Patent Publication Number: US-6990698-B2

Title: UPS shippable adjustable articulating bed

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     Not applicable 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable 
     INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC 
     Not applicable 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates generally to adjustable articulated beds having a deck mattress support surface which will articulate to separately raise the back and the upper and lower legs of a user lying thereatop. More particularly, this invention relates to such an articulated bed which has separable head/back support and leg support assemblies which are connectable together and which are easily separately shippable under conventional UPS and other common carrier shipping size and weight limits for economy. 
     2. Description of Related Art 
     Adjustable beds for comfort and therapy are extremely well known and provide support surfaces for a mattress which will incline the back/head of a user to any desired angle and will also separately incline the legs of the user for both comfort and therapeutic purposes. However, these articulated beds include mattress support or deck structure and motor driven power units which, in their assembled form, are extremely heavy and exceed all conventional economical shipping means available and therefore fall into categories of freight shipping costs which are substantially higher in shipping rates. 
     The substantially higher cost for such an adjustable bed is due, in part, to the high freight and delivery costs. Freight charges can exceed $150 and delivery and assembly costs for each adjustable twin bed, for example, weighing over 170 lbs. requires a two-man delivery team. Such costs can approach the cost of a conventional bed. 
     The popularity of adjustable beds increased when advertising programs became directed toward consumers with health or sleeping disorders or simply to recline while reading or watching television. Being manufactured primarily in conventional bedding sizes, the ease with which these inclining beds fitted into a bedroom situation greatly increased usage. 
     The construction of adjustable bed bases has changed very little over the past thirty years. Most adjustable bed bases are constructed with angle iron frames. A linear actuator lift motor is attached to pivotally connected lifting arms which independent raise and lower the head/back portion and segmented leg portions, typically moving about a stationary transverse mid torso or buttocks support area. A plywood or particleboard deck with upholstered padding is attached to the lifting arms and decorative wood or laminate panels are applied to the sides of the exposed metal frame for a finished appearance. However, these additions do not overcome the resemblance to a hospital bed. 
     The substantially higher cost for such an adjustable bed is due, in part, to the high freight and delivery costs. Freight charges can exceed $150 and delivery and assembly costs for each adjustable twin bed, for example, weighing over 170 lbs. requires a two-man delivery team. Such costs can approach the cost of a conventional bed, over $300.00. 
     Examples of prior patented adjustable beds are shown in the following U.S. Patents: 
     
       
         
           
               
               
             
               
                   
               
             
            
               
                 U.S. Pat. No. 4,381,571 
                 Elliott, et al. 
               
               
                 U.S. Pat. No. 4,385,410 
                 Elliott, et al. 
               
               
                 U.S. Pat. No. 5,063,623 
                 Bathrick, et al. 
               
               
                 U.S. Pat. No. 5,425,150 
                 Palmer, Jr., et al. 
               
               
                 U.S. Pat. No. 5,568,661 
                 Bathrick, et al. 
               
               
                 U.S. Pat. No. 5,579,550 
                 Bathrick, et al. 
               
               
                 U.S. Pat. No. 5,970,784 
                 Elliott 
               
               
                 U.S. Pat. No. 6,276,011 
                 Antinori 
               
               
                   
               
            
           
         
       
     
