Adjustable beds

Abstract: An adjustable bed comprises a head end, a foot end, and a planar mattress portion extending therebetween. The head end and foot end each feature a drive screw (32) and a nut housing (30). Each head end and foot end also features tubes which are slidingly received within the head end and the foot end. The tubes are attached via cables (24) to the nut housing (30). Upon rotation of the drive screw (32), the nut housing (30) rises or descends, thereby adjusting the height of the bed. The translational movement of the nut housing (30) along the drive screw (32) is limited by a drive screw pin (38) at the upper and lower extremities of the drive screw (32). The drive screw pin (38) selectively engages a similar slip nut pin (50, 54) located on a slip nut (44) which is received within the nut housing (30). Frictional force between the slip nut (44) and the nut housing (30) is maintained by a pair of pressure plates (66) which are compressively received within the nut housing (30). The compressive force between the slip nut (44) and the nut housing (30) is adjusted by means of a pair of set screws (76) and springs (70).

Description: The invention relates to adjustable beds. It has been proposed in adjustable beds to provide mechanisms to adjust the height of the head end and the foot end. These mechanisms have incorporated drive screws, gears, screws, and pulley and cable arrangements whereby rotation of the drive screw causes movement of a mattress bearing portion of the bed. A common problem with such beds presents itself when a drive screw mechanism within a head end is matched with a drive screw mechanism within a foot end. Oftentimes, beds are disassembled and stored when they are not needed. When the beds are reassembled, it is common for the head end of a particular bed to be fitted with a foot end of a different bed. In some cases, the drive screw mechanism with associated nut housing and pulley arrangement is at a different height along the length of the head end drive screw than is the nut housing and pulley arrangement which is associated with the drive screw mechanism in the foot end. If these head ends and foot ends are assembled into a bed without synchronising the relative locations of the nut housings, the following scenario often occurs. As the height of the adjustable bed is adjusted, the nut housing in the head end, for example, reaches the end of its travel before the drive screw assembly in the foot end reaches the end of its travel. As the motor continues turning to lift the foot end nut housing to the top position, the gears are stripped in the head end motor gear train. Patent Specification CA-A-1170198 discloses a brake mechanism for a bed having an upper frame elevatable with respect to a lower frame by linkage drive means, the brake mechanism comprising a brake nut engaged on a drive screw, the brake nut having a radially extending brake surface thereon to cooperate with a complementary radially extending surface of a surrounding brake housing, resilient means to engage the two surfaces, and spaced apart stop means on the drive screw to engage the brake nut, rotation of the drive screw operating the linkage drive means to change the direction of the upper frame until one of the stop means engages the brake nut, continued rotation of the drive screw thereafter causing the brake surfaces to slip one over the other and not cause any further movement of the linkage drive means. According to the invention there is provided an adjustable bed comprising: a head end supported by head end legs; a foot end supported by foot end legs; a mattress-bearing portion extending between and supported by the head end and the foot end; a respective drive screw, operatively engaged with each of the head and foot ends, and being selectably rotatable, the drive screw having a first drive screw pin and a second drive screw pin fixedly attached at spaced locations thereon; an annular slip nut associated with the drive screw, with slip nut threads which operatively engage the drive screw and an exterior surface having slip nut grooves therein; a pressure plate associated with the slip nut, and having pressure plate grooves in intermeshing operative engagement with the slip nut grooves; a nut housing, receiving the drive screw, the slip nut, and the pressure plate and the nut housing receiving a set screw; connecting means to connect the nut housing to the mattress-bearing portion and being effective to cause movement of the mattress-bearing portion in response to movement of the nut housings; and a spring associated with the pressure plate, the spring being compressively received between the pressure plate and the set screw, to urge the pressure plate against the slip nut to resist relative motion between the pressure plate and the slip nut. One advantage of the present invention is that it provides the capability to utilise head ends and foot ends in a single bed assembly, the drive screw assemblies in the head end and the