United States Patent 19
`Shafer et al.
`
`54 AIR CONTROL SYSTEM FOR AN ARBED
`75) Inventors: David C. Shafer; Eugene P. Duval,
`both of Menlo Park, Calif.
`
`73) Assignee: Select Comfort Corporation.
`Minneapolis, Minn
`pol1S,
`
`21 Appl. No.: 536,330
`22 Filed:
`Sep. 29, 1995
`8
`8
`Related U.S. Application Data
`63 Continuation-in-part of Ser. No. 332,833, Nov. 1, 1994, Pat.
`No. 5,509,154.
`int. C. r. A47C 27/10; H04Q7/06
`51
`52 U.S. Cl. ................................... 318/16; 5/935; Sl
`58 Field of Search .................................. 318/16; 5/448,
`5/449, 453, 455, 456, 461, 464, 480,935
`
`56
`
`References Cited
`U.S. PATENT DOCUMENTS
`fil978 Cummins.
`4,066,072
`4.224,706 9/1980 Young et al..
`4,306,322 12/1981 Young et al. .
`E. 3.
`al. .
`4.435.864 3/1984 E.
`4542547 9/1985 Sato y .
`4,638.519 1/1937 Hess.
`4,679.264 7/1987 Mollura.
`4,686,722 8/1987 Swart.
`4,797.962
`1/1989 Goode.
`4,803,744 2/1989 Peck et al. .
`4,829,616 5/1989 Walker.
`3.
`2,E. Wi
`g 6AE R
`4,944,060 7/1990 Peery et al..
`4,949,412 8/1990 Goode.
`
`
`
`USOO5652484A
`111 Patent Number:
`45 Date of Patent:
`
`5,652,484
`9
`9
`Jul. 29, 1997
`
`1/1991 Higgins et al. ............................. 5/453
`4,982,466
`1/1991. Kawasaki et al. .
`4,986,738
`4,995,124 2/1991 Wridge, Jr. et al..
`4,999,867
`3/1991 Toivio et al..
`5003,654 4/1991 Vrzalik.
`5,005.240 4/1991 Vrzalik.
`5,020,176 6/1991 Dotson
`5,035,016 7/1991 Mori et al. .
`5,044,029 9/1991 Vrzalik.
`5,051,673
`9/1991 Goodwin.
`5,062,169 11/1991 Kennedy et al. .
`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..
`5,142,719 9/1992 Vrzalik.
`5,152,021. 10/1992 Vrzalik.
`5,544,376 8/1996 Fromson ..................................... S/618
`FOREIGN PATENT DOCUMENTS
`1178719 1/1984 Canada.
`1224888 7/987 Canada.
`
`Primary Examiner-Bentsu Ro
`Attorney, Agent, or Firm-Patterson & Keough, PA.
`57
`ABSTRACT
`An automatic control system for controlling the firmness of
`a fluid supported mattress of a bed assembly. The control
`system includes a motorized fluid pump, a control unit for
`operating the pump to adjust the firmness of the air mattress,
`a handheld 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 in a two bladder air mattress from a single unit, and
`allows a user to consistently set the firmness 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.
`
`26 Claims, 18 Drawing Sheets
`
`Sleep Number Corp.
`EXHIBIT 2023
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`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 1 of 18
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`5,652,484
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`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 2 of 18
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`5,652,484
`
`
`
`6
`
`8
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`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 3 of 18
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`5,652,484
`
`
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`

`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 4 of 18
`
`5,652,484
`
`
`
`Fig. IO
`is
`
`
`
`
`
`
`
`rt.
`That it
`rif
`
`
`
`
`
`re
`
`R
`H.
`
`S.
`
`
`
`s
`
`234
`232 UNL R II
`A
`H.
`
`
`
`I. P.
`St. No
`N-a-
`
`
`
`Sleep Number Corp.
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`

`

`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 5 of 18
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`5,652,484
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`?y Hill
`At
`
`
`
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`
`
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`1 -
`
`UTR t S2F
`girl Gelei ECN
`III
`
`244
`
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`(
`24 V2O8 Y-238
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`I-AT-TT-7 U
`3OO
`28
`
`286
`
`U N
`
`A
`
`N.
`
`3OO
`
`Sleep Number Corp.
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`Page 6
`
`

