United States Patent 1191
`Shafer et al.
`
`[54] AIR CONTROL SYSTEM FOR AN AIR BED
`
`[75] Inventors: David C. Shafer; Eugene F. Duval,
`both of Menlo Park, Calif
`
`-
`
`.
`
`-
`
`[73] Assignee. 1$31352aCpggisfolt'lltirtlnorporation,
`’
`'
`
`[21] Appl. No.: 332,833
`_
`[22] Flledl
`
`N0“ 1, 1994
`
`Hlllllllllllllllllllllllllllllll||||llllllllllllllllllllllllllllllllllllll
`USOO5509154A
`[11] Patent Number:
`5,509,154
`[45] Date of Patent:
`Apr. 23, 1996
`
`4,995,124
`4,999,867
`5,003,654
`5,005,240
`5,020,176
`5,035,016
`
`2/1991 Wridge, Jr. et al. .
`3/1991 Toivio et al. .
`4/ 1991 VIZalik -
`4/ 1991 Vrzalik .
`6/1991 Dotson .
`7/1991 Mori et a1. .
`
`9/1991 Vrzalik I
`5,044,029
`5,062,169 11/1991 Kennedy et a1. .
`5,090,077
`2/1992 Caden et al. .
`5,105,488
`4/1992 Hutchinson.
`5,129,115
`7/1992 Higgins et al. .
`5,142,717
`9/1992 Everard et al. .
`
`[51] Int. Cl.6 ............................ .. A47C 27/10; H04Q 7/06
`[52] US. Cl. ..................... .. 5/453; 318/16; 5/935
`[58] Field of Search .............................. .. 5/448, 449, 453,
`
`I
`
`FOREIGN PATENT DOCUMENTS
`
`5/935’ 318/16
`
`1178719 11/1984 Canada .
`
`[56]
`
`References Cited
`
`U's' PATENT DOCUMENTS
`l/l978 Cummins.
`4,066,072
`9/1980 Young et al. .
`4,224,706
`4,306,322 12/1981 Young et al. .
`4,394,784
`7/1983 Swenson et a1_ .
`4,435,862
`3/1984 King et a1. .
`4,435,864 3/1984 Callaway .
`4,542,547
`9/1985 Sato .
`4,638,519
`1/1987 Hess -
`4,679,264
`7/1987 Mon‘u'a -
`
`eck et al. .
`
`,
`
`,
`
`2,1989 P00 6'
`4’803’744
`5,1989 walker _
`4,829,616
`1/1990 walker _
`4,390,344
`4,397,390 2/1990 wa1ker _
`4,930,174
`1/1990 Hunter .
`4,944,060 7/1990 Peery et a1. .
`4,949,412
`8/1990 Goode.
`4,982,466
`1/1991 Higgins et al. .
`4,986,738
`1/1991 Kawasaki et al. .
`
`1224888 7/1987 Canada .
`Primary Examiner—Bentsu Ro
`Attorney, Agent, or Firm—Patterson & Keough
`
`[57]
`
`ABSTRACT
`
`_
`_
`An automatic control system for controlling the ?rmness of
`a ?uid supported mattress of a bed assembly. The control
`system includes a motorized ?uid pump, a control unit for
`operating the pump to adjust the ?rmness of the air mattress,
`a hand held remote control unit for actuating the control unit,
`and a transceiver system for transmitting information signals
`between the hand held unit and the control unit. The air
`control system provides for independent control of both
`bladders 1n a two bladder 3.11‘ mattress from a single umt, and
`allows a user to consistently set the ?rmness of each mattress
`air bladder to a desired value. The air control system
`includes an air pump specially designed to minimize trans
`mission of motor noise into the environment.
`
`.
`
`.
`
`.
`
`.
`
`4 Claims, 17 Drawing Sheets
`
`Petitioner Tempur Sealy - Ex. 1009, p. 1
`
`

`

`US. Patent
`
`Apr. 23, 1996
`
`[(38
`
`5,509,154
`
`Sheet 1 of 17
`Fig. I
`(24
`
`Petitioner Tempur Sealy - Ex. 1009, p. 2
`
`

`

`US. Patent
`
`Apr. 23, 1996
`
`Sheet 2 of 17
`
`5,509,154
`
`0 PK
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`2 m
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`
`4
`
`62
`
`Petitioner Tempur Sealy - Ex. 1009, p. 3
`
`

`

`US. Patent
`
`Apr. 23, 1996
`
`Sheet 3 of 17
`
`5,509,154
`
`203
`
`Petitioner Tempur Sealy - Ex. 1009, p. 4
`
`

`

`US. Patent
`
`Apr. 23, 1996
`
`Sheet 4 0f 17
`
`5,509,154
`
`Petitioner Tempur Sealy - Ex. 1009, p. 5
`
`