     U.S. Pat. No. 4,385,410 to Elliott, et al. discloses an articulated adjustable bed with a single motor which raises the first adjustable section and, through the linkage, the second adjustable section. Another adjustable articulated bed is disclosed by the same inventor in U.S. Pat. No. 5,870,784. 
     Bathrick, et al. discloses articulated beds in U.S. Pat. Nos. 5,063,623 and 5,568,661. U.S. Pat. No. 5,063,623 is directed to a power module for an articulated bed and the &#39;661 patent is directed to an articulated bed with a modified standard frame supporting an independent power module. 
     Palmer, Jr., et al., in U.S. Pat. No. 5,425,150, teaches a device for converting a flat bed into an adjustable bed utilizing an articulating platform sandwiched between the box springs and the mattress. In U.S. Pat. No. 6,276,011, Antinori teaches an adjustable bed with a first frame and a second slide frame connected thereon. 
     To demonstrate the incentive for having a USP shippable adjustable bed, several prior patented efforts have apparently missed that mark. 
     Elliott, in U.S. Pat. No. 4,381,571 teaches an adjustable articulated bed which may be disassembled for easy shipping in a small container and which is constructed from a minimum number of components. However, this invention teaches an elongated frame member which clearly falls beyond the UPS shipping guidelines for economical category 2 shipment for packages having a weight limit of 70 lbs. and an overall size of less than 130″ as the total of length, and girth of the shipping container. 
     In U.S. Pat. No. 5,579,550, Bathrick teaches an improved articulated bed with linearly retractable head and foot sections for easier shipment in a relatively small container. Bathrick asserts that this articulated bed may be assembled by the purchaser without the need for any tools. By incorporation of telescopic head and foot portions, the Bathrick disclosure teaches size compactness but does not achieve a weight reduction necessary for the economical shipping by UPS. 
     Elliott has another patented teaching in U.S. Pat. No. 5,577,280 for a snap together adjustable articulated bed. Seven or so components are packaged in three or so separate smaller boxes for easy transport. According to Elliott, these components can be snap fit together in a very complex arrangement of linkages, motor, power carriage, frame, body portion, drag link and lateral rails. 
     The present invention is specific to the twin extra long size adjustable bed having an assembly length of 80″ and a width of 38″, the most popular size adjustable bed base in the industry. Two such side-by-side adjustable beds are used to form all king size beds because of the width limitation therefore must remain at 38″. The girth of each of the two separate head and leg support assemblies cannot exceed 92″ so that the total sum of the length and girth (2×width+2×thickness) of each shipping package does not exceed 130″. The leg-lifting section posed the greatest challenge to this limitation of size. To accomplish this size limitation, the present invention by design criteria had to have an overall shipping size, when boxed, of no longer than 39″, no thicker than 8″ and no wider than 37″ wherein the UPS shipping size is calculated to =39″+16″+74″=129″. Moreover, the lifting linkages and lifting shafts of each inner lifting frame could not protrude below the plane of the lower margins of the side panels or support legs of each assembly. Otherwise, the lifting linkage could make contact with the support slats of a conventional bed frame. 
     The present invention incorporates a platform design comprising plywood or particleboard deck panels which are upholstered with fabric and affixed to the lifting frame of each support assembly. The center section is formed of an inanimate central deck panel and side panels so that the three-piece design consisting of a head support assembly, a leg support assembly and a central stationary section are all individually shippable under UPS category oversize 2 limits. 
     BRIEF SUMMARY OF THE INVENTION 
     This invention is directed to an adjustable articulated bed with separate adjustable leg and head/back assemblies which support an articulating mattress. The invention is manufactured in three pieces specifically designed for economical shipping directly to consumers via United Parcel, FedEx or US Postal, and is easily assembled without tools. The appearance of the bed is similar to that of a standard bed box spring or platform foundation and may be assembled and placed on a traditional metal frame, headboard, or footboard with side rails. Optional adjustable height legs, which eliminate the need for the traditional metal frame, are threadably attachable into support brackets connected to the bottom of each assembly to adjust the overall height of the bed and to render it as a stand-alone unit. The three sections include a head support assembly with lifting arms pivotally attached to a head lifting frame and a deck panel attached thereatop to elevate the head and upper body; a leg support assembly with lifting arms pivotally attached to a two-part leg lifting frame with deck panels attached thereatop to elevate the legs; and a stationary center section supports the middle or buttocks area of the user. When the motor is attached between the leg and head support assemblies locking the assemblies together, the center section then slides into place therebetween. No tools, pins, clips or snaps are required for assembly. 
