Adjustable foundation and mattress assembly

A coil spring mattress and adjustable foundation assembly includes a coil spring mattress; and an adjustable foundation including a mattress support surface including a head and back section hingedly connected to an intermediate section at one end and a leg and foot section hingedly connected to the intermediate section at another end, wherein the intermediate section includes a first portion and a second portion. The intermediate or seat section is configured to increase in length upon articulation of the head and back section and/or the leg and foot section from a flat position or an increase in inclination of any section. Likewise, the intermediate or seat section is configured to decrease in length upon articulation of the head and back section and/or the leg and foot section from an inclined position to a flat position or a decrease in length upon declination of any section.

BACKGROUND

The present disclosure generally relates to mattress assemblies, and more particularly, to coil spring mattress assemblies including an adjustable foundation.

Adjustable mattress assemblies, also commonly referred to as articulating beds are commonly used in the healthcare field and in residential applications. A typical adjustable mattress assembly includes a base and an adjustable mattress frame or support, which is divided into a head and back section, an intermediate seat section, and a leg and foot section. The mattress frame sections are pivotally interconnected and have a continuous range of adjustment. The sections are moveable from a flat, user resting position to a seated position with the legs bent or the legs straight and the occupant's back angled upwardly with respect to the seat section. The sections are pivoted by motor drives, hand operated cranks or through the user's weight.

BRIEF SUMMARY

Disclosed herein is a coil spring mattress and adjustable foundation assembly and process of operation. In one embodiment, the coil spring mattress and adjustable foundation assembly includes a coil spring mattress; and an adjustable foundation frame. The adjustable foundation frame includes side frame members and transverse frame members attached at respective ends of the side frame members to define a generally rectangular shape, and at least one cross rail extending between the side frame members; a mattress support surface including a head and back section hingedly connected to an intermediate seat section at one end and a leg and foot section hingedly connected to the intermediate seat section at another end, wherein the intermediate seat section includes a first portion and a second portion, wherein the first portion is hingedly connected to the head and back section and the second portion is hingedly connected to the leg and foot section; and a first actuator having an extending and retracting member operatively coupled to a linkage assembly to effect inclination or declination of the head and back section relative to the intermediate seat section and inclination or declination of the foot and leg section, wherein the first actuator is further operative to effect an increase or decrease in a length of the intermediate seat section by movement of the first portion relative to the second portion.

In another embodiment, the coil spring mattress and adjustable foundation includes the coil spring mattress; and a foundation frame including side frame members and transverse frame members attached at respective ends of the side frame members to define a generally rectangular shape, and at least one cross rail extending between the side frame members; a mattress support surface including a head and back section hingedly connected to an intermediate seat section at one end and a leg and foot section hingedly connected to the intermediate seat section at another end, wherein the intermediate seat section includes a first portion and a second portion, wherein the first portion is hingedly connected to the head and back section and the second portion is hingedly connected to the leg and foot section; a first actuator having an extending and retracting member operatively coupled to the linkage assembly to effect selective inclination or declination of the head and back section relative to the intermediate seat section, wherein the first actuator is further operative to effect an increase or decrease in a length of the intermediate seat section by movement of the first portion relative to the second portion; and a second actuator having an extending and retracting member operatively coupled to the linkage assembly to effect selective inclination or declination of the leg and foot section.

The process for operating a coil spring mattress and adjustable foundation assembly includes changing an angle of a head and back section relative to an intermediate seat section of an adjustable foundation, the adjustable foundation comprising a mattress support surface including the head and back section hingedly connected to an intermediate seat section at one end and a leg and foot section hingedly connected to the intermediate seat section at another end, wherein the intermediate seat section includes a first portion and a second portion, wherein the first portion is hingedly connected to the head and back section and the second portion is hingedly connected to the leg and foot section; and lengthening the intermediate seat section upon inclining the head and back section by moving the first portion away from the second portion; or shortening the intermediate seat section upon declining the head and back section by moving the first portion towards the second portion, wherein a coil spring mattress remains flush with a terminal end of the head and back section during the changing of the angle of the head and back section relative to the intermediate seat section.

The disclosure may be understood more readily by reference to the following detailed description of the various features of the disclosure and the examples included therein.