`

`US. Patent
`Apr. 23, 1996
`Fig. 12
`
`Sheet 5 0f 17
`
`5,509,154
`
`206
`
`244
`
`2l6
`
`2B 2|6
`
`302
`
`300
`
`2I4 208 238
`
`240
`
`204
`288 \
`
`Fig. 13
`296
`
`290
`
`278 276
`
`302
`
`278
`276
`
`292
`
`276
`
`Petitioner Tempur Sealy - Ex. 1009, p. 6
`
`

`

`US. Patent
`
`Apr. 23, 1996
`
`Sheet 6 of 17
`
`5,509,154
`
`
`
`
`‘_II -II
`l-II —-
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`
`Fig. 15
`282\
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`
`306
`
`Petitioner Tempur Sealy - Ex. 1009, p. 7
`
`Petitioner Tempur Sealy - Ex. 1009, p. 7
`
`

`

`US. Patent
`
`Apr. 23, 1996
`
`Sheet 7 of 17
`
`5,509,154
`
`Petitioner Tempur Sealy - Ex. 1009, p. 8
`
`

`

`US. Patent
`
`Apr. 23, 1996
`
`Sheet 8 of 17
`
`5,509,154
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`
`Petitioner Tempur Sealy - Ex. 1009, p. 9
`
`Petitioner Tempur Sealy - Ex. 1009, p. 9
`
`

`

`US. Patent
`
`Apr. 23, 1996
`
`.
`
`Sheet 9 of 17
`
`5,509,154
`
`Fig. 19a
`
`400
`
`411
`
`YES 0
`
`IS A
`BUTTON
`PRESSED?
`CD
`NO
`
`402
`x
`CONTINUE
`IN SLEEP
`MODE
`
`YES
`
`- 400
`
`408
`
`403
`
`HAVE 1o
`
`SECONDS PASSED
`WITHOUT
`ACTIVITY?
`
`NO
`
`7
`
`HAVE
`Buogg?igzhl
`RELEASED
`7
`
`NO
`
`YES
`
`YES
`
`410
`
`404 X
`
`@ NO LONGER
`DISABLED
`
`400
`
`Petitioner Tempur Sealy - Ex. 1009, p. 10
`
`

`

`US. Patent
`F lg. 19b
`
`Apr. 23, 1996
`
`Sheet 10 0f 17
`
`5,509,154
`
`411
`
`BUTTON IS
`PRESSED
`
`412
`
`IS UNIT
`AWAKE?
`
`SWITCH TO / 414
`"AWAKE“ MODE
`
`416
`
`REQUEST /
`CURRENT
`PRESSURE I
`
`TRANS
`MISSION
`41a
`
`424\
`
`WHICH
`BUTTONS ARE
`DEPRESSED
`
`400
`
`ARE THE
`BUTTONS
`
`428
`
`430
`1
`BUTTONS
`ARE
`DISABLED
`UNTIL
`
`RELEASED
`
`400
`
`432
`
`SAME BUTTONS
`DEPRESSED?
`
`HOW MANY BUTTONS
`DEPRESSED?
`
`1'
`RECEIvE AND
`PROCESS MESSAGE
`9
`DISPLAY
`CURRENT
`PRESSURE
`V
`422
`SET TIMER
`COUNTING T
`
`#419
`
`420
`,1
`
`f
`
`400
`
`HAS BUTI'ON BEEN
`DEPRESSED FOR 2 SECONDS?
`
`436?
`
`——_+ (440
`
`{442
`
`INCREMENT/DECREMENT
`OF DISPLAY SETTING
`V
`438 -/ SEND COMMAND
`TO BASE UNIT
`;_____
`
`SET DISPLAY ‘ SET
`FLASHING
`' TIMER
`
`TRANS_
`
`439
`
`400
`
`MISSION
`
`Petitioner Tempur Sealy - Ex. 1009, p. 11
`
`

`

`US. Patent
`
`Apr. 23, 1996
`
`Sheet 11 0f 17
`
`5,509,154
`
`Fig. 19c
`
`@
`
`444 \ 2 BUTTONS
`ARE DEPRESSED
`INTRODUCTION
`PROCEDURE
`ALREADY
`INITIATED BY
`THIS UNIT
`
`446
`
`(460
`SEND MESSAGE
`TO BA-sE UNIT _
`
`INTRODUCTION
`PROCEDURE
`NOT ALREADY
`INITIATED BY
`THIS UNIT
`
`-
`462 N DISPLAY
`HYPHENS
`1
`
`448 N DISPLAY
`COUNTS
`
`DOWN
`
`464 \ RECEIVE
`ACKNOWLEDGEMENT
`
`l
`
`II
`450
`\ DISPLAY HYPHENS
`
`DISPLAY
`/
`"1C"
`466
`
`453
`
`452\
`
`v
`
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`
`T
`
`SEND COMMAND
`TO BASE UNIT
`
`RECEIVE COMMAND
`TO RETURN TO NORMAL
`
`'
`
`I
`
`456 / RECEIVE
`ACKNOWLEDGEMENT
`
`468J
`
`40o
`
`II
`DIPLAY "C1"
`
`INSTRUCTED
`
`400
`
`Petitioner Tempur Sealy - Ex. 1009, p. 12
`
`

