Patent Publication Number: US-11641947-B2

Title: Bedding foundation having multiple lift actuators for massage effect

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of priority to U.S. Provisional patent application Ser. No. 63/025,348 filed May 15, 2020, the disclosure of which is incorporated by reference herein in its entirety. 
    
    
     FIELD OF THE INVENTION 
     This invention relates generally to a bedding foundation having multiple lift actuators to impart a massage effect or lumbar support to a mattress above the bedding foundation. 
     BACKGROUND OF THE INVENTION 
     In the bedding industry, bases or foundations for supporting mattresses fall into two categories: 1) stationary foundations, which do not have any moving parts, and 2) adjustable bed bases which are usually motorized and have moving parts for inclining a portion of a mattress resting on the adjustable bed base and sometimes vibrating a portion of a mattress resting on the adjustable bed base. 
     Commonly adjustable bed bases include one or more motors which activate one or more drivers of the adjustable bed base to raise a portion of the bed base and mattress. In addition, such adjustable bed bases may include one or more vibratory motors which may impart vibrations to the mattress for a “massage” type effect or feel. Consequently, due to the hardware and electronics necessary to move a portion of an adjustable bed base, the adjustable bed base may be heavy and difficult to transport. Conventional stationary bedding foundations are commonly much lighter and easier to transport. 
     Adjustable bed bases are typically more expensive than conventional stationary bedding foundations because they have one or more motors for moving parts. Thus, a need exists in the bedding industry for a bedding foundation which combines desirable features of both adjustable bed bases and conventional standard bedding foundations. 
     SUMMARY OF THE INVENTION 
     According to one aspect of the invention, a bedding foundation comprises a generally rectangular frame supported by legs and a platform supported by the generally rectangular frame. The platform has an opening covered by a cover. The cover is conventionally secured to the platform. The generally rectangular frame may be made at least partially of hollow members to reduce the weight of the bedding foundation. The platform may be rigid or flexible to any desired degree. 
     The bedding foundation further comprises a mounting tray supported by the rigid platform. Multiple lift actuators are mounted inside the mounting tray. Each lift actuator raises and lowers a lift plate. The lift actuators are programmed to move the lift plates in a vertical direction through the opening in the rigid platform in a predetermined pattern. In one embodiment, the bedding foundation has five lift actuators. However, any number of lift actuators may be incorporated into the bedding foundation. 
     In a second aspect, a bedding foundation comprises a frame supported by legs and a rigid platform supported by the frame. The rigid platform has an opening covered by a flexible cover. The flexible cover is conventionally secured to the rigid platform. In some instances, the flexible cover may be omitted. 
     The bedding foundation further comprises a lift mechanism suspended by the rigid platform. The lift mechanism comprises a mounting tray and lift actuators. A lift plate is operatively coupled to each of the lift actuators and is moveable by the lift actuator. Each of the lift actuators of the lift mechanism is sized to fit through the opening in the rigid platform and is moveable in the vertical direction by the lift actuator. 
     In one preferred embodiment, each of the lift plates is the same size. In other embodiments, the lift plates are different sizes. In one preferred embodiment, each of the lift plates has the same upper profile. In other embodiments, the lift plates have upper profiles which differ from each other. 
     In a third aspect, a method of providing a massaging feeling to a mattress from a massage mechanism built into a bedding foundation. The first step in the method comprises raising and lowering multiple lift plates through an opening in a rigid platform using lift actuators. The rigid platform is supported by a generally rectangular frame supported by legs. 
     The lift actuators are secured to a mounting bracket. The mounting bracket is secured to the rigid platform. The lift actuators are programmed to raise and lower the lift plates in a predetermined manner when activated. 
     The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the summary of the invention given above, and the detailed description of the drawings given below, explain the principles of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a perspective view of a bedding foundation in accordance with one embodiment of the present invention. 
         FIG.  2    is a partially disassembled view of the bedding foundation of  FIG.  1   . 
         FIG.  3    is an enlarged perspective view of the lift mechanism of the bedding foundation of  FIG.  1   . 
