Source: http://www.google.com/patents/US5740568?dq=inventor:%22Arthur+R.+Hair%22
Timestamp: 2017-02-26 00:16:13
Document Index: 639313160

Matched Legal Cases: ['art 436', 'art 438', 'art 428', 'art 436', 'arts 438', 'art 436', 'art 434', 'arts 434', 'art 436', 'art 434']

Patent US5740568 - Snap-together bed - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inPatentsAn adjustable articulated bed manufactured in seven or so components for packing in three or so separate smaller boxes for easy transport. These components can be snap-fit together for easy assembly (and disassembly). The bed includes a bed frame, a power module or carriage and a bedding foundation....http://www.google.com/patents/US5740568?utm_source=gb-gplus-sharePatent US5740568 - Snap-together bedAdvanced Patent SearchTry the new Google Patents, with machine-classified Google Scholar results, and Japanese and South Korean patents.Publication numberUS5740568 APublication typeGrantApplication numberUS 08/707,651Publication dateApr 21, 1998Filing dateSep 5, 1996Priority dateMar 15, 1994Fee statusPaidAlso published asCA2185530A1, EP0782429A1, EP0782429A4, US5537701, US5577280, US5870784, WO1995024879A1, WO1995024880A1Publication number08707651, 707651, US 5740568 A, US 5740568A, US-A-5740568, US5740568 A, US5740568AInventorsFranklin E. ElliottOriginal AssigneeMaxwell Products, Inc.Export CitationBiBTeX, EndNote, RefManPatent Citations (12), Referenced by (41), Classifications (18), Legal Events (5) External Links: USPTO, USPTO Assignment, EspacenetSnap-together bed
US 5740568 AAbstract
1. A knock-down bed, comprising:a support frame including support posts, head and foot cross members, and opposite longitudinal members; wherein each said support post includes a straight-pin receiving opening and first and second wedge-shaped pin receiving openings, each said longitudinal member includes at each opposite end thereof a downwardly-disposed straight pin for disposition in a respective said straight-pin receiving opening and a downwardly-disposed wedge-shaped pin for disposition in a respective said first wedge-shaped pin receiving opening, and each said cross member includes at each opposite end thereof a downwardly-disposed wedge-shaped pin for disposition in a respective said second wedge-shaped pin receiving opening; and a mattress foundation assembly supported by said frame. 2. The bed of claim 1 further comprising a mattress supported on said mattress foundation assembly.
This is a divisional of application Ser. No. 08/404,326, filed Mar. 15, 1995, now U.S. Pat. No. 5,577,280, which is a continuation-in-part of application Ser. No. 08/213,675, filed Mar. 15, 1994, which issued as U.S. Pat. No. 5,537,701 on Jul. 23, 1996, and whose entire contents are hereby incorporated by reference.
Adjustable beds have been used for many years to alter the contours of top surface of mattresses to thereby adjust the support on the different portions of the bodies of persons lying on them. This support adjustment can be for therapeutic purposes, for comfort reasons, or for the user's convenience, as when the user wants to sit propped up to read, eat or watch television. Originally, this adjustment was by manually-operated mechanical levers or cranks. Later, these manually-operated mechanical devices were replaced by one or more motors which drove the adjustable bed into the desired position through gear trains, chain drives, sprocket drives, and/or threaded shafts.
The conventional adjustable bed 50 has a footboard or mattress guard 60 to restrain the foot of the top mattress 54 from projecting beyond the foot of the foundation mattress 56. When the bed 50 is curved, the top mattress 54 rides up over the foundation mattress 56 so the head of the top mattress extends beyond the head of the foundation mattress. The top mattress 54 thereby overhangs the bottom foundation 56, as shown generally by reference numeral 62, adversely effecting the wear and comfort features of the head potion of the mattress 54. Also, the frictional sliding of the top mattress 54 over the foundation mattress 56 dissipates energy, increasing the work that must be performed by the motor which adjusts the bed platform plate. In addition when raising the head end of the mattress 54 towards the foot of the bed 50, stationary nearby objects which were originally near the head of the user 64, for example a lamp 66, a radio or a telephone 68 on adjacent night tables or night stands 70, 72, are now behind the user and out of his or her convenient reach.
