Abstract:
An adjustable bed is provided that includes a bed frame defined by a pair of side rails, a rear rail, and a front rail. A mattress support is disposed on top of the bed frame and includes a plurality of support panels, coupled in succession using hinges such that at least one support panel can be articulated, causing the panel to pivot about the hinge connection with an adjacent panel. An adjustment mechanism is provided that includes torque tubes that each include a torque shaft and lift links. The torque tubes are removably attachable to the side rails of the bed frame by inserting bushings on the ends of the torque shafts into slots running along the insides of the side rails. A motor is coupled to the torque tubes, locking the torque tubes in place. A set of foot links is provided for supporting a foot panel during articulation of an adjacent leg panel.

Description:
BACKGROUND 
       [0001]    Adjustable beds are a versatile alternative to conventional beds because they allow the user to position the bed according to various configurations. Typically, adjustable beds allow for at least the head and foot of the bed to be raised and lowered. In adjustable beds, the mattress typically rests on a mattress support that consists of three or four support panels. The support panels are arranged end-to-end and each panel is pivotably connected to adjacent panels using hinges. For example, in the case of a four-section mattress support, the adjustable bed includes a head support panel, a center support panel, a leg support panel, and a foot support panel. The support panels are connected such as to allow pivotal movement between adjacent panels about parallel axes transverse to the length of the bed. 
         [0002]    Adjustable beds are typically quite heavy and include a fair amount of hardware, particularly as part of the adjustment mechanisms. Much of the hardware on most adjustable beds is interconnected and requires appropriate experience and tools to assemble. Accordingly, adjustable beds are often shipped partly pre-assembled as one large and heavy package and often must be assembled for a user by a service technician. Moreover, adjustable beds typically include shrouds or other types of covers to hide the operational hardware from view so that an appealing aesthetic appearance can be maintained. 
       SUMMARY 
       [0003]    The invention is defined by the claims below. This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. 
         [0004]    Embodiments of the present invention relate to an adjustable bed with a break-down feature that allows the adjustable bed to be manufactured and shipped in several pieces and can be reassembled by a consumer with simple tools. The adjustable bed includes a number of support panels arranged end-to-end and interconnected by hinges so that individual panels can be articulated independent from other panels. The adjustable bed also includes a base having a bed frame that includes a pair of parallel opposed side rails, a rear rail, and a front rail. An adjustment mechanism is coupled to the base and adapted to manipulate a support panel. The adjustment mechanism includes a torque tube that is rotatably coupled to the frame and that engages a support panel so that when the torque tube is rotated by a motor coupled thereto, the support panel articulates, thereby adjusting the position of the bed. 
         [0005]    Further embodiments of the present invention provide for an adjustable bed with a simple and aesthetically pleasing appearance. In some embodiments, the adjustable bed includes a frame having a pair of parallel opposed side rails, a rear rail, and a front rail. The adjustable bed also includes a mattress support that has a center support panel secured to the side rails. A head support panel is pivotably connected to one side of the center support panel and a leg panel is pivotably connected to the other side of the center support panel. A foot panel is pivotably connected to the other side of the leg panel. The adjustable bed further includes an adjustment mechanism including two torque tubes adapted to articulate the head and leg panels. The torque tubes are removably coupled with the side rails via a bushing on both ends of each torque tube that is configured to fit and slide within a slot that runs along an inside wall of the side rail. The adjustable bed also includes a pair of foot links that provide stability and support to the foot support panel during articulation of the adjacent leg support panel. 
         [0006]    According to a further embodiment of the invention, an adjustable bed is provided that includes a mattress support having a head support panel, a stationary center support panel, a leg support panel, and a foot support panel. The head support panel is configured to be articulated using a head panel adjustment mechanism that includes a torque tube slidably coupled to the side rails. The foot support panel is elevated in response to articulation of the leg support panel, which is accomplished using a foot panel adjustment mechanism that includes a second torque tube slidably coupled to the side rails. An electric motor is provided for actuating the torque tubes as well as holding the torque tubes in place. Foot links provide support to the foot panel during articulation of the leg support panel. 