foot end not having to be synchronized before assembly. Another advantage of the present invention is the ability of the mechanism to synchronise each head end and foot end drive screw assembly by running each drive screw until the nut housing and components therein reach the top or bottom of the respective drive screw. Yet another advantage of the present invention is the ability of the drive screw mechanism to raise and lower the bed without stripping the gears of the motor gear train or the threads of the drive screw. The invention is diagrammatically illustrated by way of example in the accompanying drawings, in which: Figure 1 is a front elevation in partial cross-section of a head end of an adjustable bed according to the invention; Figure 2A is an enlarged front elevation in partial cross-section of the bed of Figure 1; Figure 2B is a side elevation taken on line 2B-2B of Figure 2A; Figure 3 is an enlarged front elevation in partial cross-section of a portion of a head end or a foot end and a tubular leg of an adjustable bed according to the invention; Figure 4 is a side elevation in partial cross-section of a head end or a foot end and a tubular leg of an adjustable bed according to the invention; Figure 5 is a partially sectioned plan view of a nut housing of an adjustable bed according to the invention; and Figure 6 is a cross-sectional view taken on line 6-6 of Figure 5. Referring to the drawings, Figure 1 shows a head end 10 such as is commonly found in adjustable beds. Parallel to the head end 10 would be an identical or similar foot end (not shown). Suspended therebetween would be a planar mattress portion (not shown) which typically receives a mattress and bedding and eventually supports a person's body thereupon. Because the operation and structure of the foot end is identical to that of the head end 10, only the operation of the head end 10 will be explained. The head end 10, along with the foot end and the planar mattress receiving portion, make up the frame of a typical adjustable bed. In some adjustable beds, the height of the bed is adjustable by means of a hand crank (not shown) or an electrical motor (not shown). With reference to Figure 1, Figure 3 and Figure 4, the height of the bed is adjustable by means of front legs 12 which are attached to either side of the head end 10. On the foot end, a pair of rear legs similar to the front legs 12 depend downwardly from the foot end. A bracket 15 is fixedly mounted on each leg and can selectably support the mattress bearing portion. Slidingly received within the downwardly depending front legs 12 are front tubes 14. Attached to the bottom end 16 of each of the front tubes 14 is preferably a castor 18. Attached to the top end 20 of each front tube 14 is a respective cable 24. The cable 24 extends from the top end 20 of the front tube 14 and over a pair of pulleys 26 to a nut housing 30. With reference to Figures 2A and 2B, the nut housing 30 is translated up and down a drive screw 32 by its rotation. The rotation of the drive screw 32 may be effected by means of a hand crank (not shown), an electric motor (not shown), or other conventional arrangement. In one embodiment, rotary motion is transferred to the drive screw 32 by means of mitre gears 34. Fixedly mounted on the drive screw 32 is a first drive screw pin 38 and a second drive screw pin 40. With reference to Figures 5 and 6, a slip nut 44 is received within a hole 46 within the nut housing 30. Fixedly mounted to the top end 48 of the slip nut 44 is an upper slip nut pin 50. Fixedly mounted to the lower end 52 of the slip nut 44 is a lower slip nut pin 54. In the preferred embodiment, the slip nut 44 is made of bronze. The slip nut 44 has a threaded hole 45 therethrough which is operatively associated with the threads of the drive screw 32, such that upon rotation of the drive screw 32, the slip nut 44 translates along the axis of the drive screw 32. The outer surface of the slip nut 44 features slip nut grooves 58 cut therein. The slip nut grooves 58 are not helically extending about the outer surface of the slip nut 44, but rather extend perpendicular to the longitudinal axis of the slip nut 44. A pair of pressure plates 66 have pressure plate grooves 68 cut into an interior surface thereof. The pressure plate grooves 68 intermeshingly cooperate with the slip nut grooves 58 so that the pressure plates may selectably rotate within the slip nut grooves 58. A spring 70 is associated with each pressure plate 66. One end of the spring is adjacent the outer surface 72 of the respective pressure plate 66 and the other end of the spring is adjacent a set screw 76. The set screw 77 is threadedly received within a hole 76 in the nut housing 30. In operation, it is a common occurrence in the use of an adjustable bed, for example in hospitals or in home rental use of beds, for an adjustable bed to be disassembled and stored for a period of time. After such storage, frequently a head end of one bed is matched with a foot end of another