United States Patent [19]
`Swenson et al.
`
`[11]
`[45]
`
`4,394,784
`Jul. 26, 1983
`
`[54] AIR BED WITH FIRMNESS CONTROL
`
`4,306,322 12/1981 Young et a1. ......................... .. 5/449
`
`[75] Inventors: Gerald R. Swenson; Emil S. Swenson,
`g‘rrlllgji?g??fp?igary A‘ Ymmg’
`
`FOREIGN PATENT DOCUMENTS
`1529538 3/1970 Fed. Rep. of Germany ........ .. 5/455
`
`[73] Assignee: Dial-A-Firm International, Inc.,
`Bumsville Mirm
`[21] Appl. No.: 281,368
`[22] Filed;
`Jul, 3, 1981
`[2;]
`Clef """ "
`‘
`[
`1
`'
`' ""
`[58] Field of Search ’
`5/474 464_
`’
`'
`’
`’
`References Cited
`U.S. PATENT DOCUMENTS
`
`1
`[
`56
`
`....... .. 5/456
`3,303,518 2/1967 Ingram ..
`297/DIG. 3
`4,078,842 3/1978 Zur ...... ..
`4,224,706 9/1980 Young et _ ......................... .. 5/449
`
`""
`
`’
`
`R. 413/423 R’
`5/449 450 453456
`M23 R, ‘115/121 R’
`’
`
`Prima'y Examiner_Alexander Grosz
`Attorney, Agent, or Firm-Stephenson and Boller
`[57]
`ABSTRACT
`A bed bcirmattress fstructurehhaving at least one pneu;
`matic adder con med wit in an outer perimeter o
`resilient but relatively ?rm edging material, with top
`and bottom covers, wherein air ?ow tubes are coupled
`into the penumatic bladder and are connected to an
`electrically driven blower assembly which intakes and
`pressurizes ambient air at a moderately elevated pres
`sure to the air bladder; the blower and air flow paths
`being controllable by at least one hand held control
`unit.
`.
`
`27 Claims, 8 Drawing Figures
`
`Petitioner Tempur Sealy - Ex. 1017, p. 1
`
`

`

`US. Patent Jul. 26, 1983
`
`Sheet 1 of 3
`
`4,394,784
`
`Petitioner Tempur Sealy - Ex. 1017, p. 2
`
`

`

`US. Patent Jul. 26, 1983
`
`Sheet 2 of3
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`4,394,784
`
`50
`
`M.
`
`"Huh.
`
`WM ‘W
`
`Hull!“
`
`WI
`
`“a
`I.
`
`Petitioner Tempur Sealy - Ex. 1017, p. 3
`
`

`

`US. Patent Jul. 26, 1983
`
`Sheet 3 of 3
`
`4,394,784
`
`jg, 6‘ ‘
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`5.7 H
`
`Petitioner Tempur Sealy - Ex. 1017, p. 4
`
`