`

`US. Patent
`
`Apr. 23, 1996
`
`Sheet 12 of 17
`
`5,509,154
`
`/ INITIALIZE
`480
`COUNTER
`
`-
`F lg. 20
`
`;v
`482
`TRANSMIT
`MESSAGE /
`TO BASE
`
`l
`
`WAIT 0.2 - 0.3
`SECONDS
`
`WAS A
`VALID RESPONSE
`RECEIVED FROM
`HE BASE UNIT’7
`
`‘
`488?
`DECODE
`MESSAGE
`
`490?
`
`‘ RETURN
`
`HAVE
`7 ATTEMPTS
`BEEN MADE?
`
`YES
`
`494
`400
`(
`DISPLAY
`ERROR -_>d>
`
`CONDITION
`
`496
`INCREMENT /
`COUNTER
`
`Fig. 21
`
`INCREMENT
`
`COUNTERS @
`
`606?
`
`~
`PROCESS
`ACTION -|F
`REQUIRED @
`
`[604
`PROCESS @
`MESSAGE
`
`V
`
`Petitioner Tempur Sealy - Ex. 1009, p. 13
`
`

`

`US. Patent
`
`Apr. 23, 1996
`
`Sheet 13 of 17
`
`5,509,154
`
`Fig. 22
`
`608
`
`MESSAGE
`HAS BEEN
`RECEIVED?
`
`s10 /
`
`DECODE
`MESSAGE
`
`WAS
`CURRENT
`PRESSURE
`REQUESTED?
`
`SET FLAGS
`THAT ACTIVITY
`REQUESTED IS
`NECESSARY
`
`l
`
`616J /@
`
`604
`
`614
`
`Fig. 23a
`
`618
`
`IS HAND
`UNIT INTRODUCTION
`IN PROGRESS?
`
`v 622
`
`MUST THE
`PRESSURE BE
`
`ADJUSTMENT
`IN PROGRESS?
`
`AN ADJUSTMENT
`REQUEST IS
`PENDING
`
`Petitioner Tempur Sealy - Ex. 1009, p. 14
`
`

`

`US. Patent
`
`Apr. 23, 1996
`
`Sheet 14 0f 17
`
`5,509,154
`
`Flg. 23b
`
`628“ WRITE ID
`6307
`TO :IST
`SEND AN
`ACKNOWLEDGEMENT
`I
`TISSETR
`
`632
`
`/L
`
`631
`TRANS
`MISSION
`
`e37
`
`TRANS
`MISSION
`
`634
`
`638
`
`SECOND
`ID RECEIVED
`IN ONE
`MINUTE?
`
`IS THE
`SECOND ID
`THE SAME
`AS FIRST?
`
`SEND MESSAGE
`TO FIRST
`HAND CONTROL
`UNIT
`
`TRANS
`MISSION
`
`SEND MESSAGES
`TO RESUME NORMAL
`OPERATIONS
`
`TRANS
`MISSION
`
`647
`
`636
`
`f
`
`I
`
`SEND MESSAGE
`TO END INTRODUCTION
`PROCEDURE
`
`606
`
`WRITE SECOND _
`ID TO LIST
`
`v
`//642
`SEND MESSAGE
`TO SECOND
`HAND CONTROL
`UNIT
`
`TRANS
`MISSION
`
`/
`
`Petitioner Tempur Sealy - Ex. 1009, p. 15
`
`

`

`US. Patent
`
`Apr. 23, 1996
`
`Sheet 15 0f 17
`
`5,509,154
`
`Fig. 230
`
`CLOSE VALVE ‘
`IF NECESSARY
`
`Y
`WAIT 3 SECONDS x650
`
`START AID
`CONVERSION
`
`i
`l
`l
`
`WAIT 0.1 - 0.2
`SECONDS
`
`CALCULATE
`CHAMBER'S
`PRESSURE
`
`J 654
`
`606
`
`Petitioner Tempur Sealy - Ex. 1009, p. 16
`
`