DETAILED DESCRIPTION

Referring now toFIGS. 1-2, there is shown a perspective view of an adjustable mattress foundation10in accordance with the present disclosure. The adjustable mattress foundation10is movable between a fully horizontal position and a fully inclined position (FIG. 1), wherein the head and section and the leg and foot section are shown elevated relative to the intermediate seat section. An operator or user may sleep with the adjustable bed10generally in its fully horizontal position, in the fully inclined position, or in any position therebetween.

The adjustable mattress foundation10includes a generally rectangular foundation frame12, a mattress support surface14, and a linkage assembly16(shown more clearly inFIG. 2). The linkage assembly16is operable to articulate the various sections of the mattress support surface14, which can include a head and back section18, an intermediate seat section20, and a leg and foot section22. A covering24is disposed about the various sections18,20and22, wherein a partial cutaway view is provided in the Figures. The covering may be padded and may include a rigid substrate such as wood or plastic. Advantageously, the intermediate seat section20is formed of two pieces configured to increase in length upon articulation of the head and back section18and/or the leg and foot section22from a flat position or an increase in inclination. Likewise, the intermediate seat section20is configured to decrease in length upon articulation of the head and back section18and/or the leg and foot section22from an inclined position to a flat position or a decrease in length upon declination of any section. By doing so, a prone user does not have to shift his position on the mattress in order to accommodate the inclination or declination. Additionally and surprisingly, a coil spring mattress disposed thereon has been found to better contour to the shape provided by the different sections during articulation, which also helps minimize pinch points as will be described in more detail below.

FIGS. 3 and 4provide side sectional views of coil spring mattresses seated on adjustable foundations at an inclined position in accordance with the present disclosure and in accordance with the prior art, respectively. The coil spring mattress-adjustable foundation assembly400of the present disclosure includes an adjustable foundation410having the feature of the increased length of the intermediate seat section and the prior art coil spring mattress-adjustable foundation assembly500includes an adjustable foundation510having a static intermediate seat section, i.e., the length of the intermediate sect section does not change upon articulation.

The adjustable foundation410of the exemplary coil spring mattress-adjustable foundation assembly400can include a similar construction to adjustable foundation10, for example. As such, the adjustable foundation410includes a generally rectangular foundation frame412, a mattress support surface414upon which a coil spring mattress402is supported, and a linkage assembly416(a portion of which is shown). The linkage assembly416is operable to articulate the various sections of the mattress support surface414, which includes a head and back section418, an intermediate seat section420, and a leg and foot section422. As noted above and described more fully below, the intermediate seat section420can formed of two pieces configured to increase in length upon articulation of the head and back section418and/or the leg and foot section422from a flat position or any increase in inclination. The head and back section418of the illustrated coil spring mattress-adjustable foundation assembly is at a 65 degree angle and the leg section of the leg and foot section is at a 30 degree relative to a horizontal plane defined by ground.

In contrast, the adjustable foundation510of the prior art coil spring mattress-adjustable foundation assembly500includes a generally rectangular foundation frame512, a mattress support surface514upon which the same coil spring mattress402as depicted inFIG. 3is supported, and a linkage assembly516(a portion of which is shown). The linkage assembly516is operable to articulate the various sections of the mattress support surface514, which includes a head and back section518, an intermediate seat section520, and a leg and foot section522. The intermediate seat section520is static and does not increase or decrease in length upon articulation of the head and back section518and/or the leg and foot section522. The head and back section518of the illustrated coil spring mattress-adjustable foundation assembly500is at a 65 degree angle and the leg section of the leg and foot section is at a 30 degree relative to a horizontal plane defined by ground.

Compared to the prior art adjustable foundation510without the extendible intermediate seat section520, the adjustable foundation of the present disclosure provides the intermediate seat section420with increased distance upon inclination, which enables an increased bend radius of curvature and improved coil behavior for the coil spring mattress402when seated thereon. Less constraint and compression is observed while increasing the longevity of the coils. The less constraint translates to increased comfort level to the user. Moreover, by increasing the length of the intermediate section420relative to the head and back section418the sliding of the coil spring mattress402against the head and back section418that would typically occur with prior art coil spring/adjustable foundation assemblies500is substantially decreased or eliminated, which reduces wear and tear on the head and back section. Still further, the coil spring mattress402contours gently with the exemplary coil spring mattress-adjustable foundation assembly400and remains flush with the terminal end of the head and back section418as shown, thereby improving aesthetics of the coil spring adjustable foundation assembly.