         [0007]    These and other aspects of the invention will become apparent to one of ordinary skill in the art upon a reading of the following description, drawings, and the claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    The present invention is described in detail below with reference to the attached drawing figures, wherein: 
           [0009]      FIG. 1  is a perspective view showing an adjustable bed in accordance with an embodiment of the present invention; 
           [0010]      FIG. 2  is a side view of an adjustable bed with a mattress in accordance with an embodiment of the present invention; 
           [0011]      FIG. 3  is a bottom view of an adjustable bed having a removably attached adjustment mechanism in accordance with an embodiment of the present invention; 
           [0012]      FIG. 4  is an enlarged bottom view showing an exemplary coupling of a torque tube and a side rail of an adjustable bed in accordance with an embodiment of the present invention; 
           [0013]      FIG. 5  is an enlarged perspective showing an exemplary coupling of a torque tube using a slot in a side rail of an adjustable bed in accordance with an embodiment of the present invention; and 
           [0014]      FIG. 6  is another perspective view of an adjustable bed with a mattress in accordance with an embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0015]    Referring to the drawings, and particularly to  FIG. 1 , there is illustrated an adjustable bed  10  in accordance with an embodiment of the present invention. The adjustable bed  10  includes a bed frame  12 , a mattress support  14 , and an exemplary adjustment mechanism  16  in accordance with an embodiment of the present invention. As illustrated in  FIG. 1 , the bed frame  12  is roughly rectangular and includes a pair of parallel opposed side rails  18  and  20 , a front rail  22 , and a rear rail  24 . The bed frame  12  can also include legs  26 . In the illustrated embodiment, the legs  26  are welded onto the side rails  18  and  20 , thereby minimizing noise to due metal parts moving against other metal parts or parts of another material. In another embodiment, the legs  26  can be detachable or adjustable legs. In an embodiment, side rails  18  and  20 , front rail  22 , and rear rail  24  are hollow tubular structures. In embodiments, the hollow tubular structures are rectangular, and in other embodiments, the tubular structures can be rounded. 
         [0016]    As illustrated in  FIG. 1 , mattress support  14  includes a number of support panels  30 ,  32 ,  34 , and  36 . A center support panel  30  is secured on a first side to one side rail  18  and on a second side to the other side rail  20 . The center support panel  30  is pivotably coupled on a third side to one side of a head support panel  32  and pivotably coupled on a fourth side to one side of a leg support panel  34 . The other side of leg support panel  34  is pivotably connected to a foot support panel  36 . These pivotable couplings are achieved by including a hinge  38  at each interface between two adjacent support panels  30 ,  32 ,  34 , and  36 . In an embodiment, mattress support  14  includes four support panels  30 ,  32 ,  34 , and  36 . In other embodiments, mattress support  14  can include fewer than four support panels, while in still further note, mattress support  14  can include more than four support panels. 
         [0017]    As illustrated in  FIG. 1 , the adjustment mechanism  16  includes a torque tube  40  that is disposed between the two side rails  18  and  20 , and is rotatably coupled to each side rail  18  and  20 . The torque tube  40  includes a torque shaft  42  extending between the two side rails  18  and  20  and a pair of parallel opposed lift links  44  that include lift wheels  46  that engage the head support panel  32 . An electric motor  48  is coupled with the torque tube  40  and is adapted to cause the torque shaft  42  to rotate, thereby moving the lift links  44  to cause articulation of the head support panel  32 . For example, rotation of the torque shaft  42  in a first direction (counter-clockwise in  FIG. 1 ) causes the lift links  44  to apply a rotational force in the first direction to the head support panel  32 , thereby causing the head of the adjustable bed  10  to articulate. Although not shown in  FIG. 1 , the adjustable bed  10  may also include a second torque tube used to articulate the leg support panel  34 . The adjustable bed  10  includes a pair of parallel opposed foot links  52  (only one of which is shown in  FIG. 1 ) that provide support to the foot support panel  36  such that foot support panel  36  can elevate in response to articulation of the leg support panel  34 . 