`

`1
`
`.
`
`AIR BED WITH FIRMNESS CONTROL ‘
`
`4,394,784
`
`.,
`2
`@IBQRiEE DESCRIPTION OF THE DRAWINGS
`'Y'An'understanding of the operation and advantages of
`thelinvention will become apparent from the following
`speci?cation, and with reference to the appended draw
`ings, ' in which:
`FIG. 1 is a perspective view of a preferred embodi
`ment of the invention;
`FIG. 2 is a perspective view, partially broken away,
`illustrating the air mattress of the invention;
`FIG. 3 is a top view of the power source;
`FIG. 4 is a cross-sectional view taken along the lines
`4-4 of FIG. 3;
`FIG. 5 is a cross-sectional view taken along the lines
`5—5 of FIG. 3;
`_
`FIG. 6 is a cross-sectional view taken along the lines
`6—6 of FIG. 3;
`-
`FIG. 7 is a cross-sectional view taken along the lines
`7—7 of FIG. 3; and
`FIG. 8 is a schematic diagram of the control portion
`of the invention.
`
`DESCRIPTION OF THE PREFERRED
`EMBODIMENT
`Referring ?rst to FIG. 1, the preferred embodiment
`of the invention is shown in perspective view. A bed 10
`has a box spring 12 and a mattress 14. Box spring 12 is
`constructed according to well-known techniques, and
`mattress 14 is constructed according to the teachings
`hereinafter recited. A pair of air lines 16 and 18 respec
`tively are coupled to mattress 14, and terminate at
`power source 20. A pair of control units 22 and 24 are
`electrically connected to power source 20 and will be
`hereinafter described. The dotted line shown on FIG. 1,
`which divides mattress 14 into two halves, is indicative
`of the construction of the preferred embodiment of
`mattress 14, wherein each of the mattress halves are
`independently adjustable relative to ?rmness.
`FIG. 2 shows a perspective view of mattress 14 in
`partial breakaway. Mattress 14 has a bottom cover 26
`and a top cover 28, one or both of which may be made
`from soft, padded material. Top cover 28 in particular,
`may be made in conformance with practices and proce
`dures relating to conventional mattresses, and may be
`attached to an outer cover 21 over the mattress by
`means of zippers or other fasteners. An edging material
`30 forms an outer perimeter around mattress 14. Edging
`material 30 is constructed from relatively ?rm, yet resil
`ient, material such as foam or coil springs con?ned
`within a rectangular cover. Edging material 30' may also
`be constructed from other types of springs or other
`semiresilient material, with the objective of having resil
`iency characteristics such that a person sitting on the
`edge of the mattress will not unduly deform the edging
`material. It is also important that edging material 30 be
`suf?ciently rigid to con?ne within its perimeter the air
`bladder or air bladders which form a part of mattress 14.
`If edging material 30 is constructed in sections as shown
`in FIG. 2, it is important that the abutting ends of the
`respective sections are locked together. This can be
`accomplished by constructing interlocking mechanisms
`at the respective section edges, or preferably by enclos
`ing the entire perimeter in, a cloth or plastic, tightly
`?tting cover 21. The edging material 30 is typically
`approximately four inches in width and ?ve-six inches
`in height.
`At least one air bladder 32 or 34 is contained within
`the volume de?ned by edging material 30 and the top
`
`BACKGROUND OF THE INVENTION
`The present invention relates to bedding and mattres- 5
`ses, and more particularly to mattresses of a type includ
`ing pneumatic bladders as an important support element
`in the construction of the mattress. The invention spe
`ci?cally relates to an apparatus for providing variable
`?rmness control to beds having air mattresses as a struc
`tural feature.
`Beds utilizing air mattresses as an important and func
`tional component thereof are known in the art. The best
`and most recent example of such a bed may be found in
`U.S. Pat. No. 4,224,706, issued Sept. 30, 1980, and U.S.
`patent application No. 094,347, ?led Nov. 14, 1979 now
`U.S. Pat. No. 4,306,322, both of which are owned by the
`assignee of the present invention. These beds relate
`speci?cally to air beds having a “closed” air system,
`whereas the present invention relates to an air bed hav
`ing an “open” air system. By contrast, a “closed” air
`system in a pneumatic bed assembly incorporates an air
`mattress of some structure which is coupled through
`appropriate tubes to an air bladder, wherein a predeter
`mined volume of air is sealably con?ned by the two air
`elements. Relative ?rmness of such a pneumatic bed
`assembly is achieved by controllably transferring some
`of the air volume between the mattress and the air blad
`der, and vice versa, and the patents above referred to
`achieve this result through a mechanism for controlling
`the total volume of the air bladder. Such a mechanism
`requires the con?nement of the air bladder in a closed
`but variable volume, and includes means for increasing
`and decreasing the con?nement volume so as to either
`permit air to flow from the mattress into the air bladder
`or to force air from the air bladder into the mattress.
`When air is released from the air mattress into the blad
`der the “feel” of the bed becomes softer, and when air
`is forced from the bladder into the mattress, the “feel”
`of the bed becomes more ?rm.
`
`25
`
`30
`
`35
`
`SUMMARY OF THE INVENTION
`
`The present invention utilizes an air mattress assem
`bly of a particular and preferred construction, in combi
`nation with an externally energized and powered air
`pressure source. In a preferred embodiment of the in
`vention the air mattress is constructed in two indepen
`dent sections, each section having an air tube coupled to
`a source of air pressure. The source of air pressure is
`selectively controllable by means of independently op
`erable control mechanisms, which preferably may be
`hand held, and which permit either an increase in air
`pressure to a section of air mattress or the release
`thereof, thereby providing independent adjustment and
`control of relative ?rmness of each air mattress section.
`It is therefore a principal object of the present inven
`tion to provide an air mattress having adjustable control
`of ?rmness by means of a control unit which may be
`operated while lying on the mattress. '
`It is another object of the present invention to pro
`vide variable ?rmness control for two mattress sections
`in the same bed.
`‘
`I
`'g
`It is a further object of the present invention to pro
`vide ?rmness control for air, mattresses‘by means of an
`open air system which‘ derives ambient air and elevates
`its pressure suf?cient to control the system.
`I
`'
`
`45
`
`50
`
`55
`
`65
`
`Petitioner Tempur Sealy - Ex. 1017, p. 5
`
`