`

`US. Patent
`
`Apr. 23, 1996
`
`Sheet 16 of 17
`
`5,509,154
`
`Fig. 23d
`
`HAS
`EST'MATED
`INFLATION!
`DEFLATION
`PERIOD
`ENDED?
`
`HAVE 3 SEC.'S
`PASSED SINCE
`LAST READING?
`
`662/“ CALCULATE
`
`CURRENT ‘“_*®
`
`PRESSURE ‘
`
`YES 660
`T
`0562:3115 ——->®
`
`PRESSURE *—
`
`'
`
`FURTHER
`ADJUSTMENT
`NECESSARY’?
`
`606
`
`RESET
`TIMER
`
`606
`
`663
`
`FURTHER
`ADJUSTMENT
`NECESSARY?
`
`SET NEW
`ADJUSTMENT
`REQUEST
`PENDING
`
`l
`
`NOTE THAT
`ADJUSTMENT
`HAS OVERSHOT
`
`665 \L
`
`606
`
`Petitioner Tempur Sealy - Ex. 1009, p. 17
`
`

`

`US. Patent
`
`Apr. 23, 1996
`
`Sheet 17 of 17
`
`5,509,154
`
`Fig. 23e
`
`see\ C?
`CURRENT
`
`‘ CALCULATE
`
`PRESSURE ‘
`
`’@
`
`668
`
`COMPARE
`CURRENT PRESSURE
`AND TARCET
`PRESSURE
`
`DIFFERENCE
`< 0.01 PSI
`
`606—\
`
`6701
`I
`
`NO
`ADJUSTMENT
`
`DIFFERENCE
`> 0.01 PSI
`
`672
`6821
`CALCULATE DEFLATION
`MOTOR
`SPEED
`
`INFLATION
`OR DEFLATION
`NECESSARY
`
`674 7
`INFLATION CALCULATE
`MOTOR
`SPEED
`
`II
`CALCULATE /684
`THE AMOUNT
`OF TIME UP
`TO 25.5 SEC.
`MAXIMUM
`
`START fess
`MOTOR '
`IF
`NECESSARY
`l
`
`OPEN -/ 688
`vALvE
`
`606
`
`I
`676 "—\~' CALCULATE
`THE AMOUNT
`OF TIME UP
`TO 25.5 SEC.
`MAXIMUM
`
`678“ START
`MOTOR
`
`‘
`680 N“ OPEN
`vALvE
`
`606
`
`Petitioner Tempur Sealy - Ex. 1009, p. 18
`
`