         [0018]    Turning now to  FIG. 2 , an adjustable bed  10  is shown to include, as illustrated in  FIG. 1 , a bed frame  12  and a mattress support  14 . Additionally, the illustration of  FIG. 2  includes a mattress  54  attached to the top of the mattress support  14 , an exemplary head panel adjustment mechanism  56 , an exemplary leg panel adjustment mechanism  58 , and a pair of parallel opposed foot links  52  in accordance with an embodiment of the present invention. In an embodiment, the mattress  54  is attached to the mattress support  14  using mattress retainer clips. In another embodiment, the mattress  54  is attached to the mattress support  14  using mattress retainer brackets such as those described in U.S. Pat. No. 7,047,579 to Piana et al. In a further embodiment, the mattress  54  is attached to the mattress support  14  using an attachment panel such as is described in U.S. application Ser. No. (not yet assigned), filed (date not yet established, Attorney Docket No. LGPL.139922). 
         [0019]    As shown in  FIG. 2 , the head panel adjustment mechanism  56  includes a first torque tube  40  having lift links  44 . The lift links  44  are attached to a torque shaft (not shown in  FIG. 2 ) at a first end and include lift wheels  46  rotatably coupled to a second end that engage the head support panel  32 . The leg panel adjustment mechanism  58  includes a second torque tube  60  having lift links  62 . The lift links  62  are attached to a torque shaft (not shown in  FIG. 2 ) at a first end and include lift wheels  66  rotatably coupled to a second end that engage the leg support panel  34 . 
         [0020]    The two torque tubes  40  and  60  are connected to, and operated by, an electric motor  48 . One example of an electric motor suitable for use with embodiments of the present invention includes the OKIN OKIMAT 2, available from OKIN of Gummersbach, Germany. As illustrated, the first torque tube  40  engages the head support panel  32  such that when the first torque tube  40  is rotated in a first direction (e.g., counter-clockwise), the head support panel  32  is rotated in the first direction (e.g., counter-clockwise) around the hinge  41 , thereby actuating the head of the adjustable bed  10  to cause the same to be oriented in an upright position. It should be understood by those of ordinary skill in the art that the various adjustable portions of adjustable bed  10  can be adjusted by varying degrees into a multitude of positions. Similarly,  FIG. 2  also illustrates that the second torque tube  60  engages the leg support panel  34  such that when the second torque tube  60  is rotated in a second direction (e.g., clockwise), leg support panel  34  is rotated in the second direction (e.g., clockwise) around the hinge  43 , thereby actuating the foot of the adjustable bed  10  to cause the same to be oriented in an upright position. 
         [0021]    Adjustable bed  10  further includes at least one foot link  52  that is rotatably coupled on one end to a foot support panel  36  and rotatably coupled at the other end to frame  12 . The foot link  52  acts as a lever to guide foot support panel  36  into an elevated position with respect to frame  12  when support panel  34  is rotated into an upright position. The foot support panel  36  rotates in the first direction (e.g., counterclockwise) about hinge  45  when leg support panel  34  is rotated in the second direction (e.g., clockwise) about hinge  43 . It will be understood by those of ordinary skill in the art that this configuration provides for adjusting bed  10  into traditional positions associated with an adjustable bed  10 . 
         [0022]    Turning now to  FIG. 3 , the adjustable bed  10  is shown from underneath. As illustrated, the adjustable bed  10  includes a bed frame  12 , a mattress support  14  and adjustment mechanisms  56  and  58 . The bed frame  12  includes a pair of opposed side rails  18  and  20 , a rear rail  22 , and a front rail  24  that generally form a rectangular base. In embodiments, the rails  18 ,  20 ,  22 , and  24  can be tubular rails and in some embodiments, the rails  18 ,  20 ,  22 , and  24  are rectangular. The mattress support  14  is shown to comprise a center support panel  30  that is fixably attached at one or more attachment points  70  on each side to the side rails  18  and  20 . Attachment points  70  can include, for example, screws or bolts. The mattress support  14  further includes a head support panel  32 , a leg support panel  34 , and a foot support panel  36 , with adjacent panels coupled by a hinge  38 . A pair of parallel opposed foot links  52  are pivotably attached to the side rails  18  and  20  at a first end  72  and pivotably attached to the foot support panel  36  at a second end  73 . The attachments  72  can include bolts in combination with bearings, or other hardware adapted for creating a pivotable connection and the attachments  73  can include, for example, screws or bolts. 
