When an increased
`
`pressure in the bladder is desired, the pump 112 is energized and floods the
`
`improved valve enclosure assembly with compressed air. At this point in the
`
`inflate! deflate cycle, the valve 218 and the solenoid 210 are in the sealed disposition
`
`as depicted in Figure 2'.
`
`The solenoid 21E!
`
`is then actuated and the translatable plunger 214
`
`advances From the disposition in contact with the gasket hanger 160, as depicted in
`
`Figure 2, into contact with the valve member 226 to unseat the valve member 22E
`
`from the valve seat 230, as depicted by arrow A in Figure 8.
`
`In a preferred
`
`embodiment, the combined force of the valve spring 228 and the air pressure from
`
`the bladder against which the solenoid Eli] must act is less than one pound, with the
`
`preferred range of force being between .25 and .4 pounds and the optimum force
`
`being approximately .4 pounds. When the valve member 226 is unseated,
`
`compressed air passes through the air passageway 222 in the valve body to inflate
`
`the bladder.
`
`1When the inflate,’ deflate cycle commanded by the controller 126 calls
`
`for deflation of the bladder, the pump 112 is left unenergized and the valve 218 is
`
`opened as previously described. Certain types of pumps 112 permit the exhausting
`
`of compressed air through the pump 112 by effectively running the pump in
`
`15
`
`Petitioner Tempur Sealy — Ex. 1002, p. 1?
`
`
`
`reverse. With such types of pumps 112, this is the preferred means of deflating the
`
`bladder.
`
`Certain types of pumps 112 are fluidly sealed when they are in the
`
`unpowered state. Accordingly, an alternative route to deflate the bladder must be
`
`provided.
`
`In such case, a second solenoid 21D and valve 218 is incorporated in the
`
`improved valve enclosure assembly lflfl. The second valve 218 simply opens into
`
`the interior of the housing of the pump 112. Accordingly, to deflate the bladder the
`
`first valve 218 is opened as previously described and the second valve 218 is also
`
`opened, thereby permitting compressed air from the bladder to flov.r through the
`
`first valve 218 into the enclosure 130 and out through the second valve 218 to the
`
`interior of the housing of the pump 112. from which the air is ultimately exhausted.
`
`As depicted in Figure 2r inflatable bed 120 may have a left bladder 122
`
`and a right bladder 124.
`
`In such case, the improved valve enclosure assembly 100
`
`must
`
`incorporate two solenoids 213 and two valves 218, one valve 213 being
`
`connected to the left air hose 1115 and the second valve 2'13 being connected to the
`
`right air hose 118. The two valves function to inflate and deflate the left and right
`
`air bladders 122, 124 as previously described for the single bladder embodiment.
`
`In
`
`the case of using a pump 112 that is sealed when powered down. the third valve 218
`
`is utilized to exhaust air from the left and right bladders I22, 124 as previously
`
`described in relation to the single bladder embodiment.
`
`Further, with the controller 125 as depicted in Figure 2, a desired
`
`inflation of either the left bladder I22 or the right bladder 124 may be commanded.
`
`=rr'i
`
`f3tilla...
`
`'L'..Ha...
`
`16
`
`Petitioner Tempur Sealy — Ex. 1002, p. 13
`
`
`
`Such command may require either an inflation or a deflation of the left or right
`
`bladders 122, ]24.
`
`In order to meet the command, the processor of the pump 112
`
`must be able to continuously monitor pressure in the respective left bladder or right
`
`bladder 122, 124 as desired. With some configurations of the pump 112; monitoring
`
`can be provided by coupling the pressure monitoring port 146 of the rear cover 132
`
`to the processor.
`
`Alternatively, with other types of pumps 112, such monitoring must be
`
`taken from the valve 213 and may not be continuous, as provided for above.
`
`Accordingly, the valves 218 include the optional pressure monitor tab 24D.
`
`in such
`
`case, the pressure monitor tab 241:} of the valve 213 to the left pressure sensor 22, as
`
`depicted in Figure 1. The valve 218 that is fluidly coupled to the right bladder 124
`
`includes a fluid coupling from the right pressure sensor 24 to the pressure monitor
`
`4'Ii'r‘5'-II-iI'iI!EH15535'-2.2
`
`tab 242].
`
`It will he recognized that the foregoing embodiments are merely
`
`exemplary of the invention, and that modifications and extensions will be obvious
`
`which do not depart from the scope of the invention as defined by the following
`
`claims.
`
`1?
`
`Petitioner Tempur Sealy — Ex. 1002, p. 19
`
`
`
`
`
`
`
`..1..-...1.f9..”.:...::.-ll"5-|:.-wasas
`
`1What is claimed is:
`
`l.
`
`An improved valve enclosure assembly for use with an air inflatable
`
`mattress having at least one air bladder inflated by compressed air, a pump fluidly
`
`coupled to the at least one air bladder for providing compressed air thereto, and a
`
`processor for providing commands to the improved valve enclosure assembly
`
`during an inflate ,3 deflate cycle, the improved valve enclosure assembly being fluidly
`
`coupled intermediate the pump and the at least one air bladder for controlling the
`
`inflation of the at least one air bladder, comprising:
`
`an enclosure defining a substantially fluidly sealed air chamber
`
`and having at least one air inlet to the air chamber being fluidly
`
`coupled to the pump; and
`
`pressure monitor means being operably coupled to the processor
`
`and being in fluid cornuumication with the at least one bladder for
`
`continuously monitoring the pressure in the at least one bladder.
`
`2.
`
`The improved valve enclosure assembly of claim 1 wherein the
`
`pressure monitor means continuously monitors the pressure in the at least one
`
`bladder during an inflateX deflate cycle.
`
`3.
`
`The improved valve enclosure assembly of claim 1 wherein the
`
`pressure monitor means monitors the pressure in the at least one bladder by
`
`monitoring the pressure in the air chamber.
`
`18
`
`Petitioner Tempur Sealy — Ex. 1002, p. 20
`
`
`
`4.
`
`The improved valve enclosure assembly of claim 1 further including at
`
`least one valve being fluidly sealingly disposed in a valve aperture defined in the
`
`enclosure by a snap—fit engagement therewith and being in Fluid commimication
`
`with both the exterior of the enclosure and with the air chamber.
`
`5.
`
`The improved valve enclosure assembly of claim 1 wherein a plurality
`
`of guides and stops are disposed within the enclosure for correctly positioning
`
`components within the enclosure.
`
`6.
`
`The improved valve enclosure assembly of claim 5 further including at
`
`least one solenoid operated valve disposed within the enclosure, said plurality of
`
`guides and stops for disposing [he solenoid with respect to the valve.
`
`?.
`
`The improved valve enclosure assembly of claim 1 further including at
`
`least one valve disposed within the enclosure, the at least one valve being snap fit
`
`in an aperture defined in a wall of the enclosure.
`
`8.
`
`_ The improved valve enclosure assembly of claim I" wherein the at least
`
`one valve has a circumferential ramped face, said ramped face for compressively
`
`engaging a circumferential beveled face of the aperture to effect the snap fit of the at
`
`least one valve.
`
`19
`
`Petitioner Tempur Sealy — Ex. 1002, p. 21
`
`
`
`9.
`
`The improved valve enclo
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