`

`5,509,154
`
`1
`AIR CONTROL SYSTEM FOR AN AIR BED
`
`TECHNICAL FIELD
`
`This invention relates to improved methods and apparatus
`for attaining and regulating the ?uid pressure in one or more
`?uid accommodating structures. More particularly, the
`invention relates to improved air pumps, controllers, infor
`mation processing and hand controls for measuring and
`varying the air pressure in an air mattress.
`
`BACKGROUND OF THE INVENTION
`
`10
`
`15
`
`20
`
`2
`applied weight to the mattress. The air mattress had to have
`an internal structure to support much of the users weight in
`order to prevent the escape of large volumes of air while
`regulating the pressure at the previously set value. The
`internal structure interfered with the comfort advantages of
`having an air supported mattress.
`Another design of a pressure control unit provided a
`digital display of the internal pressure and push buttons. See
`U.S. Pat. N 0. 5,020,176. The user could either use a constant
`pressure mode where the pressure could be set by the user.
`The user also had the option of using a manual mode where
`the pressure was not kept constant but where the user
`directly controlled the ?ow of ?uid into or out from the
`mattress.
`In these previous designs, if the bed contained two
`separate mattresses or air bladders, two hand control units
`were supplied with each controlling its respective air blad
`der. Therefore, a person lying on one side of the bed could
`not assist their bed partner on the other side of the bed with
`an adjustment of the air pressure on the other side of the bed
`without physically going to that side of the bed. The hand
`control units were physically attached to the control unit,
`thereby restricting the location of a particular unit.
`The processing involved in these earlier control systems
`for air beds was minimal. The constant pressure systems
`involved a periodic examination of the pressure and a
`comparison with the desired value. Air was then added or
`removed as needed with several steps used if needed to
`obtain the desired pressure. In the manual control designs,
`the operator directly controlled the pump and the release
`valve to control the ?ow of ?uid into or out of the mattress.
`Electric motor driven pumps have been used in the past to
`in?ate air mattresses. The operating noise of such pumps
`was a common source of consumer complaints. The pumps
`were most frequently utilized when the bed user was pre
`paring to go to sleep. A noisy pump detracted from the
`restful atmosphere necessary to induce sleep. The most
`frequent cause of noisy operation of such pumps is the rigid
`mounting of the fan motor to the pump housing. Such rigid
`mounting transmits vibrations and noises generated by the
`pump motor to the pump housing and to the environment
`around the pump. Further avenues of noise transmission to
`the environment in air pumps are the supply air inlet and the
`cooling air inlet. Sound insulating and dampening materials
`could be built into the pump motors and housings, but only
`at the risk of thermal insulation and resultant over heating of
`the pump motors.
`It would be an advantage in the industry to provide a quiet
`pump in which the noise and vibration of the fan motor is
`dampened with respect to the pump housing and wherein
`adequate cooling of the pump motor was provided for.
`Further, the air inlet and cooling air inlet should be designed
`to minimize the amount of fan noise transmitted there
`through. It would be an important advance to provide a
`multi-speed motor to provide for optimal pumping with less
`noise and with a minimum of overheating problems. With
`respect to the control of the units, it would be a distinct
`advantage to have hand control units where the user of the
`unit was not tethered to the pump unit, and where the user
`could control both air bladders in the case where each side
`of the bed had its own independent bladder. It would also be
`a decided advance in the art to be able to accurately and
`consistently monitor and control the pressure of the air
`mattress to a desired setting.
`
`SUMMARY OF THE INVENTION
`
`The air control system of an air bed in accordance with the
`present invention in large part solves the problems outlined
`
`Air supported mattresses are used with cots and beds to
`provide yieldable body supports. The air mattresses can be
`in?ated with hand operated pumps or bag pumps. Motor
`driven blowers and pumps have also been used more effec
`tively to supply air under pressure to air mattresses. U.S. Pat.
`Nos. 4,908,895 and 4,644,597, assigned to the assignee of
`the present invention, describe possible constructions of air
`mattresses.
`The air mattresses will typically sit within a border which
`supports the mattress such as that described in U.S. Pat. No.
`4,991,244, also assigned to the assignee of the present
`invention. Double, queen or king size beds can involve two
`air mattresses or two air chambers with individually adjust
`able air pressures. These air chambers may be further
`divided internally with free ?uid ?ow between these further
`divisions. The air mattresses can be equipped with a one
`way air pressure relief valve operable to limit the air
`pressure in the air mattress to about 1 psig (pounds per
`square inch gauge, i.e., relative to ambient pressure) to
`prevent seam separation and blowout.
`The biasing or ?rmness characteristics of an air mattress
`are determined by the pressure of the air in the air mattress.
`Control mechanisms have been used to adjust the in?ation of
`air mattresses. Young et al. in U.S. Pat. No. 4,224,706, for
`instance, disclose a mechanism for adjusting the amount of
`air in an air mattress. The mechanism disclosed in the ‘706
`patent includes one or more receptacles connected to air
`mattresses for supplying air to and receiving air from the air
`mattresses. These receptacles are located in the frame below
`the mattress. The internal volumes of the receptacles are
`changed by the rotation of a hand crank. The variation of the
`volume in the receptacles adjusts the pressure of the air in
`the air mattresses.
`Other control systems for air mattresses have allowed
`operators to vary the air pressure within the mattress at the
`touch of a button. The hand control units in these systems
`were either located on the air tube connecting the pump to
`the mattress or the hand controlv units made an electrical
`connection to the pump and solenoid valves. See, for
`example, U.S. Pat. Nos. 4,897,890, 4,829,616, 4,890,344,
`also assigned to the assignee of the present invention.
`These hand control units typically allowed for the trans
`mittance of two instructions to the pump/control unit. These
`instructions were either to increase or to decrease the pres
`sure. The users had to rely on their tactile senses in adjusting
`the air pressure because the units supplied no information to
`the user regarding the pressure in the mattress.
`One previous design of pressure control for an air mat
`tress involved keeping the air pressure constant at all times
`whether the user was on the mattress or not. See U.S. Pat.
`Nos. 5,142,717 and 4,995,124. A control unit allowed for a
`preset pres sure to be set. One problem with this arrangement
`was the dramatic change in pressure at the time a user
`
`25
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`30
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`35
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`40
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`45
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`50
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`55
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`60
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`65
`
`Petitioner Tempur Sealy - Ex. 1009, p. 19
`
`