         [0023]    The head adjustment mechanism  56  includes, as illustrated in  FIG. 3 , a torque tube  40  having a torque shaft  42  extending between the two side rails  18  and  20  and a pair of parallel opposed lift links  44  attached to the torque shaft  42  at a first end and extending away from the torque shaft  42 . The lift links  44  each include a lift wheel  46  rotatably coupled to a second end that engages the head support panel  32 . Similarly, the leg panel adjustment mechanism  58  includes a second torque tube  60  having lift links  62 . The lift links  62  are attached to a torque shaft  64  at a first end and include lift wheels  66  rotatably coupled to a second end that engage the leg support panel  34 . 
         [0024]    The torque shafts  42  and  64  each extend between the side rails  18  and  20  and are rotatably coupled to the side rails  18  and  20  such that the torque tubes  40  and  60  can be removed from the frame  12  without the use of tools. This removable coupling is achieved by configuring the torque shafts  42  and  64  to slide into and along slots  74 . Further, the torque shafts  42  and  64  each include a fitting  76  for attaching an electric motor (not illustrated in  FIG. 3 ) thereto. The electric motor can rotate the torque shafts  42  and  64 , thereby actuating the lift links  44  and  66 , causing the head support panel  32  and the leg support panel  34  to articulate, respectively. 
         [0025]      FIG. 4  illustrates an enlarged bottom view showing an exemplary attachment of a torque tube  40  to a side rail  18 . As illustrated in  FIG. 4 , the torque shaft  42  includes a bushing  80  attached to the end. The bushing  80  includes a first cylindrical portion  82 , a narrower second cylindrical portion  84 , a ridge  86 , and a third cylindrical portion  88 . It is apparent from the the illustration of  FIG. 4  that the components  82 ,  84 ,  86 , and  88  of the bushing  80  generally form a key structure configured to fit within a key-hole structure defined by an opening  92  to a slot  94  that runs along an inside surface of the side rail  18 . The opening  92  is oriented on a bottom surface of the side rail  18  and includes a lower portion  96  of the slot  94 . The slot  94  is slightly wider than the second cylindrical portion  84  of the bushing  80  but narrower than the first cylindrical portion  82  and the ridge  86 , such that the slot  94  receives and supports the bushing  80 . Turning to  FIG. 5 , after inserting the bushing  80  into the opening  92 , the torque shaft  42  slides up the lower portion  96  of the slot  94  and then onto an upper, roughly horizontal portion  98  of the slot  94 . The torque shaft  42  can be slid along the upper portion  98  of the slot  94  until the torque shaft  42  is oriented in an assembled position  100 , as illustrated in  FIG. 4 . 
         [0026]    The present invention has been described in relation to particular embodiments, which are intended in all respects to be illustrative rather than restrictive. In embodiments, an adjustable bed is described that is configured such that the frame, adjustment mechanisms, motor and mattress support can be manufactured and shipped disassembled. In some embodiments, the adjustable bed can be assembled by a consumer with relative ease and simple tools. Moreover, as illustrated, for example, in  FIG. 6 , an adjustable bed  10  is presented that includes simple adjustment mechanisms  110  and other construction such that the adjustable bed has a simple and sleek appearance. In some embodiments, the adjustable bed doesn&#39;t include a complex assembly of mechanisms, thus limiting the necessity of attaching a shroud to the adjustable bed to mask such an assembly. Alternative embodiments will become apparent to those of ordinary skill in the art to which the present invention pertains without departing from its scope. 
         [0027]    From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects set forth above, together with other advantages which are obvious and inherent to the system and method. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.