`

`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 6 of 18
`
`5,652,484
`
`F.ig. 14
`2O4.
`288 \ 298 328
`325, 3O8
`
`rt HAYAT, R
`
`3O 32
`
`
`
`
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`
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`
`278
`292-
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`|S
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`el
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`g
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`R-326
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`is E C
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`W
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`as
`Fig. 15
`S/
`- Ii fa is
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`| (TTDT -
`ult"
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`37
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`326
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`
`3O6
`
`Sleep Number Corp.
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`Page 7
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`

`

`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 7 of 18
`
`5,652,484
`
`
`
`Fig. 16a
`
`Sleep Number Corp.
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`Page 8
`
`

`

`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 8 of 18
`
`5,652,484
`
`2 22232
`
`
`
`
`
`eaarar -a-
`
`.
`
`Sleep Number Corp.
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`Page 9
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`

`

`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 9 of 18
`
`5,652,484
`
`
`
`Sleep Number Corp.
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`

`

`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 10 of 18
`
`5,652,484
`
`400
`
`
`
`SA
`BUT ON
`PRESSED?
`GD
`NO
`
`401
`
`
`
`
`
`S THE
`UNIT IN
`SLEEP
`MODEP
`
`NO
`
`408
`
`
`
`
`
`
`
`HAVE 10
`SECONDS PASSED
`WITHOUT
`ACTIVITY?
`
`410
`
`YES
`
`SLEEP
`
`Fig. 19a
`
`411
`
`YES
`
`-Ga)
`
`402
`
`
`
`YES
`
`CONTINUE
`N SLEEP
`MODE
`
`400
`
`O
`
`403
`
`
`
`NO
`
`
`
`
`
`HAVE
`DSABLED
`BUTTON BEEN
`RELEASED
`
`404
`
`
`
`
`
`YES
`
`BUTTONS
`NO LONGER
`DISABLED
`
`to
`
`Sleep Number Corp.
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`Page 11
`
`

`

`U.S. Patent
`Fig. 19b
`
`Jul. 29, 1997
`(a)
`
`Sheet 11 of 18
`
`5,652,484
`
`411
`
`412
`
`424
`
`BUTTONS
`PRESSED
`
`YES
`WHICH
`BUTTONS ARE
`DEPRESSED
`
`400
`
`426
`yes x1 ARE THE
`O BUTTONS
`
`
`
`DSABLED?
`
`430
`
`BUTTONS
`ARE
`DSABLED
`UNTIL
`RELEASED
`
`428
`
`NO
`
`ARE
`SAME BUTTONS
`DEPRESSED2
`
`YES
`
`
`
`432
`
`
`
`
`
`HOW MANY BUTTONS
`DEPRESSED?
`
`NO
`
`SWITCH TO
`"AWAKE" MODE
`
`414
`
`416
`
`5SET
`PRESSURE
`
`RECEIVE AND
`PROCESS MESSAGE
`
`TRANS
`MISSION
`418
`
`419
`
`
`
`DISPLAY
`CURRENT
`PRESSURE
`
`420
`
`SET TIMER
`COUNTING
`
`422
`
`O
`
`400
`
`
`
`
`
`
`
`HAS BUT ON BEEN
`DEPRESSED FOR 2 SECONOSP
`
`
`
`436
`
`YES
`
`440
`
`442
`
`NCREMENTIDECREMENT
`OF DISPLAY SETTING
`
`SET DISPLAY
`FLASHING
`
`SET
`TMER
`
`4.38
`
`SEND COMMAND
`TO BASE UNIT
`
`TRANS-
`MISSION
`
`439
`
`4OO
`
`Sleep Number Corp.
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`