`

`5,509,154
`
`3
`above. The air'control system hereof includes a motorized
`pump specially designed to reduce noise, and includes a
`remotely operated hand held control unit untethered from
`the air pump. The user of a bed assembly controlled by the
`air control system hereof can accurately and consistently
`adjust the ?rmness of the air mattress to a desired setting.
`The remote hand control unit in accordance with the air
`control system of the present invention allows the user to set
`the ?rmness of both bladders in a double bladder air mattress
`independently of each other.
`The hand held control unit communicates with the base
`unit by way of a radio transceiver. The base unit monitors
`and transmits to the hand held unit a measure of the air
`mattress ?rmness, and responds to commands from the hand
`held unit to change the ?rmness of the mattress.
`The motorized pump is capable of operating at several
`speeds to minimize noise while optimizing pumping condi
`tions. The motor speeds can be stepped through a pre
`determined manner to obtain optical motor speed while at
`the same time monitoring motor temperature to prevent
`overheating. The base unit is specially designed to prevent
`transmission of undue motor noise from the base unit into
`the surrounding environment. Microprocessors in both the
`hand held control and the base unit allow for the optimiza
`tion of pumping conditions without interaction of the user
`beyond selection of a desired ?rmness.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`15
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`25
`
`30
`
`4
`FIG. 16 is a top plan view with phantom lines depicting
`the power board beneath the impeller;
`FIG. 17 is a top plan view of the air distribution unit with
`the right solenoid valve shown in phantom;
`FIG. 18 is a side elevational view of the air distribution
`unit with the right and left solenoid valves shown in phan
`tom;
`FIGS. 19a-19c are ?ow diagrams depicting the process
`ing steps of the hand control processor upon pressing one or
`two buttons;
`FIG. 20 is a ?ow diagram depicting the transmission
`sequence followed by the hand control processor;
`FIG. 21 is a ?ow diagram depicting the overall operation
`of the base processor;
`FIG. 22 is a ?ow diagram depicting the receiving and
`decoding of messages by the base processor; and
`FIGS. 23a~23e are ?ow diagrams depicting the process
`ing of time dependent actions by the base processor.
`
`DETAILED DESCRIPTION OF THE
`INVENTION
`
`FIG. 1 contains a view of a resilient support 10 in
`conjunction with an air control system in accordance with
`the present invention. Resilient support 10 is preferably a
`?uid ?lled bed and more preferably an air bed to accom
`modate one or more persons. Resilient support 10 has a
`generally rectangular base or box spring unit 12 adapted to
`be supported on a floor or a frame engaging the ?oor. A
`mattress unit 14 is located on top of box spring unit 12.
`Mattress unit 14 has a generally panshaped resilient member
`16 having upright linear side edges 18 and 20 joined to a
`transverse front edge 22 and a comparable transverse rear
`edge 24.
`Side edges 18, 20, front edge 22 and the rear edge 24 are
`integral with the peripheral portions of a generally ?at
`bottom 26 to form therewith a generally rectangular cham
`ber 28. A pair of side by side longitudinal air bladders 30 and
`32 are located in rectangular chamber 28. The air bladders
`30 and 32 comprise air mattresses or air bags that can
`include a plurality of transverse and/or longitudinal cham
`bers adapted to accommodate air under pressure. The air
`bladders 30 and 32 are of a size to ?ll rectangular chamber
`28. Commercially available air bladders vary in size from 23
`to 34 inches wide and 67 to 84 inches long. Preferably, the
`air bladders 30, 32 have an in?ated thickness of 5.5 inches.
`Other types and sizes of air bladders as well as bladders
`designed to accept other ?uids, e.g. water, can be used in
`mattress unit 14 for resilient support 10.
`A generally rectangular cover 38 ?ts over edges 18, 20, 22
`and the rear edge 24 to enclose the top of chamber 28. As
`shown in FIG. 1, a portion of the cover 38 has been rolled
`back to illustrate the side-by-side placement of air bladders
`30, 32 in rectangular chamber 28.
`The air control system 40, in accordance with the present
`invention, functions to provide air under pressure to air
`bladders 30, 32 and to control the pressure of the air bladders
`30, 32. The air control system 40 includes a hand control
`unit 42 and a base unit 44.
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`35
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`45
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`50
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`55
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`FIG. 1 is a perspective view of an air bed, partly in
`section, depicted in conjunction with an air control system
`in accordance with the present invention;
`FIG. 2 is a plan view of a hand control unit of the air
`control system;
`FIG. 3 is an expanded view of one digit and the half digit
`of the display of the hand control unit;
`FIG. 4 is a schematic view of the inside of the hand
`control unit;
`FIG. 5 is an exploded view of the base unit of the air
`control system;
`FIG. 6 is a top plan view of the base unit processor board
`with a schematic representation of the base processor and
`the base receiver/transmitter;
`FIG. 7 is a side view of a tube and hose ?tting that is used
`to attach an air mattress to the base unit;
`FIG. 8 is a perspective view of the hose ?tting that
`connects to a receptacle in the base unit;
`FIG. 9 is a cross sectional view of a receptacle in the base
`unit which accepts the hose ?tting of FIG. 8;
`FIG. 10 is a side elevational view of the fan unit and air
`distribution unit mounted on the lower housing portion of
`the air pump housing;
`FIG. 11 is a top plan view of the fan unit and air
`distribution unit mounted on the lower housing portion of
`the air pump housing;
`FIG. 12 is an elevational view, taken from the right side
`as depicted in FIG. 4, of the fan unit and air distribution unit
`mounted on the lower housing portion of the air pump
`housing;
`FIG. 13 is a side elevational view of the fan unit;
`FIG. 14 is a sectional view taken from the perspective of
`line 14-14 of FIG. 13;
`FIG. 15 is a side elevational view of the fan of the fan unit;
`
`Hand Control Unit
`
`65
`
`Hand control unit 42 is preferably a remote unit physi
`cally unconnected to the remainder of the air control system
`40. The hand control unit 42 allows a user to control the air
`pressure within the air bladders 30, 32 while lying on the
`
`Petitioner Tempur Sealy - Ex. 1009, p. 20
`
`