`

`3
`and bottom covers 26 and 28. In the preferred embodi
`ment, shown in FIG. 2, an air bladder 32 and an air
`bladder 34 are positioned in side by side relationship.
`An intermediate pad or cushion 36 may be used to par
`tially support and separate air bladders 32 and 34, par
`ticularly if the curvature of the respective air bladders is
`semicircular. Each of the air bladders is formed from a
`plurality of rectangular or cylindrical tubes, with full
`internal air flow communication between the respective
`tubes forming the bladder. A port for admitting and
`exhausting air is affixed at one end of each of the air
`bladders 32 and 34, and is respectively coupled to air
`tube 16 and 18. Air tubes 16 and 18 pass through open
`ings in edging material 30 or between edging material
`30 and either of the covers 26 or 28, to project and
`extend externally of mattress 14.
`FIG. 3 shows a top view of power source 20 and
`control units 22 and 24. A blower 38 is affixed to a base
`40 and is electrically driven by means of power cord 39.
`Power cord 39 is connected to a terminal block 42.
`Blower 38 may be actuated by a signal from control unit
`22 via line 23, or by control unit 24 by a signal over line
`25. Air line 16 is coupled to a solenoid-operated air
`valve 46, and air line 18 is coupled to a solenoid
`operated air valve 48. Solenoid-operated air valves 46
`and 48 are identical in construction, each having a deac
`tivated position wherein the flow of air through respec
`tive connected air lines is blocked and an actuated posi
`tion wherein the flow through the respectively con
`nected air lines is opened. Air valve 48 is coupled to air
`line segment 49, and air valve 46 is coupled to air line
`segment 47; segments 47 and 49 are in turn both coupled
`to air line segment 50 which connects into blower 38.
`FIG. 4 is a cross-sectional view taken along the lines
`4—4 of FIG. 3. Blower 38 is ?tted at its intake end into
`a housing 44. Housing 44 is attached to wall 45 which
`forms a structural wall of power source 20. A motor 52
`is mounted within blower 38, and a motor shaft 54 is
`coupled to a blower wheel 56. Blower wheel 56 may be
`of the construction described herein, or other similar
`construction, which receives air at inlets 55 proximate
`its center and centrifugally accelerates the air ?ow to be
`released through an outlet 57 proximate its outside cir
`cumference. A plate 58 having a plurality of center
`perforations serves to admit intake air into blower
`wheel 56. Plate 58 is af?xed within blower 38 a short
`distance upstream from blower wheel 56. A plate 60 is
`af?xed a short distance downstream from blower wheel
`56, and has a plurality of openings 61 to permit exhaust
`air to ?ow over motor 52. A plate 62 is attached to the
`downstream end of motor 52, and has a plurality of
`openings 63 to permit exhaust air to escape from blower
`38.
`FIG. 5 shows a cross-sectional view taken along the
`lines 5—5 of FIG. 3. Blower wheel 56 is attached to
`motor shaft 54 to rotate therewith. Blower wheel 56 has
`a plurality of blades 64 which preferably are arcuate
`sections as illustrated in FIG. 5. As blower wheel 56
`rotates in the direction shown by arrow 66, intake air
`received through inlets 55 (see FIG. 4) is accelerated
`outwardly toward the outer ends of blades 64. Since
`blower wheel 56 is enclosed within blower 38, the radi
`ally outward flow of air is directed to outlet 57, which
`is tangentially arranged relative to blower 38. The out
`let air is therefore directed into air line 50, at a slightly
`elevated pressure. In the preferred embodiment, the
`operation of blower wheel 56 causes a pressure increase
`of 1-2 pounds per square inch (psi). The air passing
`
`4,394,784
`4