`

`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 12 of 18
`
`5,652,484
`
`Fig. 19c
`
`444
`
`2 BUTTONS
`ARE DEPRESSED
`
`INTRODUCTION
`PROCEDURE
`ALREADY
`
`THIS UNIT
`
`460
`
`SEND MESSAGE
`
`462 - DISPLAY
`
`446
`
`INTRODUCTION
`PROCEDURE
`NOT ALREADY
`NITIATED BY
`THIS UNIT
`
`448
`
`DISPLAY
`COUNTS
`DOWN
`
`464
`
`RECEIVE
`ACKNOWLEDGEMENT
`
`
`
`O 45
`
`453
`
`452
`
`DISPLAY HYPHENS
`
`466
`
`DSPLAY
`"1C"
`
`TRANS-
`MSSION
`
`SEND COMMAND
`O BASE UNIT
`
`RECEIVE COMMAND
`TO RETURN TO NORMAL
`
`456
`
`RECEIVE
`ACKNOWLEDGEMENT
`
`468
`
`40O O
`
`
`
`458
`
`DPLAY"C1"
`OR "C2' AS
`INSTRUCTED
`
`to-CD
`
`461
`
`TRANS
`MISSION
`
`Sleep Number Corp.
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`Page 13
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`

`

`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 13 of 18
`
`5,652,484
`
`480
`
`
`
`NITALIZE
`COUNTER
`
`Fig. 20
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`TRANSMT
`482
`MESSAGE 1.
`TO BASE
`
`WAIT 0.2 - 0.3
`SECONDS
`
`484
`
`WASA
`VALD RESPONSE
`RECEIVED FROM
`HE BASE UNIT?
`
`DECODE
`MESSAGE
`
`
`
`RETURN
`
`HAVE
`7 ATTEMPTS
`BEEN MADEP
`
`DISPLAY
`ERROR
`CONDITION
`
`
`
`INCREMENT L
`COUNTER
`Fig. 21
`
`
`
`INCREMENT
`
`COUNTERS (v)
`
`
`
`
`
`
`
`PROCESS
`ACTION IF
`
`RECURED (v)
`
`
`
`
`
`PROCESS
`MESSAGE (v)
`
`
`
`Sleep Number Corp.
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`

`

`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 14 of 18
`
`5,652,484
`
`Fig. 22
`
`608
`
`
`
`
`
`
`
`
`
`MESSAGE
`HAS BEEN
`RECEIVED?
`
`61 O
`
`DECODE
`MESSAGE
`
`
`
`
`
`WAS
`CURRENT
`PRESSURE
`REQUESTED?
`
`
`
`
`
`
`
`SET FLAGS
`THAT ACTIVITY
`REQUESTED S
`NECESSARY
`
`616
`
`
`
`Fig. 23a
`
`618
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`S
`ACTION
`RECURED?
`
`SHAND
`UNT INTRODUCTION
`N PROGRESS2
`
`622
`
`MUS THE
`PRESSURE BE
`
`SAN
`ADJUSTMENT
`N PROGRESST
`
`
`
`
`
`TRANS
`MISSION
`
`614
`
`
`
`ANADJUSTMENT -
`REQUEST IS
`PENDING
`
`Sleep Number Corp.
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`Page 15
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`

`

`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 15 of 18
`
`5,652,484
`
`Fig. 23b
`
`628
`
`630
`
`WRITE D
`TO LIST
`
`SEND AN
`ACKNOWLEDGEMENT
`
`632 ir
`
`637 - A
`
`631
`
`TRANS
`MISSION
`
`TRANS
`MISSION
`
`634
`
`
`
`
`
`638
`
`
`
`SECOND
`D RECEIVED
`EN ONE
`MINUTEP
`
`YES
`
`S THE
`SECOND D
`THE SAME
`AS FIRST?
`
`644
`
`SEND MESSAGE
`TO FIRST
`HAND CONTROL
`UNIT
`
`
`
`636
`
`
`
`NO
`
`SEND MESSAGE
`TO END INTRODUCTION
`PROCEOURE
`
`(v)
`
`606
`
`WRITE SECOND
`ID TO LIST
`
`640
`
`SEND MESSAGE
`TO SECOND
`HAND CONTROL
`UNIT
`
`642
`
`TRANS
`MISSION
`
`643
`
`
`
`645
`
`TRANS
`MISSION
`
`
`
`SEND MESSAGES
`TO RESUMENORMAL
`OPERATIONS
`
`TRANS
`MISSION
`
`646
`
`647
`
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`