     It is therefore an object of this invention to provide a UPS shippable bed which may be shipped under UPS oversize category 2 size and weight limits for economy. 
     It is another object of this invention to provide an adjustable bed having the appearance of a conventional box spring-type bed and which is supported atop a standard metal bed frame. 
     Still another object of this invention is to provide a UPS shippable adjustable bed which is fully articulating by industry standards and which will easily and economically be shipped in three separate boxes directly to the consumer. 
     Yet another object of this invention is to provide a UPS shippable adjustable bed which is easily assemblable by the consumer without the need for tools. 
     Still another object of this invention is to allow one man to carry and deliver an adjustable bed around narrow corners, narrow stairways, spiral staircases and narrow hallways of a consumer&#39;s home. 
     Yet another object of this invention is convenient serviceability of assemblies, avoiding the traditional adjustable bed&#39;s requirement of in-home service by a service technician, the present invention being serviceable with the shipment of new parts or assemblies directly to the consumer. 
     In accordance with these and other objects which will become apparent hereinafter, the instant invention will now be described with reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
         FIG. 1  is a perspective view of the leg lifting assembly and back/head lifting assembly in their shipping containers with the central section also shown unpacked. 
         FIG. 2  is a view similar to that of  FIG. 1  fully unpacked. 
         FIG. 3  is a simplified side elevation schematic view of the assembled invention. 
         FIG. 4  is an enlarged side elevation view of the actuating lever and actuating shaft of each of the lifting assemblies. 
         FIG. 5  is an end view of  FIG. 4 . 
         FIG. 6  is a perspective view of the invention in a partially assembled configuration. 
         FIG. 7  is a perspective view of the invention showing each of the lifting frames in an upper orientation. 
         FIG. 8  is a view similar to that of  FIG. 7  showing the center support section and all side panels in position. 
         FIG. 9  is a view similar to that of  FIG. 8  showing the lifting frames in their downward, flat position. 
         FIG. 10  is a view of the invention also showing the head and leg deck panels in position. 
         FIG. 11  is a view of the invention in its fully assembled configuration and showing the lifting frames in an upper orientation. 
         FIG. 12  is an enlarged view of the central portion of the invention absent the center support section and showing the lifting frames in an upper orientation. 
         FIG. 13  is an enlarged view of the leg lifting frames of  FIG. 12 . 
         FIG. 14  is an enlarged view of the central portion of one side of the head lifting frame. 
         FIG. 15  is a side elevation view of the preferred embodiment of the lifting motor assembly. 
         FIG. 16  is an enlarged perspective view of one end of the motor assembly in engagement with one of the actuating shafts of one of the lifting mechanisms. 
         FIG. 17  is an enlarged view of one of the moveable leg supports of the invention. 
         FIG. 18  is a perspective view of two articulated beds  10 ′ atop a foundation, each supporting an articulating mattress AM. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings, and firstly to  FIG. 1 , the invention is there shown generally at numeral  10 . The invention  10 , in partially packaged configuration, includes a packaged ready-to-ship head/back support assembly  12  and a packaged ready-to-ship leg support assembly  14 . The invention  10  also includes a stationary center section  16  shown unpackaged. These packages  12  and  14  are preferably of equal size. The motor assembly M, which is provided by an independent manufacturer, is shipped in a container with center section  16 . 
     UPS SHIPPING LIMITS 
     UPS oversize category #1 limits packages weighing under 30 lbs. and having a length added to girth of less than 108 inches. This category could not be achieved with the invention. However, oversize category #2 packages can weigh up to 70 lbs. and have a length added to girth of up to 130″. This is the most economical shipping mode for the invention. UPS oversize category #3 packages, that which is now typically used for adjustable articulated beds, must be over 70 lbs. but less than 90 lbs. and have a length added to girth of box over 130″ but less than 165″. 
     The importance of UPS oversize #2 category is illustrated as follows: 
     EXAMPLE 
     Five category #2 boxes will ship from Sarasota, Fla. to Knoxville, Tenn. at a cost of $123. The same shipment under UPS oversize category #3 would ship at a cost of $527, a difference of $404, over three times the shipping cost of oversize category #2. 