As shown inFIG. 4, the prior art coil spring mattress-adjustable foundation assembly500results in a tighter radius of curvature due to the static non-extendible configuration of the intermediate seat section520, which significantly affects contour of the mattress402when at an inclined position. The shorter distance can result in lift off (poor contouring) depending on the properties the coil spring mattress. Moreover, the user can feel pinched at the surface of the coil spring mattress402of the prior art mattress-adjustable foundation assembly500depending on the degree of inclination. Still further, inclination of the prior art coil spring mattress-adjustable foundation assembly500causes the coil spring mattress402to slide beyond the terminal end of the head and back section518as shown, which can affect the aesthetics as well as causing the sheets covering the coil spring mattress to become undone.

As shown inFIG. 5, the generally rectangular foundation frame12generally includes side frame members24,26, transverse frame members28,30attached to respective ends of the side frame members to define the generally rectangular shape to the foundation frame10, and support legs32at corners of the foundation frame12for elevating the foundation frame relative to ground. The support legs32may be secured to the frame members. The foundation frame12further includes one or more cross rails34extending from one side rail24to the other side rail26. A frame casing36is disposed about a perimeter of the foundation frame12and has a width sufficient to shield the linkage assembly16from view when the various sections18,20,22of the mattress support surface14is in a flat position. The frame casing36as shown extends upward from the foundation frame, i.e., the frame casing36is attached at about a lower surface thereof to the foundation frame12. The cross rails34are spaced about and are configured to provide additional support to the mattress support surface14as well as provide an opening sufficient to accommodate the linkage assembly16, which primarily underlies the intermediate or seat portion20. As shown, two cross rails34are spaced apart from one another and generally positioned to support the leg and foot section22, and one cross rail is generally positioned to support the head and back section18. However, it should be apparent that more or less cross rails could be utilized.

As shown more clearly inFIG. 6, the illustrated head and back section18includes a rigid frame38including three longitudinal cross members40extending from one side of the frame to an opposing side and a transverse cross bar42. At least two of the longitudinal cross members40aare equally spaced from a midline of the rigid frame and positioned to be in general alignment with a roller arm of the linkage assembly16. As will be discussed in greater detail below, the roller arm engages the longitudinal cross member of the head and back section during operation thereof. The third longitudinal cross member40bmay be at a midline of the rigid frame38, which provides additional support to the frame. Transverse cross bar42is disposed at a lower portion of the rigid frame. The rigid frame38has a width dimension about equal to a width of a mattress to be used with the adjustable foundation. The length of the rigid frame38is generally dimensioned to at least accommodate the length of a typical user's head and back section. A plurality of transverse and longitudinal wires44,46, respectively, may be coupled to a top surface of the rigid frame40so as to provide additional support to the mattress when in use.

In another embodiment, the head and back section18includes a powered head tilt as is generally shown inFIG. 7. The head and back section18includes a first portion50hingedly connected to a second portion52. An actuator via a link arm (not shown) is coupled to the first portion50to effect movement thereof relative to the second portion52. Each portion50,52includes a rigid frame54,56, respectively, wherein the rigid frame54of the first portion50is dimensioned to articulate an end of the mattress disposed thereon, e.g., the user head region and the rigid frame56of the second portion52is generally dimensioned to accommodate the lumbar region of a user. Each portion may further include a plurality of transverse and longitudinal wires58,60, respectively, coupled to a top surface of the rigid frame. The second portion52, which bears the greatest weight load relative to the first portion50when in use, includes three longitudinal cross members62extending from one side of the frame to an opposing side and a transverse cross bar64, which has a similar function as the embodiment described inFIG. 6.