`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 16 of 18
`
`5,652,484
`
`Fig. 23c
`
`648
`CLOSE WALVE
`IF NECESSARY 1.
`
`
`
`WAT 3 SECONDS
`
`650
`
`
`
`
`
`
`
`START AWD
`CONVERSION
`
`652
`
`WAIT O.1 - O.2
`SECONDS
`
`654
`
`CALCULATE
`CHAMBER'S
`PRESSURE
`
`
`
`656
`
`606
`
`Sleep Number Corp.
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`

`

`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 17 of 18
`
`5,652,484
`
`Fig. 23d
`
`658
`
`659
`
`NO
`
`
`
`
`
`
`
`HAVE 3 SEC'S
`PASSED SINCE
`LAST READING
`
`YES - 660
`
`
`
`CALCULATE
`CURRENT
`PRESSURE
`
`
`
`661
`
`HAS
`ESTMAED
`NFLATION/
`DEFLATION
`PERIOD
`ENDEDT
`
`YES
`
`CALCULATE
`CURRENT
`PRESSURE
`
`FURTHER
`ADJUSTMENT
`NECESSARY?
`
`NO
`
`
`
`
`
`
`
`FURTHER
`ADJUSTMENT
`NECESSARY?
`
`
`
`
`
`
`
`
`
`
`
`662
`
`663
`
`
`
`664
`
`
`
`YES
`
`(v)
`606
`
`SET NEW
`ADJUSTMENT
`RECQUEST
`PENDING
`
`YES
`
`REE
`
`657
`
`cy
`
`665
`
`
`
`NOTE THAT
`ADJUSTMENT
`HAS OVERSHOT
`
`cos ()
`
`Sleep Number Corp.
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`

`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 18 of 18
`
`5,652,484
`
`Fig. 23e
`
`G)
`
`666
`
`CALCUATE
`
`CURRENT
`
`PRESSURE
`
`606- (v)
`
`DFFERENCE
`< O.O. PS
`
`670
`
`NO
`ADJUSTMENT
`
`
`
`
`
`668
`
`
`
`COMPARE
`CURRENT PRESSURE
`AND TARGET
`PRESSURE
`
`DFFERENCE
`> 0.01 PS
`
`682
`
`672
`
`
`
`674
`
`CALCUATE DEFLATON
`MOTOR
`SPEED
`
`
`
`NFLATON
`ORDEFLATION
`NECESSARY
`
`NFLATION CALCULATE
`MOTOR
`SPEED
`
`CACULATE
`THE AMOUNT
`OF TIME UP
`TO 25.5 SEC.
`MAXIMUM
`
`
`
`
`
`684
`
`676
`
`CAL CULATE
`THE AMOUNT
`OF ME UP
`TO 25.5 SEC.
`MAXIMUM
`
`686
`
`START
`MOTOR
`IF
`NECESSARY
`
`OPEN 1688
`WALVE
`
`c.
`
`678
`
`START
`MOTOR
`
`68O
`
`OPEN
`VALVE
`
`606-(v)
`
`Sleep Number Corp.
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`Page 19
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`