         FIG.  4    is a bottom perspective view of the bedding foundation of  FIG.  1   . 
         FIG.  5    is a cross sectional view taken along the line  5 - 5  of  FIG.  1    showing the lift plates in a lowered position. 
         FIG.  5 A  is a cross sectional view like  FIG.  5    showing one of the lift plates in a raised position. 
         FIG.  5 B  is a cross sectional view like  FIG.  5    showing the lift plates in different positions. 
         FIG.  5 C  is a cross sectional view like  FIG.  5    showing the lift plates in other positions. 
         FIG.  5 D  is a cross sectional view like  FIG.  5    showing the lift plates in other positions. 
         FIG.  5 E  is a cross sectional view like  FIG.  5    showing the lift plates in other positions. 
         FIG.  6    is a cross sectional view taken along the line  6 - 6  of  FIG.  1   . 
         FIG.  7    is a perspective view of a bedding foundation in accordance with another embodiment of the present invention. 
         FIG.  8    is a perspective view of a bedding foundation in accordance with another embodiment of the present invention. 
         FIG.  9    is a perspective view of a bedding foundation showing different surface members which may be used in accordance with the present invention. 
         FIG.  10    is a perspective view of a bedding foundation in accordance with another embodiment of the present invention. 
         FIG.  11    is a flow chart of the operation of the bedding foundation in accordance with the present invention. 
         FIG.  12    is a cross-sectional view of another embodiment of bedding foundation in accordance with the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to  FIG.  1   , there is illustrated a bedding foundation  10  incorporating the principles of the present invention. As seen in  FIG.  1   , the bedding foundation  10  is used to support a mattress  11 , shown in dashed lines. Any mattress may be supported by the bedding foundation; this document is not intended to limit the type of mattress which may be supported. 
     As best shown in  FIG.  2   , the bedding foundation  10  comprises a generally rectangular frame  12 , comprising two end rails  14  and two side rails  16 . As best shown in  FIG.  2   , when assembled, the end and side rails  14 ,  16  may be secured together with any conventional means, including fasteners. As best shown in  FIGS.  2  and  6   , each of the end rails  14  and each of the side rails  16  has a hollow interior  18 . 
     Legs  20  support the rectangular frame  12  above the ground a desired distance. Although the legs  20  are illustrated being secured to the end rails  14 , they may be secured to any part of the generally rectangular frame  12 . Although one configuration of leg is shown, the legs may be any shape or size. The present invention is not intended to limit the legs in any manner. 
     For purposes of this document, the head end of the bedding foundation  10  will be indicated by the numeral  22  while the foot end of the bedding foundation  10  will be indicated by the numeral  24 . 
     As best shown in  FIG.  2   , a rigid platform  26  is secured to the generally rectangular frame  12  in any known manner. The rigid platform  26  has a larger footprint than the generally rectangular frame  12  and extends outwardly from the perimeter of the generally rectangular frame  12  on all four sides. As best shown in  FIG.  6   , the rigid platform  26  has a perimeter edge  28  about which is placed a protective shroud  30 . As best shown in  FIG.  2   , the protective shroud  30  comprises four pieces joined together at the corners using any known method: two end pieces  31  of the same length and two side pieces  33  of a different, greater length. 
     The rigid platform  26  is typically made of wood but may be made of any known material. The protective shroud  30  may be made of rubber, plastic, or any soft material. One purpose of the protective shroud  30  to protect users from contacting the perimeter edge  28  of the rigid platform  26  to prevent injuries. 
     As best shown in  FIG.  2   , the rigid platform  26  has a rectangular opening  25  covered by a cover  27 . The cover  27  may be secured to the rigid platform  26 . The cover  27  may be made of any durable fabric which is elastic enough to stretch a bit as shown in  FIGS.  5 A- 5 C  yet strong enough to withstand the pressure and friction caused by movement of the lift plates  46   a - 46   e . Although the drawings illustrate a rectangular opening  25  of a certain size, the drawings are not intended to be limiting. The opening in the rigid platform may be any desired size and shape. 