     As for the present invention, according to UPS category oversize #2 shipping requirements, each of these packages  12  and  14  cannot weigh more than 70 lbs. and cannot include a length of package, added to a girth of package of more than 130″. The length of the shipping package is here defined as the longest side  18  of the packages  12  and  14 . As described in the Background, the length of  18  of each of these shipping containers  12  and  14  will typically be established at 39″, being the traditional width of a 38″ wide twin size bed, adding 1″ of package thickness, totaling 39″ in length. The girth is here defined as being equal or to the distance around the packages  12  and  14  perpendicular to length  18  or twice the sum of  20  and  22  when added together. The design criteria of the present invention has established the thickness  22  of each of these packaged assemblies  12  and  14  to be 8″ while the width  20  of the packaged assembly has been determined by the uniqueness of the invention to be no more than approximately 37″. Therefore, length  18 =39″ added to girth ( 20  and  22  doubled) equals 90″, for a total of 129″, just under the oversize #2 UPS maximum 130″. Moreover, as will be made clear herebelow, the simplicity of the lifting mechanisms of the present invention facilitates a weight of approximately 65 lbs., well below the maximum overall limit of 70 lbs. 
     Referring now to  FIG. 2 , the invention is there shown unpackaged at  10 ′. The invention  10 ′ includes a leg support assembly  24  and a back/head support assembly  26  (hereinafter referred to as the “head” assembly), and a stationary center section  16 . The stationary center section  16  includes a central deck panel  28  which is constructed of a plywood support panel covered atop the upper surface by suitable upholstery materials. Likewise, downwardly extending side panels  30  are also formed of a plywood support panel covered by decorative upholstery material to have the outward appearance of a conventional box spring. 
     The leg support assembly  24  includes a stationary perimeter frame  76  and a leg lifting frame  32  having hinged at  111  deck panels  110  and  112  best seen in  FIG. 11  formed of plywood support panels covered with an upholstery arrangement of choice. Side panels  38  and end panels  40  are also formed of plywood panels having an upholstered outer surface simulating the appearance of a conventional box spring mattress. The head support assembly  26  also includes a stationary frame  94  and a lifting frame assembly  34 , also having an upholstered deck panel  36  all of which will be described in detail herebelow. 
     Referring now to  FIGS. 3 to 5 , the invention  10 ′ is shown in  FIG. 3  schematically to show the components and articulation of each of the leg support and head support assemblies  24  and  26 , respectively. Each of the assembly components  16 ,  24  and  26  are sized in collective assembled length and width to fit on and be supported by a conventional metal bed frame assembly F which includes longitudinal angle iron rails R and support legs L. 
     The leg support assembly  24  generally includes a stationary frame  76  forming a rigid rectangular perimeter and a leg lifting frame  32  for the legs and feet. An actuating shaft  64  extends transversely across the central portion of the stationary frame  76  and is there held for rotation only. An actuating arm  62  is rigidly connected at a proximal end thereof to the actuating shaft  64 . Two pairs of spaced lifting arms  50  and  54  are pivotally connected together at  56 , the other end of lifting arm  50  being pivotally connected at  52  to the stationary frame  76 . As a general note, all pivotal axes referred to herein are transverse to the overall longitudinal length of the adjustable bed  10 ′. 
     The distal end  68  of actuating arm  62  is pivotally connected to a rigid link  66  which is pivotally connected at the other end thereof at  74  to a mid point of lifting arm  50 . Another rigid link  70  is pivotally connected at  72  to a mid point of lifting arm  62 , while the other end thereof is pivotally connected to lifting arm  54  at  60 . By this arrangement, the entire leg lifting frame  32  is pivoted and articulates to a typical elevated position shown in phantom wherein the actuating shaft  64  is rotated by a motor (described herebelow) in the direction of arrow A causing lifting arms  50  and  54  to articulate upwardly in the direction of arrow B. 
     Still referring to  FIG. 3 , the head lifting frame  34  of the head support assembly  26  also includes a transversely oriented actuating shaft  86  which is held for rotation only within the stationary frame  94 . Included in the head lifting frame  34  is a pair of lifting arms  80  each of which is pivotally connected about transverse axis  82  to the proximal or central portion of the stationary frame  94 . A rigid link  84  is pivotally connected at one end to the actuating shaft  87  while the other end thereof at  90  is pivotally connected to another rigid link  88  which is pivotally connected at its other end  92  to a mid portion along the lifting arm  80 . By this arrangement, when the actuating shaft  86  is rotated in the direction of arrow C, the head lifting arm  80  is rotated upwardly into any selected in-use position in the direction of arrow D. 