`

`5,652,484
`
`1.
`AIR CONTROL SYSTEM FOR AN ARBED
`
`This is a continuation-in-part of application Ser. No.
`08/332,833 filed Nov. 1, 1994 now U.S. Pat. No. 5,509,154.
`
`TECHNICAL FIELD
`This invention relates to improved methods and apparatus
`for attaining and regulating the fluid pressure in one or more
`fluid 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.
`
`5
`
`10
`
`2
`preset pressure to be set. One problem with this arrangement
`was the dramatic change in pressure at the time a user
`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. No. 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 flow of fluid 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 flow of fluid into or out of the mattress.
`Electric motor driven pumps have been used in the past to
`inflate 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 overheating 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.
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`BACKGROUND OF THE INVENTION
`Air Supported mattresses are used with cots and beds to
`provide yieldable body supports. The air mattresses can be
`inflated 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. 4908.895 and 4,644,597, assigned to the assignee of
`the present invention, describe possible constructions of air
`attesSeS.
`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
`30
`divided internally with free fluid flow 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 firmness 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 inflation 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 control 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
`65
`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
`
`Sleep Number Corp.
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`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
`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 firmness 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 firmness of both bladders in a double bladder airmattress
`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 firmness, and responds to commands from the hand
`held unit to change the firmness 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 firmness.
`BRIEF DESCRIPTION OF THE DRAWINGS
`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. 2A is a plan view of a hand control unit of the air
`control system;
`FIG. 2B 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 fitting that is used
`to attach an air mattress to the base unit;
`FIG. 8 is a perspective view of the hose fitting 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 fitting 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
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`housing;
`FIG. 13 is a side elevational view of the fan unit;
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`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;
`FIG. 16A is a top plan view with phantom lines depicting
`the power board beneath the impeller;
`FIG. 16B is a schematic partial section view of a
`re-oriented pump housing and base;
`FIG. 16C is a schematic partial section view of a
`re-oriented pump housing and base with improved air rout
`ing means;
`FIG. 17 is a top plan view of the air distribution unit with
`the right solenoid valve shown in phantom;
`FIG. 18A is a side elevational view of the air distribution
`unit with the right and left solenoid valves shown in phan
`tOm;
`FIG. 18B is a perspective view of the inner portion of a
`snap-fit air distribution unit;
`FIG. 18C is a partial perspective view of the outside of a
`snap-fit air distribution unit;
`FIG. 18D is a partial top perspective view of the outside
`of a snap-fit air distribution unit;
`FIGS. 19a-19c. are flow diagrams depicting the process
`ing steps of the hand control processor upon pressing one or
`two buttons;
`FIG. 20 is a flow diagram depicting the transmission
`sequence followed by the hand control processor;
`FIG. 21 is a flow diagram depicting the overall operation
`of the base processor;
`FIG. 22 is a flow diagram depicting the receiving and
`decoding of messages by the base processor; and
`FIGS. 23a–23e are flow diagrams depicting the process
`ing of time dependent actions by the base processor.
`DETALED 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
`fluid filled 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 floor. 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 flat
`bottom 26 to form therewith a generally rectangular cham
`ber 28. Apair of side by side longitudinal airbladders 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 fill 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 inflated thickness of 5.5 inches.
`Other types and sizes of air bladders as well as bladders
`designed to accept other fluids, e.g. water, can be used in
`mattress unit 14 for resilient support 10.
`A generally rectangular cover 38 fits over edges 18, 20, 22
`and the rear edge 24 to enclose the top of chamber 28. As
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`5,652,484
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`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 airbladders
`30, 32. The air control system 40 includes a hand control
`unit 42 and a base unit 44.
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`The portable power supply 116 is made up of a disposable
`battery or arechargeable 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 unitD 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 receiverd
`transmitter 120 can receive radio signals or transmit radio
`signals, but it cannot transmit and receive at the same time.
`Base Unit Embodiments
`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
`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 airbladder 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 (10Hz) 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
`signalis 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 162 is a digital processor, for example
`Motorola MC68HCOSP6 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 16-bit capture/compare
`timer. The software for the processor 162 is stored in the
`ROM memory during fabrication.
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`Hand Control Unit Embodiments
`Hand control unit 42 shown in FIG. 2A is preferably a
`remote unit physically unconnected to the remainder of the
`air control system 40. FIG. 2B shows an alternate embodi
`ment hand control unit 742, which comprises an analog
`pressure gage indicator 804, and air control buttons 806,
`808. Hand control unit 742 is preferably used with the
`alternate pump configuration described in relation to FIG.
`16B, although it is useful with various pump configurations.
`The hand control unit 42 allows a user to control the air
`pressure within the air bladders 30, 32 while lying on the
`mattress unit 14 or in any other position in the vicinity of the
`air control system 40. Hand control unit 42 is preferably
`used with pump 152 described later below, although it is
`useful with various pump configurations.
`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
`30
`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.
`Preferably, the button (either 106 or 108) which is designed
`to increase the pressure in an airbladder has a protruding top
`portion as felt by the user, while that button designed for
`deflating or reducing air pressure in an air bladder is
`designed with a depressed top portion as felt by a user. This
`further optimizes the ergonomics of the hand control unit
`and facilitates use without even viewing the unit.
`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 willfunction. 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 44
`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.
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`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 mirror image fashion. Each of the
`prongs 195, 196 include an axial portion 197 extending
`outwardly from the enlarged portion 190 of the conn