     The bedding foundation  10  further comprises a wave cassette  42  removably secured to the rigid platform  26 . More particularly, the wave cassette  42  is removably secured to the rigid platform  26  using two parallel support rails  32  secured to the rigid platform  26  in any known manner including fasteners (not shown) passing through openings  35  in the support rails  32  and through the rigid platform  26 . Although  FIG.  3    illustrates three openings  35  per support rail  32 , any number of openings of any desired shape may be used. In the event one or more of the lift actuators of the wave cassette  42  requires repair or replacement, the wave cassette  42  may be quickly and easily removed from the bedding foundation  10 . 
     As best shown in  FIG.  3   , each support rail  32  is a unitary member have a horizontally oriented mounting flange  34 , a connecting portion  36  extending downwardly from an inner edge of the mounting flange  34  and a lower flange  38  extending inwardly from the lower edge of the connecting portion  36 . As best shown in  FIG.  3   , each support rail  32  is identically formed but oriented oppositely. The support rails  32  of lift mechanism  42  are oriented such that the mounting flanges  34  extend away from each other while the lower flanges  38  are extend towards each other. As shown in  FIG.  6   , the lower flanges  38  of each support rail  32  provides base upon which rests five lift actuators  40   a - 40   e . Although one shape of support rail is illustrated, the support rail of the present invention may assume other shapes. 
     As best shown in  FIG.  3   , the wave cassette  42  of the bedding foundation  10  further comprises a pair of hollow stabilizers  52  welded or otherwise secured to the connecting portions  36  of the support rails  32  of the lift mechanism  42  and extending therebetween. As best shown in  FIG.  5   , each hollow stabilizer  52  has a hollow interior  54 . 
     As best seen in  FIG.  3   , the wave cassette  42  of the bedding foundation  10  comprises five lift actuators  40   a - 40   e  between the hollow stabilizers  52 . Lift actuator  40   a  is upstream of lift actuator  40   b  which is upstream of lift actuator  40   c  which is upstream of lift actuator  40   d  which is upstream of lift actuator  40   e . As best seen in  FIGS.  3  and  5   , a lift plate  46   a  is part of lift actuator  40   a , a lift plate  46   b  is part of lift actuator  40   b , a lift plate  46   c  is part of lift actuator  40   c , a lift plate  46   d  is part of lift actuator  40   d  and a lift plate  46   e  is part of lift actuator  40   e . Each lift plate  46   a ,  46   b ,  46   c ,  46   d ,  46   e  is shown as being the same size and having a generally planar configuration. However, any one of the lift plates may be a different shape or size than those illustrated. Although any lift actuator may be used, one that has proven satisfactory is a Linak product Item number BASE1000A0F100100 available at http://www.linak.com. Although the drawings show the wave cassette  42  having five lift actuators, a wave cassette in accordance with the present invention may have any number of lift actuators. 
       FIGS.  5 - 5 C  illustrate methods of providing a massaging feeling to a mattress using a wave cassette  42  built into a bedding foundation  10 .  FIG.  5    illustrates all five lift plates  46   a - 46   e  in a lowered position as determined by the lift actuators  40   a - 40   e .  FIG.  5 A  illustrates the lift plate  46   c  in its raised or up position as determined by the lift actuator  40   c  with the other lift plates  46   a ,  46   b ,  46   d  and  46   e  being in a lowered position. Each lift plate  46   a - 46   e  is controlled by an associated lift actuator  40   a - 40   e  which may be controlled remotely (wirelessly) or via a wired connection. 
       FIG.  5 B  illustrates the lift plates  46   a - 46   e  being raised incrementally from a lowered position to a raised position as determined by the associated lift actuators  40   a - 40   e . This movement of the lift plates  46   a - 46  creates a rearwardly directed wave type of movement in the mattress  11  above the bedding foundation  10  as indicated by arrow  50 . 
       FIG.  5 C  illustrates the lift plates  46   e - 46   a  being raised incrementally from a lowered position to a raised position as determined by the associated lift actuators  40   a - 40   e . This movement of the lift plates  46   a - 46   e  creates a forwardly directed wave type of movement in the mattress  11  above the bedding foundation  10  as indicated by arrow  60 . 