bed. In this case, it is common for the nut housing 30 to be at a different position along the drive screw 32 in the head end 10 than might be true in the foot end. When such a head end 10 and foot end are assembled and the bed is either lowered or raised to one extreme, the nut housing and associated assembly will reach the end of a drive screw 32 prior to the assembly at the other end of the bed. In such case, the gears of the motor gear train can be stripped due to the power of the electric motor. In the apparatus described such stripping of gears is avoided and the location of the nut housing 30 and associated parts can be synchronised via mechanical means. The drive screw 32 in each of the head end 10 and the foot end are rotated until one of the slip nut pins 50, 54 contacts one of the drive screw pins 38, 40. When a drive screw pin contacts a slip nut pin, the slip nut 44 is forced to rotate together with the drive screw 32 due to the rotative force applied to the slip nut 44 through the pins. Because the slip nut grooves 58 and pressure plate grooves 68 are parallel grooves extending about the periphery of the slip nut 44, the pressure plates 66 slide within the slip nut grooves 58. In this way, the gears of the motor gear train are not damaged as they rotate until the corresponding nut housing 30 at the other end of the bed also reaches the same extreme position, whether it be top or bottom. In order for the assembly shown in Figures 5 and 6 to operate in this manner, the frictional force between the pressure plates 66 and the slip nut 44 which resists rotational movement between the pressure plates 66 and the slip nut 44 must be set so that it is less than the force required to shear the drive screw pins 38, 40, or the slip nut pins 50, 54, or the gears of the motor gear train. This frictional force is adjustable by adjusting the compressive force of the springs 70 by adjusting the set screw 76. In the preferred embodiment, the spring 70 is made of 2mm (0.078 inch) diameter music wire and has a spring constant of 4316kg/m (241.8 lbs/inch). The preferred spring has 5.5 active coils and 7.5 total coils. An adjustment procedure for springs of the preferred embodiment requires that the set screw 76 be adjusted so that the spring 70 is completely compressed. At this point, the set screw 76 is withdrawn one half turn. In addition, a lubricant is applied to the interface of the pressure plate grooves 68 and the slip nut grooves 58. The preferred lubricant is sold under the tradename "Nyogel". Preferably, the "Nyogel" lubricant should be applied between the pressure plate 66 and the slip nut 44. A second preferred lubricant, "Lubriplate #1242", should preferably be applied between the screw plates and the slip nut 44.

Claims: An adjustable bed comprising: a head end (10) supported by head end legs (12); a foot end supported by foot end legs; a mattress-bearing portion extending between and supported by the head end (10) and the foot end; a respective drive screw (32), operatively engaged with each of the head and foot ends, and being selectably rotatable, the drive screw having a first drive screw pin (38) and a second drive screw pin (40) fixedly attached at spaced locations thereon; an annular slip nut (44) associated with the drive screw (32), with slip nut threads which operatively engage the drive screw and an exterior surface having slip nut grooves (58) therein; a pressure plate (66) associated with the slip nut (44), and having pressure plate grooves (68) in intermeshing operative engagement with the slip nut grooves (58); a nut housing (30), receiving the drive screw (32), the slip nut (44), and the pressure plate (66) and the nut housing receiving a set screw (76); connecting means (24, 26, 15) to connect the nut housing (30) to the mattress-bearing portion and being effective to cause movement of the mattress-bearing portion in response to movement of the nut housings (30); and a spring (70) associated with the pressure plate (66), the spring (70) being compressively received between the pressure plate (66) and the set screw (76), to urge the pressure plate (66) against the slip nut (44) to resist relative motion between the pressure plate (66) and the slip nut (44). An adjustable bed according to claim 1, wherein rotation of the set screw (76) adjusts the resistance. An adjustable bed according to claim 1, including a respective pair of cables (24) having first ends secured to the legs (14) of the head end or the legs (14) of the foot end and second ends secured to the respective nut housing (30) to adjust the height of the head end or foot end in response to movement of the slip nut (44). An adjustable bed according to claim 1, wherein the slip nut grooves (58) are perpendicular to a rotational axis of the drive screw (32).

Inventors: MILLER ROBERT E, QUINTILE MARK J, MILLER, ROBERT E., QUINTILE, MARK J.
Applicants: INVACARE CORP, INVACARE CORPORATION
Application year: 1992
Main classification: A47C19
IPC codes: A61G7, A47C19