Referring back toFIG. 6, the intermediate seat section20includes a first portion66and a second portion68, wherein the first and second portions collectively define the seat section20and function to increase a length of the intermediate seat section20when the adjustable foundation10is raised from a flat position to an inclined position. In a similar manner, the first and second portions66,68, respectively, function to shorten a length of the intermediate or seat section20when the adjustable foundation10is declined, e.g., from an inclined position to a flat position. The increase or decrease in length is represented by arrow70. The first portion66includes a rigid frame74hingedly connected at one end to the head and back section rigid frame38such that the head and back section18pivots at pivot point72when inclined or declined. The other frame end is a free end and is close to or abuts the second portion68when the adjustable foundation12is in a flat position. The rigid frame74may further include a plurality of transverse and longitudinal wires76,78, respectively, coupled to a top surface thereof. Advantageously, the motion and extension of the first portion66of the intermediate seat section20causes the head and back section18to slide towards the wall, which helps to counteract the amount of distance that the mattress is traveling away from the headboard in order for the occupant to maintain proximity to the night stand. The motion and extension of the first portion66eliminates the need for an additional retracting frame.

The second portion68includes u-shaped rigid frame80and is hingedly connected to the leg and foot section36at one end. The other end includes an opening defined by the u-shaped rigid frame. During operation, the first portion66is dimensioned to laterally move within the u-shaped opening provided in the second portion68, wherein the second portion68is stationary. The rigid frame80may further include a plurality of transverse and longitudinal wires82,84, respectively, coupled to a top surface thereof. Coupled thereto are support members85, which are configured to seat upon the side members24,26of the foundation frame12when assembled so as to provide additional support.

The leg and foot section22includes first and second portions86,88hingedly connected to one another, wherein first portion86is also hingedly connected to the intermediate seat section20as described above. Similar to the sections18,20above, the first and second portions86,88of the leg and foot section22include rigid frames90,92, respectively, and a plurality of transverse and longitudinal wires94,96, respectively, coupled to a top surface thereof.

Referring now toFIGS. 8-10, the linkage assembly16includes a linkage support frame100having a dimension configured to abut or be in close proximity to the interior perimeter of the foundation frame12. The linkage support frame100, which is seated on cross rails34, includes side frame members102,104, and transverse frame members106,108attached to respective ends of the side frame members to define a rectangular shape. The side frame members102,104further include two pairs of pillars110,112, spaced apart from one another underlying the seat section. The pillars110,112, are configured to receive torsional members114,116extending between the side members102,104, which are operative with the linkage assembly16to articulate sections18,20,22of the adjustable foundation12. Cross bar118is also attached to the side members102,104as shown and is indirectly positioned underneath torsional member116.

As shown more clearly inFIG. 10, a linear actuator120is attached at one end to the cross bar118and at the other end to crank arm122. Crank arm122includes one end pivotally connected the end of the actuator120and the other end is fixedly attached to the torsional member114. The linear actuator122includes a motor (not shown) effective to create actuator motion in a straight line so as to rotate the torsional member114upon extension and retraction of the linear actuator. A pair of roller arms124is coupled at one end to torsional member114and includes a roller126at the other end. The roller arms124are spaced apart from one another and aligned with the longitudinal cross members40aof the head and back section18. In this manner, upon actuation of the linear actuator120to effect rotational movement of the torsional member114, the rollers126contact the longitudinal cross members40aupon inclination and declination of the head and back section18.

Referring now toFIG. 10, a pair of crank arms130is attached at about respective ends to the torsional member114. Link arms132are attached to the other end of the crank arms130to define pivot point131and to the rigid frame74of the first portion66of the intermediate or seat portion20. Upon inclination/declination of the head and back portion18, which is hingedly connected to the first portion66, the torsional member114will rotate as a consequence of the extension/retraction of the linear actuator120, which will move the first portion66relative to the second portion68, thereby increasing or decreasing the length of the intermediate or seat section20.