Another problem with the prior art adjustable articulated beds is that they are difficult to transport to the end user and assemble. Often they are transported in a single large box having dimensions of 60"×81"×21"and weighing two hundred and eight pounds. The large box requires two (or more) delivery men to carry it to the user's desired location. This can be very tiring or dangerous if the box must be carried long distances or up many steps. Because of its size dimensions it is also very awkward for the delivery men to negotiate it up narrow winding staircases. Additionally, the size dimensions can make it difficult to pack the box efficiently and compactly in the storage compartments of the transport vehicle(s).
Directed to remedying the above-mentioned disadvantages of the prior art, an improved electrically-powered adjustable articulated bed is herein disclosed. The bed includes a foundation having a head section, which supports the head portion of an overlying mattress, and a generally separate body section, which supports the body portion of the mattress. The foundation is supported by and in a stationary frame. A first motor supported by the frame raises and lowers the foundation head section and thereby the mattress head potion. The mattress can be that disclosed in U.S. Pat. No. 4,234,981, for example.
Pivotal links connect to the head end of the frame at one link end and to brackets secured to the underneath of the head section at the other link end. Thus, as the head section is pivoted up, these (fixed length) links cause the motorized foundation assembly to transverse within the lower frame and the extreme head end of the mattress to move only in a fixed vertical plane. The first and second motors can be operated by a pendant-type or wireless controller placed on a night stand adjacent to the head end of the bed. The user has easy access to the controller due to the combined pivotal and transverse movements of the head section of the bed. The multiconductor electrical pendant cord may have a small diameter especially if low voltages are used to activate switching of high voltages in a controller located under the bed. Infra-red or radio frequency types of controllers may be used when it is desired to eliminate the direct wiring and/or when the controller is to perform other functions such as switching the lights or operating television, radio or video cassette recorders. One or more massage motors can also be incorporated into this bed as would be apparent to those skilled in the art.
To provide improved packaging, transport, assembly and disassembly a preferred bed construction is manufactured in basically seven separate pieces. The foundation comprises a body component (including articulated foot, thigh and seat sections) and a separate head component; the (knock-down) lower frame comprises four separate components; and a separate modular power carriage component (including the first and second drive motors) for adjustably configuring the foundation (and thereby the mattress supported thereon) is provided. Each of the components can be packed and transported in its own separate box. Preferably three boxes will be used and the components will be packaged therein as follows: the foundation parts; the lower frame parts; and the carriage component. The largest of these boxes has dimensions of 60"×50"×10" and when packed weighs only ninety pounds, and the smallest of these boxes when packed weighs only thirty pounds. These boxes can thus be easily handled and carried by a single man. Although he may have to take the time to make a few trips from his delivery track to the desired assembly location, the much greater expense of a second delivery man is not needed.
With the operation of the first motor 92 the foundation head section 86 is caused to have three simultaneous movements, as can be perhaps best understood by looking at FIG. 9. The first movement is the upward pivoting of the foundation head section 86 to a maximum of sixty degrees, the second is a vector motion of approximately seven inches out along the pivot axis and the third motion moves the foundation head section horizontally forward about twelve and five-eighths inches towards the end 94 of the frame 82, that is, towards an adjacent wall (see FIG. 1) at the head end of the frame. These three motions when combined result in the movement as shown by the dotted lines in FIGS. 9 and 10. This resulting movement causes the forwardmost edge 100 of the foundation head section 86 and thus the head edge 102 of mattress 90 to move vertically varying only by a horizontal inch in a straight line; that is, the head portion of the mattress moves with a "versed sine" motion. The head edges 100, 102 of the foundation head section 86 and of the mattress 90 remain aligned as can be seen in the upper right corners of FIGS. 10 and 11, and unlike the prior art as shown at 62 in FIG. 1. Additionally and referring to FIG. 10; the shoulders 104 of the user 106 lying on the mattress 90 remain in (substantially) the same vertical plane when in the lower flat position and when in the raised position as can be understood from FIG. 10. Lamps, phones, clocks, bed controls and other nearby objects (see FIG. 1) are still conveniently positioned and oriented for the user. He does not need to reach back behind him to access them.