`

`5
`
`6
`
`5,509,154
`
`mattress unit 14 or in any other position in the vicinity of the
`air control system 40.
`The top surface 102 of hand control unit 42 contains a
`digital display 104, two buttons 106, 108, and a two position
`switch 110. Digital display 104 presents
`information
`received from the base unit 44. Preferably, the digital display
`104 is made up of a liquid crystal display (LCD). The LCD
`is made up of two digits 112'ranging from 0—9 and a half
`digit that can only be a 1 or unilluminated. In this preferred
`embodiment, each digit 112 is made up of 7 segments 113,
`as shown in FIG. 3, and the half digit 114 is made up of two
`segments 115, the top and bottom of the 1. The liquid crystal
`display is backlit by two preferably amber light emitting
`diodes. Digital display 104 displays for the user a number
`related to the pressure within the air bladders 30, 32.
`The two buttons 106, 108 and the switch 110 provide for
`the communication of a command from the user to the air
`
`control system 40. The two buttons 106, 108 are adapted to
`be used by the user to initiate an inflation or deflation cycle,
`request the display of the current pressure or to instruct the
`base unit 44 to recognize the hand control units 42.
`The position of two position switch 110 selects the air
`bladder 30, 32 on which the operations of the hand control
`unit 42 will function. The top surface 102 of the hand control
`unit 42 can include markings indicating left or right near the
`corresponding side of switch 110. The preferred convention
`for determining the left/right side of mattress unit 14 is from
`the perspective of a person laying on their back with their
`head in the proximity to the front edge 22 (hose side) of the
`mattress unit 14, although other conventions can be used.
`For a system having a single air bladder 30, either position
`of the switch 110 will allow adjustment of the pressure in the
`air bladder 30 if a Y—hose is used to attach the base unit 42
`to the mattress unit 14, as described below.
`Referring to FIG. 4, the interior of the hand control unit
`42 contains a portable power supply 116, a hand control
`processor 118 and a hand control receiver/transmitter 120.
`The portable power supply 116 is made up of a disposable
`battery or a rechargeable battery. The hand control processor
`118 receives input from buttons 106, 108 and base unit 44
`through hand control receiver/transmitter 120 and sends
`output to digital display 104 and base unit 44. The hand
`control processor 118 is a digital processor, for example a
`Motorola MC68HC05P4 microcontroller with a little more
`
`than 4 Kbytes of ROM (program) memory, 176 bytes of
`RAM memory, 20 I/O port pins, 1 input-only port pin, 1
`timer output pin, and a 16-bit capture/compare timer. The
`software for the hand control processor 118 is stored in the
`ROM memory during fabrication. The hand control proces-
`sor 118 is permanently encoded at manufacture with an eight
`bit unit ID code and a four bit revision code for the software
`
`version by the selection of appropriate resisters within the
`hand control unit 42. Hand control receiver/transmitter 120
`
`is adjusted to a proper electromagnetic frequency to receive
`from and transmit to base unit 44. The hand control receiver/
`transmitter 120 can receive radio signals or transmit radio
`signals, but it cannot transmit and receive at the same time.
`
`Base Unit
`
`The base unit 44 of the present invention is depicted in
`FIG. 5. The base unit 44 contains a motorized pump 152,
`pressure sensors 156, 158 (FIG, 10), and a base unit pro-
`cessing board 160 (FIG. 11). Referring to FIG. 6, the base
`processing board 160 contains the base processor 162 and
`the base receiver/transmitter 164. The base unit 44 is con-
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`10
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`nected to air bladders 30, 32 by way of flexible tubular lines
`or tubes 166, 168 through inlet receptacles 170, 172. Tubes
`166, 168 allow the air control system 40 to place additional
`air or to remove air from the air bladders 30, 32 to achieve
`a desired air pressure within the air bladders 30, 32. For a
`single air bladder 30 mattress unit 14, tubes 166, 168 can be
`replaced with a Y— shaped tube (not shown) so either the right
`or left side commands will effect the single air bladder 30 or,
`alternatively, the unused inlet receptacle 170, 172 can be
`plugged. An electrical plug 174 is designed to be connected
`to a conventional ac power receptacle. An electrical power
`cord 176 connects plug 174 to base unit 44.
`The base receiver/transmitter 164 is tuned to an electro-
`magnetic frequency that is preferably selected to be in the
`radio frequency range. The electromagnetic frequency is
`preferably within the range from 315 MHz (105 Hz) to 350
`MHz. The selection of the radio frequency part of the
`electromagnetic spectrum enables the clear transmission of
`the signal without the need for the user to point the hand
`control unit 42 at the base receiver/transmitter 164. The
`signal is transmitted in digital form at the rate of 833 bits per
`second. The base receiver/transmitter 164 can receive radio
`
`signals or transmit radio signals, but it cannot transmit and
`receive at the same time.
`
`The pressure sensors 156, 158 are standard piezoelectric
`pressure sensors such as those available from IC Sensors
`Inc. The cap on the pressure sensors 156, 158 contain a small
`hole to allow air under ambient pressure to enter. This allows
`the measurement of the variation from ambient pressure by
`the pressure sensors 156, 158. The circuitry to amplify the
`signal from the piezoelectric sensor and to perform the
`analog to digital conversion is also standard in the art.
`The processor 160 is a digital processor, for example
`Motorola MC68HC05P6 microcontroller with a little more
`than 4 Kbytes of ROM (program) memory, 176 bytes of
`RAM memory, 20 I/O port pins, 1 input-only port pin, 8—bit
`analog to digital converter, and a l6-bit capture/compare
`timer. The software for the 162 is stored in the ROM
`memory during fabrication.
`Referring to FIGS. 7, 8 and 9, tube 166 is shown in
`conjunction with a tube fitting 180. Tube fitting 180 is
`selectively, detachably received within an inlet receptacle
`170, 172, it being understood that the tube 168 is identical
`in construction with tube 166. Fitting 180 is preferably
`comprised of a one piece, synthetic resin, generally tubular
`body 182. The fitting body 182 includes a tube receiving end
`184, a body midportion 186, and male connector head 188.
`The male connector head 188 includes an enlarged sealing
`portion 190. The sealing portion 190 carries a sealing o-ring
`192. Connector head 188 also includes connecting tip 194.
`Connecting tip 194 includes a pair of generally semicircular
`in cross section prongs 195, 196. The prongs 195, 196 are
`arranged on the tip 194 in rrrirror image fashion. Each of the
`prongs 195, 196 include an axial portion 197 extending
`outwardly from the enlarged portion 190 of the connector
`head 188, and a half-circumferential portion 198 arranged in
`generally L~shaped fashion with the axial portion 197.
`Circumferential portion 198 includes beveled perimeter 199,
`and a projecting boss portion 200.
`Referring to FIG. 9, each of the inlet receptacles 170, 172
`include a generally tubular inner wall 201, and a boss
`receiving aperture 203. A connector head 188 of a respective
`hose fitting 180 is detachably received within a respective
`receptacle 170, 172, with the sealing O-ring 192 carried by
`the enlarged portion 190 of the connector head 188 received
`in sealing contact with the receptacle internal side wall 201.
`
`Petitioner Tempur Sealy - Ex. 1009, p. 21
`
`Petitioner Tempur Sealy - Ex. 1009, p. 21
`
`