`through air line 50 is therefore l-2 psi higher pressure
`than static room air pressure. Air line 50 is coupled into
`air lines 47 and 49 through a “T” connection (not
`shown), and air lines 47 and 49 are respectively con
`nected to air valves 46 and 48. Air valves 46 and 48 are
`commercially available solenoid-operated air valves,
`such as for example Model UX826089, manufactured by
`Automatic Switch Company, Florham Part, NJ. 07932.
`Air valves 46 and 48 are actuated by electrical signals
`from control units 22 and 24 as will be hereinafter de
`scribed.
`FIG. 6 shows a cross-sectional view of blower 38
`taken along the lines 6—-6 of FIG. 3. A plate 60 is tightly
`?tted within blower 38 at a position slightly down
`stream from blower wheel 56. Plate 60 has a plurality of
`openings 61 arranged in a circular pattern, the diameter
`of which is slightly larger than the diameter of motor
`52. Openings 61 permit the exhaust of excess air from
`blower wheel 56, and this exhaust air is directed about
`the outer casing of motor 52 for cooling purposes.
`FIG. 7 shows a cross-sectional view taken along the
`lines 7—7 of FIG. 3. A plate 62 is tightly con?ned
`within blower 38 at a position downstream from motor
`52. Plate 62 has a plurality of openings 63 arranged in a
`circular pattern, the diameter of which is slightly larger
`than the diameter of motor 52, thereby directing a por
`tion of the ?ow of exhaust air from blower 38 around
`the outer casing of motor 52.
`’
`FIG. 8 is a schematic diagram of the control portion
`of the invention. Control units 22 and 24 are of identical
`construction, and therefore only one control unit will
`be described by way of example. Control unit 22 com
`prises a hand held housing having a pushbutton 71
`which is mechanically linked to switching elements 710
`and 71b. When pushbutton 71 is depressed both switch
`elements 710 and 71b are closed. Pushbutton 71 is la~
`beled “up”‘or “?rm” or similar nomenclature on the
`external face of control unit 22. The mechanical tech
`niques of construction of pushbutton 71 and switch
`elements 71a and 71b are well within the known prior
`art and will not be further described herein.
`Switch element 710 is in series with the electric sole
`noid coil of air valve 46; switch element 71b is in series
`with the electric motor 52. One side of power line 39 is
`connected to all of the switching elements described
`herein, the other side of power line 39 being acommon
`connection respectively to air valve 46, motor 52, and
`air valve 48. Switch 72 is in series with air valve sole
`noid 46, and is in parallel connection with switch ele
`ment 710. Therefore either switch 72 or switch 71a may
`energize solenoid valve 46. Switch 72 is labeled “down”
`, or “sof ” or similar nomenclature on the external face of
`control unit 22. The internal electrical connections of
`control unit 24 are identical to the internal electrical
`connections of control unit 22, and therefore a person
`operating either control unit 22 or control unit 24 may
`selectively energize either the connected air valve and
`motor in combination, or the air valve alone, depending
`upon which control unit pushbutton is depressed.
`In operation, a person lying on mattress 14 has access
`to control unit 22 or 24, depending upon which section
`of mattress 14 the person is lying. For purposes of exam
`ple it will be assumed that the person is lying on the
`mattress section which is controllable by control unit
`22. When it is desired to increase the ?rmness of the
`mattress section, the pushbutton 71 of control unit 22 is
`depressed, thereby actuating motor 52 and engaging
`solenoid valve 48. Solenoid valve 48, when engaged,
`
`60
`
`65
`
`25
`
`40
`
`'
`
`Petitioner Tempur Sealy - Ex. 1017, p. 6
`
`