     To preferably render the invention to have the appearance of a conventional box spring mattress, the upholstered side panels  38  and end panels  40  are attached by mechanical fastener means shown in the figures to the outer surfaces of the stationary frames  76  and  94 . These side panels  38  may also provide the bearing surface along the lower margins thereof for support within the side rails R of the bed frame F. The stationary center section  16  is also partially supported by its end panels  30  within and against the central portion of each of the side rails R and fit against and between each of the support assemblies  24  and  26 . Support for the center section  16  is primarily provided by the central ends  76   a  and  94   a  of stationary frames  76  and  94  as seen in  FIGS. 6 ,  10  and  14 . When optional legs are attached, stationary center section  16  is supported by support assemblies  24  and  26 . 
     Referring now to  FIGS. 4 and 5 , each of the actuating shafts  64  and  84  (not shown) include an actuating lever  100  held spaced from the center of rotation of the actuating shaft  64  by arm  102 . The motor M, of conventional well known design available as will be described herebelow, causes the powered rotation of the actuator lever  100  by causing movement in the direction of arrow E and thus rotation in the direction of arrow A. 
     In  FIG. 6 , the invention  10 ′ is there shown partially assembled. The motor M has been attached to each of the actuating shafts  64  and  86  and all but two of the side panels  38  have been attached to the stationary frames  76  and  94 . Note that the motor M and the access slots N in  FIGS. 4 ,  15  and  16  for receiving each of the actuator shafts  64  and  86  will establish a proper spacing between each of the support assemblies  24  and  26  so as to properly receive the stationary center section  16 . Note further that removable legs  96  which threadably engage into a support collar  116  as seen in  FIG. 17  welded to corner angle plate  98  may be used in lieu of, or in addition to, the conventional bed frame F for properly supporting the adjustable bed  10 ′. 
     Referring now to  FIGS. 7 to 11 , various orientations and stages of assembly are there depicted. In  FIG. 7 , each of the lifting frames  32  and  34  are shown in an upwardly extended orientation with respect to each of the stationary frames  76  and  94 , respectively. In  FIG. 8 , the same orientation of lifting frames is there shown with the addition of the stationary center section  16  being installed in proper position.  FIG. 9 , the lifting frames  32  and  34  are in the downward flat position while in  FIG. 10 , each of the deck panels, i.e. the leg support panels  110  and  112 , hinge together along hinge line  111 , and the head support deck panel  114  have been attached by mechanical fasteners to each of the respective lifting frames  32  and  34 , respectively. In  FIG. 11 , the entire invention  10 ′ is shown in its fully assembled configuration with each of the lifting frames  32  and  34  in their upwardly deployed orientation with the padded deck panels  110 / 112  and  114  attached thereto. 
     Details of the lifting frame assemblies  32  and  34  are shown in  FIGS. 12 to 14  while a side elevation view of the preferred embodiment of the motor M is shown in  FIG. 15 . Attachment of one end of motor M to one of the actuating shafts  64  is shown in  FIG. 16  wherein sliding lid P will enclose and retain the actuating shaft  64  in proper position for controlled and powered rotation thereof as described with respect to  FIGS. 4 and 5 . 
     The preferred motor is available from Dewart Antriebs-und SystemTechnic GMB and Co. KG of Germany. The Duomat 6 model is preferred although this company offers a Duomat 5 model as well. Another supplier of motors is the Okin Company of Japan under the trademark OKIMAT and OKIMAT 3LI, 3, 2 or other manufacture of line motors. 
     The actual mattress structure is not shown and is only optionally intended to accompany the invention or be a part thereof as the top mattress may be selected from any commercially available which are suitable for adjustable beds. Likewise, the mattress frame F previously described is also not intended to be a part of this invention which will adapt to virtually any conventional frame support for the box mattress structure or with legs  96  attached, stand alone. 
     Referring now to  FIG. 18 , a fully assembled king-size bed is there shown at  120  and includes two side-by-side adjustable articulating beds  10 ′ each supported atop a bed foundation T. An articulating mattress AM is positioned on each of the articulating beds  10 ′ to provide independent adjustability as shown. 
     While the instant invention has been shown and described herein in what are conceived to be the most practical and preferred embodiments, it is recognized that departures may be made therefrom within the scope of the invention, which is therefore not to be limited to the details disclosed herein, but is to be afforded the full scope of the claims so as to embrace any and all equivalent apparatus and articles.