       FIG.  5 D  illustrates the lift plates  46   e - 46   a  being in positions to create a hill shape as determined by the associated lift actuators  40   a - 40   e . This movement of the lift plates  46   a - 46   e  creates a bump or hill in the mattress  11  above the bedding foundation  10 . Lift plate  46   c  is in its raised position while lift plates  46   a  and  46   e  are each is a lowered position. Lift plates  46   b  and  46   d  are in intermediate positions. 
       FIG.  5 E  illustrates the lift plates  46   e - 46   a  being in positions to create a hill shape as determined by the associated lift actuators  40   a - 40   e . This movement of the lift plates  46   a - 46   e  creates a bump or hill in the mattress  11  above the bedding foundation  10 . Lift plates  46   a  and  46   b  are each in a raised position while lift plates  46   d  and  46   e  are each in a lowered position. Lift plate  46   c  is in an intermediate position. 
     Although the drawings show lift plates  46   a - 46   e  in predetermined positions, those skilled in the art will appreciate that the lifts plates  46   a - 46   e  may be in any desired positions. The drawings are not intended to be limiting. 
       FIG.  6    illustrates a cross-section of the bedding foundation showing the details of lift actuator  40   e . The other lift actuators  40   a ,  40   b ,  40   c  and  40   d  are identical to lift actuator  40   e.    
       FIG.  7    illustrates the operation of another embodiment of bedding foundation  10   a  adapted to support a mattress (not shown) above the bedding foundation  10   a . For purposes of this document, the head end of the bedding foundation  10   a  will be indicated by the numeral  22   a  while the foot end of the bedding foundation  10   a  will be indicated by the numeral  24   a . Bedding foundation  10   a  comprises a generally rectangular frame  12  as described above. Legs  20  support the generally rectangular frame  12  above the ground a desired distance. 
     As best shown in  FIG.  7   , bedding foundation  10   a  has a platform  26   a  comprising an adjustable head section  162  and a stationary section  164 . The adjustable head section  162  is movable between a lowered position (not shown) and a raised position shown in  FIG.  7    in any known manner. The bedding foundation  10   a  further comprises three lift actuators  166   a - 166   c  secured to the stationary section  164  of the platform  26   a . Each lift actuator  166   a - 166   c  includes a lift plate  168   a - 168   c  for exerting an upward force on a mattress (not shown) resting on the bedding foundation  10   a.    
       FIG.  8    illustrates another embodiment of bedding foundation  10   b  adapted to support a mattress (not shown) above the bedding foundation  10   b . For purposes of this document, the head end of the bedding foundation  10   b  will be indicated by the numeral  22   b  while the foot end of the bedding foundation  10   b  will be indicated by the numeral  24   b . Bedding foundation  10   b  comprises a generally rectangular frame  12  as described above. Legs  20  support the generally rectangular frame  12  above the ground a desired distance. 
     As best shown in  FIG.  8   , bedding foundation  10   b  has a platform  26   b  comprising a first set  170  of movable front flaps  172  hingedly secured to a stationary portion  174  of the platform  26   b  with hinges  176 . Each of these front flaps  172  is movable between a raised position shown in  FIG.  8    in which their front edge is above their rear edge and a lowered generally horizontal position (not shown). Although three front flaps  172  are illustrated any other number of front flaps  172  of any desired shape and size may be used to exert an upward force on a mattress (not shown) above the bedding foundation  10   b.    
     As best shown in  FIG.  8   , the platform  26   b  of bedding foundation  10   b  further comprises a second set  180  of movable rear flaps  182  hingedly secured to a stationary portion  174  of the platform  26   b  with hinges  176 . Each of these rear flaps  182  is movable between a raised position shown in  FIG.  8    in which their front edge is below their front edge and a lowered generally horizontal position (not shown). Although three rear flaps  182  are illustrated any other number of rear flaps  182  of any desired shape and size may be used to exert an upward force on a mattress (not shown) above the bedding foundation  10   b . Any known lift actuator may be used to lift one or more of the flaps simultaneously or independently. 