`

`15
`
`20
`
`25
`
`4,394,784
`6
`5.‘
`~17. The apparatus of claim 6, further comprising a
`opens the air flow path from air line 49 to-air line 18,'and
`second circular plate af?xed within said housing inter
`therefore permits pressurized air developedby blower
`mediate said fan and said motor, said plate having a
`wheel 56 to flow via line 50 to air-line 18., The flow of
`plurality of openings arranged proximate said motor.
`this pressurizedv air is directed into the air mattress sec
`8.4 The apparatus of claim 7, further comprising a
`tion, and increases the pressure within the connected air
`pressurized air outlet tangentially positioned ‘relative to
`bladder. This increase in pressure is sensed‘by the per
`son lying on the air bladder as an increase in relative
`said fan and said housing.
`.
`.
`?rmness of the mattress. In the event the person desires
`9. The apparatus of claim 8, further comprising a
`to decrease the firmness of they air mattress‘ section push
`third circular plate’af?xed in said housing downstream
`button' 72‘of control unit 22 is depressed. This engages
`said motor, said plate having a plurality of openings
`arranged proximate said motor.‘
`solenoid-operated ' air valve 48, but does not actuate
`motor 52. The engagement of solenoid valve 48 ‘causes
`10. The apparatus of "claim 9, wherein said fan further
`the air flow path between air line 18 and 49 to open, and
`comprises a~plurality of arcuate vanes generally radially
`provides a relief path for air con?ned within the air
`directed from said axis.
`,
`mattress section. This con?ned air exhausts backward
`11. The apparatus of claim 8, wherein both of said
`through air line 18, air line 49 and air line 50 into blower
`means for actuating further comprises a control unit
`38, thereby reducing the con?ned air pressure in the air
`remotely positionable from said blower and having
`mattress section and giving the sensation of reduced
`control switches therein.
`?rmness in the air mattress section. As soon as the push
`' 12. The apparatus of claim 11, further comprising two
`button of control unit 22 is released solenoid valve 48
`air bladders con?ned within said mattress, each of said
`becomes deactuated and the air ?ow path is closed.
`air bladders being connected to said blower pressurized
`The present invention may be embodied in other
`air outlet through an independent air valve and means
`speci?c forms without departing from the spirit or es
`for actuating, and each of said bladders having an inde
`sential attributes thereof, and it is therefore desired that
`pendently operable control unit associated therewith.
`the present embodiment be considered in all respects as
`13. The apparatus of claim 12, wherein each of said
`illustrative and not restrictive, reference being made to
`control units further comprise two switching elements,
`the appended claims rather than to the foregoing de
`one switching element being capable of energizing said
`scription to indicate the scope of the invention.
`blower and said air valve to open air flow through said
`What is claimed is:
`air line, and the other switching element being capable
`1. An air bed system having ?rmness control of an air
`of energizing said air valve to open air ?ow through
`bladder con?ned within a mattress, comprising
`said air line without energizing said blower.
`(a) an air blower having an intake to atmospheric air
`14. A pneumatic bed assembly having ?rmness con
`and having an exhaust to atmospheric air, and hav
`trol of a mattress, comprising
`ing a pressurized air outlet;
`(a) a mattress having resilient but relatively rigid
`(b) an air line connected to said pressurized air outlet
`perimeter edge material and an enclosed cavity
`and connected to said air bladderg
`therein;
`(c) an air valve interposed in said air line for selec
`(b) a pair of pneumatic bladders positioned in side by
`tively-opening and closing air ?ow therethrough;
`side relation in said cavity, each of said bladders
`(d) means for actuating said air valve for opening air
`having an air line coupled thereto and extending
`?ow through said air line and for energizing said
`outside said perimeter material;
`air blower; and
`‘
`(0) an air valve connected to each of said air lines;
`(e) means for actuating said air valve for opening air
`(d) a blower coupled to both of said air valves;
`flow through said air-line and for deenergizing said
`(e) means for actuating said blower and one of said air
`air blower.
`‘
`valves; and
`. 2. The apparatus of claim 1, wherein both of said
`-
`(f) means for actuating one of said airvalves without
`means for actuating further comprises a control unit
`actuating said blower.
`remotely positionable from said blower and having
`15. The apparatus of claim 14, further comprising
`control switches therein.
`‘
`second means for actuating said blower and the other of
`3. The apparatus of claim 2, further comprising two
`said air valves, and second means for actuating the
`air bladders con?ned within said mattress, each of said
`other of said air valves without actuating said blower.
`air bladders being connected to said blower pressurized
`16. The apparatus of claim 15, further comprising a
`air outlet through an independent air valve and means
`resilient separator between said air bladders.
`for actuating, and each of said bladders having an inde
`17. The apparatus of claim 15, wherein said blower
`pendently operable control units associated therewith.
`further comprises a housing enclosing an electric motor
`4. The apparatus of claim 3, wherein each of said
`and connected fan, said housing having an air intake at
`control units further comprise two switching elements,
`one end and an air exhaust at the other end thereof.
`one switching element being capable of energizing said
`18. The apparatus of claim 17, further comprising a
`blower and said air valve to open air ?ow through said
`?rst plate within said housing between said fan and said 5
`air line, and the other switching element being capable
`housing air intake, said plate having openings near the
`of energizing said air valve to open air ?ow through
`center thereof.
`said air line without energizing said blower.
`19. The apparatus of claim 18, further comprising a
`5. The apparatus of claim 1, wherein said blower
`second plate within said housing between said fan and
`further comprises a cylindrical housing having a center
`said motor, said plate having a plurality of openings
`axis on which an electric motor and fan are af?xed.
`proximate said‘ motor.
`6. The apparatus of claim 5, further comprising a ?rst
`20. The apparatus of claim 19, further comprising an
`circlar plate af?xed within said housing adjacent said
`opening in said housing between said ?rstand second
`fan said plate having openings proximate the axis of said
`plates and proximate said fan.
`housing.
`
`60
`
`30
`
`35
`
`40
`
`45
`
`50
`
`65
`
`Petitioner Tempur Sealy - Ex. 1017, p. 7
`
`