Referring to FIG. 4, frame 82 includes four corner posts 108, 110, 112, 114 with casters 116 fitted to the bottoms of each of them, snap fit into post bottom sockets. A pair of longitudinal rails 118, 120 and a pair of lateral rails 122, 124 connect the posts 108, 110, 112, 114 into a rectangular configuration. Four rail guide members 128, 130, 132, 134 are each connected at their ends to respective corner posts 108, 110, 112, 114 by passing (or floating) through post holes with a tenon and mortise fit. They extend inwardly and longitudinally above the side rails 122, 124 and are held at their inner ends by respective brackets 136, 138, 140, 142 secured above to the longitudinal rails by welding thereto. Four coupler sleeves (or clam shell bushings or linear bearings) 144, 146, 148, 150 encircle respective ones of these rail guide members 128, 130, 132, 134 and are secured to the frame 154 of the motorized foundation assembly 84 by connecting brackets 156, such as shown in FIG. 10, having a pin attachment and rocking capabilities to account for deflection. Thus, when the motor 92 is powered the motorized foundation assembly 84 slides longitudinally along the rail guide members 128, 130, 132, 134. The couplers alternatively can be constructed as upper and lower rollers, which can have curved engagement surfaces, instead of the bushings.
The pivotal or lifting movement of the foundation head section 86 can be understood, for example, by comparing FIGS. 5, 7 and 8 which show the raising of the head section and the linkage for doing such. Referring thereto it is seen that as the motor 92 operates through a drive gear the drive shaft 172 is rotated. This rotation causes a nut 174 secured with pivot pins on the shaft 172 to be moved along the shaft. A torque tube assembly shown generally at 176 is secured by a connector arm 178 to the nut 174, and as the nut is driven along the shaft 172 it causes the torque tube assembly to pivot about a pivot point 180 on the frame 154. The arm 178 is firmly secured to the cross bar or tube 182 of the torque tube assembly 176 using a "spanner wrench" type of securement together with welding. The torque tube assembly 176 includes a triangular bell crank 184 with one corner of the triangle corresponding to the pivot point 180, another corner including the transverse torque tube 182 to which the connector arm 178 is secured and a third corner. A lifting link 188 at one end thereof is pivotally secured at point 189a to that third corner and the other end of the link is pivotally secured at point 189b to a primary hinge 190. The primary hinge 190, in turn, is pivotally connected at end point 192 to the foundation frame 154. Thus, point 189b travels in an arc about point 192 and point 189a travels in an arc about point 180 as motor 92 is operated.
A pair of tubular lateral support members 223a, 223b extend spaced and parallel across a central portion of the foundation frame 154. Each has a square cross section fitting into corresponding square apertures in the foundation frame 154. Mounted midway on the members 223a, 223b are a pair of motor mounting plates 224. The motors 92, 96 are pivotally mounted at opposite ends of the plates and on opposite sides of the members at pivot points 225a, 225b, respectively. Pivot points 225a, 225b provide pivot, thrust and anchor points for the respective motors 92, 96. This mounting and support of the motors is similar to the arrangement described in the previously-mentioned 4,407,030 patent. One important difference though is that two (spaced) support members 223a, 223b, instead of a single support member, are used. This provides for more user seat room on the bed and thereby less pinching.