Link arms134include an end pivotally connected to the other end of the crank arms130and pivotally connected at the other end to crank arm136. The other end of crank arm136is coupled to torsional member116. As a result, upon extension/retraction of the linear actuator120, torsional member116will rotate in addition to torsional member114. Crank arms138are coupled to the torsional member116and is pivotally connected at the other end to link arm140, wherein the other end of the link arm140is hingedly coupled to either the first portion86or the second portion88of the leg and foot section22at about the hinged connection such that rotation of the torsional member116indirectly via linear actuator120will move the selected portion86or88of the leg and foot section22upwards or downwards depending on whether the leg and foot section is being raised or lowered. In the above described embodiment, the single actuator will provide simultaneous tilting (inclination/declination) of the head and back section18and tilting of the foot and leg section22, wherein the intermediate or seat section20is lengthened relative to the flat position upon moving to a tilt position or shortened upon declination. Moreover, the above mechanism and configuration permits “wall hugging” placement of the mattress since the head and back section18pivots about a fixed axis defined by torsional member114and the motion and extension of the first portion66of the intermediate seat section20causes the head and back section18to slide towards the wall, i.e., towards a head end of the adjustable foundation assembly. By doing so, the adjustable mattress assembly, if having the head end abutting a wall, will cause the head and back section18to “wall hug”, i.e., stay in close proximity to the wall regardless of inclination angle. Advantageously, this permits constant and easy access to a night table that may be disposed adjacent to the head and back section.

In another embodiment shown inFIGS. 11-12, the adjustable foundation10includes a second actuator such that independent movement of the head and back section18and the leg and foot section22can be effected. In this embodiment, the mattress support frame100includes an additional cross bar202extending between side members102,104and generally positioned underlying torsional member114. A second linear actuator204is attached at one end to the cross bar202and pivotally connected at the other end to crank arm206. Crank arm206is coupled at the other end to torsional member116. Similar to the first linear actuator120, the second linear actuator204includes a motor (not shown) effective to create actuator motion in a straight line so as to rotate the torsional member116upon extension and retraction of the linear actuator. A pair of roller arms208is coupled at one end to torsional member116and includes a roller210at the other end. The roller arms208are spaced apart from one another, wherein the roller arms208are aligned with the longitudinal cross members210in the first portion86of the leg and foot section22. In this manner, upon selective actuation of the second linear actuator204to effect rotational movement of the torsional member116, the rollers210contact the longitudinal cross members212upon inclination and declination of the head and back section18.

In this embodiment, the first linear actuator120is free of crank arms136,138and link arms134, which were operable to articulate the leg and foot section22in the embodiment described above. As a result, selective actuation of the first linear actuator120is operative to move the first portion66of the intermediate or seat section20and effect inclination or declination of the head and back section18. The end user then has the choice of selective actuation of the first and/or second linear actuators120and/or204, respectively, to provide the desired positioning of the mattress support surface14.

In still another embodiment shown inFIGS. 13-16, the head and back section18includes a vibratory unit generally designated300coupled to a lumbar support member302. The head and back section18includes a rectangular shaped opening304in the second portion52and a lumbar support member302within the opening304. The lumbar support member302includes a rectangular shaped rigid frame306hingedly connected at a top end of the opening304to the second portion52. The rectangular rigid frame may be selectively raised as shown or coplanar relative to the first portion52. In this manner, the vibratory units300, which are coupled to the lumbar support member302, can be moved upwardly at an arc so that the vibratory unit may maintain contact and effectiveness with a mattress disposed thereon. The rigid frame306further includes a transverse cross member308extend therebetween. Vibratory units300, two of which are shown, are coupled to the transverse cross bar308. However, it should be apparent that more or less vibratory units300can be utilized.

The vibratory unit300generally includes a variable speed motor with a shaft and an eccentric weight attached to the shaft causing the motor to vibrate when in use. The frequency of the vibrations produced within the mattress may be controlled by varying the speed of each motor. The amplitude of the vibration may be controlled by re-positioning the eccentric weight. Operation of the individual vibrating units thusly imparts a resonating effect to the mattress and to a person reclining upon the mattress. By varying the frequencies of the vibratory impulses and the level of resonance, a person may recline upon the mattress for its comforting effects or, alternatively, be slowly lulled to sleep.

As shown more clearly inFIG. 15, the lumbar support member302can be articulated via actuator310. The actuator310is coupled to a crank arms312attached to a torsional member314. Roller arms316are coupled to the torsional member314such that the extension or retraction of the actuator, e.g., a linear actuator, effects rotation of the torsional member via crank arms312, which effects inclination declination of the lumbar support member302.

It should be apparent that any of the section18,20, and22of the adjustable foundation can be modified to include a vibratory unit such as described above. By way of example, vibratory units can be coupled to the first portion86of the leg and foot section22.