       FIG.  9    illustrates another embodiment of bedding foundation  10   c  adapted to support a mattress (not shown) above the bedding foundation  10   c . For purposes of this document, the head end of the bedding foundation  10   c  will be indicated by the numeral  22   c  while the foot end of the bedding foundation  10   c  will be indicated by the numeral  24   c . Bedding foundation  10   c  comprises a generally rectangular frame  12  as described above. Legs  20  support the generally rectangular frame  12  above the ground a desired distance. 
     As best shown in  FIG.  9   , bedding foundation  10   c  has a platform  26   c  comprising a plurality of tops  190   a - 190   f . Any one of these tops may be secured to any lift platform shown or described herein. The tops provide different feelings to a mattress when used with a lift actuator. The tops illustrated are not intended to be limiting but instead merely suggest certain ideas. 
       FIG.  10    illustrates another embodiment of bedding foundation  10   d  adapted to support a mattress (not shown) above the bedding foundation  10   d . For purposes of this document, the head end of the bedding foundation  10   d  will be indicated by the numeral  22   d  while the foot end of the bedding foundation  10   d  will be indicated by the numeral  24   d . Bedding foundation  10   d  comprises a generally rectangular frame  12  as described above. Legs  20  support the generally rectangular frame  12  above the ground a desired distance. 
     Bedding foundation  10   d  has a plurality of transversely extending slats  192 . A tray  194  is located between adjacent slats  192 . A lift actuator  196  having an upper platform  198  is secured in each tray  194 . Although  FIG.  10    illustrates five lift actuators, any number of trays  194  and lift actuators  196  may be incorporated into any bedding foundation shown or described herein. Although one configuration of tray  194  is illustrated, any other configuration of tray may be used, provided the tray is supported by the slats  192  of the bedding foundation  10   d.    
       FIG.  11    is a schematic flow chart showing the operation of a bedding foundation in accordance with the present invention. 
       FIG.  12    illustrates the operation of another embodiment of bedding foundation  10   e  adapted to support a mattress  11  above the bedding foundation  10   e . For purposes of this document, the head end of the bedding foundation  10   e  will be indicated by the numeral  22   e  while the foot end of the bedding foundation  10   e  will be indicated by the numeral  24   e . Bedding foundation  10   e  comprises a generally rectangular frame  12  as described above. Legs  20  support the generally rectangular frame  12  above the ground a desired distance. 
     As best shown in  FIG.  12   , bedding foundation  10   e  has a pliable or flexible platform  26   e  unlike the rigid platform  26  described herein. The pliable or flexible platform  26   e  preferably has no openings or cutouts therein. However, a pliable or flexible platform having one or more opening or slits may be used in a foundation like foundation  10   e  or any other foundation shown or described herein. The bedding foundation  10   e  further comprises a plurality of transversely extending slats  192 , like foundation  10   d  shown in  FIG.  10   . A tray  194  is located between adjacent slats  192 . A lift actuator  196  having an upper platform  198  is secured in each tray  194 . Although  FIG.  12    illustrates two lift actuators, any number of trays  194  and lift actuators  196  may be incorporated into foundation  10   e  or any other bedding foundation shown or described herein. Although one configuration of tray  194  is illustrated, any other configuration of tray may be used, provided the tray is supported by the slats  192  of the bedding foundation  10   e.    
     The use of a pliable or flexible platform may be used in connection with any concept described or shown herein. 
     The various embodiments of the invention shown and described are merely for illustrative purposes only, as the drawings and the description are not intended to restrict or limit in any way the scope of the claims. Those skilled in the art will appreciate various changes, modifications, and improvements which can be made to the invention without departing from the spirit or scope thereof. The invention in its broader aspects is therefore not limited to the specific details and representative apparatus and methods shown and described. Departures may therefore be made from such details without departing from the spirit or scope of the general inventive concept. For example, the roller concept of the present invention may be used in an adjustable bed base. Any of the hollow members of the bedding foundation may be at least partially solid. The invention resides in each individual feature described herein, alone, and in all combinations of any and all of those features. Accordingly, the scope of the invention shall be limited only by the following claims and their equivalents.