Thus, as the bell crank 184 is rotated, the pendulum or rocker link 212 is rotated clockwise away from the foot of the bed thereby pulling link 220 which pulls the secondary hinge 204. The secondary hinge 204, as it is being pulled towards the right as seen in the drawings, rides on the rollers 194, 196 within the slots 200, 204. See, for example, FIG. 9A. The secondary hinge 204 moves relative to the primary hinge 190 by this roller-slot relationship. As the primary hinge 190 is rotating about sixty degrees, it is being pulled along with the rest of the motorized frame assembly 84 on the sleeves (or bushings or linear bearings) 144, 146, 148, 150 due to the reactive force through supper member(s) or link(s) 160 (and 162). The motions of the rollers 194, 196, the pivot point connection 192 of the primary hinge 190 to the assembly frame 154, the pivotal connection 228 of the drag links 164, 166 to the back of the frame head section 86 and the pivotal connections 229 of the members 164, 166 to the tube 158 are shown in FIG. 9A. The positions of each of these elements are shown therein at zero, fifteen, thirty, forty-five and sixty degree orientations of the head section 86. As can be seen, roller 194 moves in a small arc and roller 196 moves in a larger arc.
As best seen in FIG. 11, the foundation body section 88 includes three articulated sections, namely, a seat or center section 230, a thigh section 232, and a lower leg or foot section 234. Each of these sections is articulated relative to the adjacent section or sections. The seat section 230 is fixed to the foundation frame 154, the thigh section 232 is pivotal relative to the seat section 230 about point 236, and the foot section 234 is pivotal about point 238 and movable relative to both of the sections. The mechanism for controllably moving or adjusting the thigh and/or foot sections 232, 234 is similar to that illustrated in the previously-mentioned 4,407,030 patent and reference is hereby again made to that patent. The mechanism is operated by the operation of the motor 96. The motor 96 has a gear train which drives a threaded shaft 240, which passes through a threaded, low friction bushing or nut 242, which is connected thereto with pivot screws. A torque tube assembly 244 is provided, similar to the one at the forward end of this bed. It includes a triangular plate or bell crank 246 secured at one corner to one end of the cross bar member 250 (another bell crank plate is secured at the other bar member end as seen in FIG. 4 for example), at a second corner pivotally to the foundation frame 154 at point 252, and at its third corner pivotally at point 254 to a lifter link or a pivot arm 256. Lifter link 256 is pivotally attached at its opposite end at point 258 to a longitudinal support member 260 secured to the thigh section 232.
Another drag link embodiment is shown in FIGS. 21-23 generally at 434. Instead of connecting and disconnecting this drag link 434 for assembly and disassembly directly to the bed frame, the drag link is formed in two parts. The upper round tubular part 436 is pivotally secured to the foundation head section 86 via a bracket 437 and the lower round tubular part 438 is pivotally secured to the frame via a tab 440. And both parts then can be releasably coupled together at the central portion of the elongated long drag link 434 thereby formed, by releasable coupling means best shown in FIGS. 22 and 23 generally at 444. It is seen there that the lower drag link part 428 has an enlarged head sleeve 446 into which the lower end 448 (FIG. 22) of the upper drag link part 436 is received. And when received therein, slots in the drag link parts 438, 436 align and a spring clip 450 can be inserted into the aligned slots to secure the two parts together, to prevent movement in both directions. That is, the lower end 448 of the upper drag link part 436 slides inside of and into the upper end 446 of the lower drag link part 434 and then they are locked into place with a clip 450. The clip 450 extends around the circumference of one of the tubes and a spring arm or tab 452 locates into the aligned slots through both of the tubes. To release the two parts 434, 436 one need only press down on the spring portion of the clip 450 which then lifts the tab 452 out of the two slots. The upper drag link part 436 can then be slid out from inside of the lower drag link part 434 to pull the two parts apart. Similar arrangements described below for snap-fit securing the foundation head section 86 relative to the carriage 84 and the foundation body section 86 relative to the carriage are provided