`

`7
`
`8
`
`5,509,154
`
`A boss 200 of one of the two connecting head prongs 196,
`197 is detachably received within the aperture 203.
`Pump 152 has three major subcomponents: pump outer
`housing 202, fan unit 204, and air distribution unit 206.
`Pump outer housing 202 has three subcomponents: lower
`outer housing portion 208, upper outer housing portion 210,
`and flexible mount 212. Generally, the lower outer housing
`portion 208 provides the mounting base for the fan unit 204
`and the upper outer housing portion 210. The upper outer
`housing portion 210 is mated to the lower outer housing
`portion 208, enclosing the fan unit 204 without physical
`contact therewith. Since the upper outer housing portion 210
`of pump outer housing 202 is not in contact with the motor
`unit 204, mechanical dampening of the fan unit 204 is
`required only between the fan unit 204 and the lower outer
`housing portion 208 to which the fan unit 204 is mounted in
`order to minimize vibration and noise transmission.
`
`Referring to FIGS. 5, 10 and 11, the lower outer housing
`portion 208 is comprised of a base 213 and peripheral lip
`214. Lower outer housing portion 208 is preferably made of
`a therrno plastic material. The base 213 is designed to be
`generally flat in order to facilitate being placed upon the
`floor proximate to the air bed. The peripheral lip 214 has an
`upper margin into which interlocking marginal grooves 215
`are formed.
`
`Four upwardly directed support posts 216 for fan unit 204
`are formed integral with base 213. The support posts 216
`project above the upper margin of the peripheral lip 214. The
`support posts 216 have a central bore 218 defined therein to
`facilitate the passage of a connecting screw therethrough.
`Smaller connecting posts 219 are also formed integral to
`base 213. Connecting posts 219 are designed to facilitate the
`connection of the upper outer housing portion 210 to lower
`outer housing portion 208. A central bore 220 is defined in
`connecting posts 219 in order to facilitate passage of a
`connecting screw therethrough.
`A helica