`

`4,394,784
`8
`7
`housing air intake, said plate having openings near the
`21. The apparatus of claim 20, wherein said housing
`center thereof.
`further comprises a cylindrical structure and said hous
`' 25. The apparatus of claim 24, further comprising a
`ing opening is tangential to said cylindrical structure.
`second plate within said housing between said fan and
`22. The apparatus of claim 15, wherein each of said
`said motor, said plate having a plurality of openings
`means for actuating said blower and respective > air
`proximate said motor.
`valves further comprise a control unit remotely posi
`26. The apparatus of claim 25, further comprising an
`tionable relative to said blower.
`-
`opening in said housing between said ?rst and second
`23. The apparatus of claim 22', wherein said'blower
`plates and proximate said fan.
`1
`further comprises a housing enclosing an electric motor
`27. The apparatus of claim 26, wherein said housing
`and connected fan, said housing having an air intake at
`further comprises a cylindrical structure and said hous
`one end and an air exhaust at the other end thereof.
`ing opening is tangential to said cylindrical structure.
`24. The apparatus of claim 23, further comprising a
`?rst plate within said housing between said fan and said
`
`i i t i i
`
`’
`
`l
`
`15
`
`25
`
`30
`
`35
`
`45
`
`50
`
`55
`
`65
`
`Petitioner Tempur Sealy - Ex. 1017, p. 8
`
`