A number of ways of providing a bed frame which can be assembled and disassembled without using any tools are illustrated in the drawings. A preferred embodiment is shown in FIGS. 26-29. FIG. 26 shows one of the four frame corners--the left front corner, and a similar construction is provided for the other three corners of the bed frame, as can be understood from FIG. 13. The front cross rail member 498 (or 308) is permanently affixed to the left front support post 310 into which a suitable caster 500 is fitted into its bottom surface. The left longitudinal rail assembly 304 includes a square bottom tubular rail 502 and a diamond-shaped top rail 504 (or 380) along which the roller glide assembly 370 rolls. They are secured together with a flat plate 506 having square and diamond openings through which the two rails pass. Corresponding square and diamond-shaped openings 512, 514 in the rearward face of the support post 310 are provided into which the two rails 502, 504, respectively, are fitted. When fitted therein the male portion 520 of a camlock mounted to the connector plate 506 fits into the female potion 526 of the camlock on the support post 310. Shown in FIG. 28 are the stator 527, the rotor 528, and the connector screws 529. The lever or handle 530 on the male portion 520 can then be rotated to effect a camlocking action, which is better understood with reference to FIGS. 27-29. Two butterfly-shaped wedge members 532 are provided on the male potion of rotor 528. When the turning handle or lever 530 is turned, the wedge members 532 wedge up against corresponding surfaces 536 on female portion 526, thereby exerting a camming effect and securing the male and female portions 520, 526 together, with a window-latch type of action. "Left" and "right" acting camlocks would preferably be provided for the bed frame. The two tabs 539 with holes, as shown in FIG. 28 for example, are provided to secure a front cover (not shown) to the frame if desired.
A still further method of connecting the longitudinal rails, cross rails, and corner posts to form a rectangular hock-down bed frame is shown in FIGS. 32-34 generally at 570, wherein it is seen that the cross mils, the longitudinal rails, and the support posts are all separable components. A (zinc) die east member 574 at the bottom of the support post 576 has an opening 578 with a slot 580 facing the cross rail 590 and a similar opening-slot arrangement 592, 594 facing the longitudinal rail 598. At the ends of the rails of both the longitudinal and cross rail members 590, 598 are wedge-shaped configurations 600, 602, respectively, similar to that shown in FIG. 31. These are configured and adapted to fit down into the corresponding openings 578, 592 and slots 580, 594 in the support post 576. As can be understood from FIG. 34, three opening-slots are shown so that a single die cast member configuration can be used for all four posts. Above the lower cast member 574 is a plate 606 having a longitudinal channel 608 with a through-opening 610 in the center of it. The longitudinal rail assembly 612 includes a second rail member 614 spaced above the lower member 598, provided as the guide rail and connected by a connecting post 620 in a U-shaped arrangement. The end of the top member 614 extends a distance beyond the wedge-shaped configuration 602 and has a downward cylindrical pin 622. This pin 622 then fits into the opening 610 in the channel 608. A plate 626 connects the upper and lower rail members 614, 598 as shown in FIG. 32.
FIG. 36 shows generally at 640 a simple electrical schematic of the bed 300. It shows a power supply 642, such as conventional one hundred and ten or two hundred and twenty volt power supplies operably connected to the forward and rear motors 92, 96 and the forward and rear vibrating motors 322, 324. The operations of these four motors are then controlled by a hand held control 644, held and operated by the user. Examples of remote control units which can be adapted for this bed are the "RM" and "RPS" units available from Maxwell Products, Inc. of Cerritos, Calif. and those disclosed in copending U.S. application Ser. No. 08/277,511, filed Jul. 19, 1994.
From the foregoing detailed description, it will be evident that there are a number of changes, adaptations and modifications of the present invention which come within the province of those skilled in the art. However; it is intended that all such variations not departing from the spirit of the invention be considered as within the scope thereof as limited solely by the claims appended hereto.
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19990218Sep 28, 2001FPAYFee paymentYear of fee payment: 4Sep 29, 2005FPAYFee paymentYear of fee payment: 8Sep 23, 2009FPAYFee paymentYear of fee payment: 12RotateOriginal ImageGoogle Home - Sitemap - USPTO Bulk Downloads - Privacy Policy - Terms of Service - About Google Patents - Send FeedbackData provided by IFI CLAIMS Patent Services