Abstract:
A multiple configuration air mattress pump system is disclosed. The pump system includes a number of standard components with a few inexpensive varied components to allow for easy and less expensive use of the pump with mattresses having varying numbers of inflatable zones. An improved sealed manifold is also disclosed.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation-in-part of and claims the benefit under 35 U.S.C. §120 of U.S. application Ser. No. 11/869,334, filed Oct. 9, 2007, now U.S. Pat. No. ______, which claims priority under 35 U.S.C. §119 to U.S. Provisional Application No. 60/897,616, filed Jan. 26, 2007. The foregoing applications are both specifically incorporated herein by reference for all purposes. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates generally to the field of air mattresses. More specifically, it relates to a pump system that can be used with mattresses having a varying number of individually-inflatable zones. The pump system has a common platform and a manifold that can accommodate a range of pump sizes, differing numbers of air control valves, and varied configurations of faceplates for easy and cost-effective manufacturing and use with mattresses that have different numbers of inflatable zones. 
       BACKGROUND 
       [0003]    Pumps for mattresses are well known for providing controlled air flow to inflatable mattresses. One such system is disclosed in U.S. Pat. No. 5,044,029 to Vrzalik. Vrzalik teaches an air control system wherein the bed and frame itself incorporates the system, and therefore greatly increases the cost of manufacturing by requiring integration of the controls into the mattress. Another air control mechanism, which is external to the bed itself, is disclosed in U.S. Pat. No. 6,037,723 to Schafer. A major limitation of this and other similar air control systems is that the systems can inflate only the specific number of chambers for which they are designed, and can therefore be used only with mattresses containing the matching number of inflatable chambers. Separate pumps therefore need to be manufactured for each type of mattress model. 
         [0004]    The requirement for existing pumps to be customized to accommodate the number of inflatable chambers in the mattress with which they will be used greatly increases manufacturing costs and time, and decreases overall market efficiency by requiring a unique pump for each style of bed. None of the existing airbed control systems currently in use provide an interchangeable, efficient pump system, but rather are manufactured and sold with substantial differences in appearance, internal design, and component configuration for use with mattresses with varying numbers of zones. The mechanical and software designs presently used are typically single-pump based and require a manufacturer to create new tool sets for internal components, new circuit board designs, and new external enclosures to create the different pump systems with respect to the number of air zones to be controlled. Existing pump systems do not lend themselves to the development or sale of a comprehensive product line that can be easily and cost-effectively configured to produce multiple finished products that have significantly differentiated functionality but a consistent overall appearance. 
         [0005]    Accordingly, a need exists for a multiple configuration pump system in which a variety of pump sizes and face plates as well as varying number of air control valves can be incorporated into a standard platform and manifold for use with mattresses having different numbers of inflatable zones. This system provides the components that are the most expensive to tool as the common universal components, and the least expensive and simply-tooled components to be the variable ones. Inventory can be built to a nearly-finished state, and quickly and inexpensively configured with the variable components at the last moment based on actual market demand. 
         [0006]    Furthermore, such a system solves the current problems of an increased expense of manufacturing multiple types of pump systems for use with mattresses having different numbers of zones, and also provides a universal pump for convenience of retailers and consumers. A multiple configuration system also allows for streamlined testing procedures and lower testing costs, such as standard durability drop tests, form, fit and function tests, and compliance tests across the configurations. The standardized pump systems also allow for use of the same packaging for each pump system, including both the inner packaging and outer shipping box, fewer inventory SKUs, standardized packaging lines, processes and employee training, and standardized pallet size and storage requirements. 
         [0007]    A need also exists for a sealed manifold for such an air pump system. Pumps for mattresses are well known for providing controlled air flow to inflatable mattresses, however, current pumps are not capable of accurately controlling pressure in the chamber of the manifold. Repeatable accuracy is important in devices aimed at long-term care facilities and other medical applications where accurate control of sleep surface firmness plays a direct role in avoiding pressure sores. Currently, medical grade products which posses this required level of control are orders of magnitude more expensive than consumer level products. Additionally, air leaks through the pump have historically been a perceived weakness of the air chamber type systems. For example, a single hair or dust bunny in the sealing port could cause a chamber leak in such models. A manifold that employs air control valves that use a reinforced or redundant sealing system provides greatly enhanced pressure control and precludes air leaks in the system. 
       SUMMARY 
       [0008]    The present invention provides a multiple configuration mattress pump. The pump system includes a manifold which is adapted to connect a varying number of air control valves to control air flow to the related number of inflatable mattress zones. The platform can accommodate a variety of pump sizes. Additionally, the platform is adapted to easily hold changeable faceplates containing a number of tube holes corresponding to the number of mattress zones. The number of plugs used to fill the holes in the manifold for unused air control valves for use with beds having fewer than the maximum number of zones can vary. The pump system includes a circuit board which fits onto the platform, the software of which can be programmed to match the number of air control valves corresponding to each inflatable zone. The invention may include a wired or wireless pendant connected to the circuit board of the platform, allowing the user to control the airflow in each inflatable zone. The invention may also include a pony board with a number of connection ports equal to the maximum number of air control openings in the manifold, with the output wires contained in a single arm and allowing for a single connection from the valves to the circuit board where multiple valves are used. 
         [0009]    The present invention has several advantages and benefits over the prior art. Other objects, features and advantages of the present invention will become apparent after reviewing the following detailed description. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a side perspective view of an air mattress pump system in accordance with one embodiment of the present invention shown without an enclosure top and with certain details removed; 
           [0011]      FIG. 2  is a top view of a pump system in accordance with one embodiment of the present invention shown without an enclosure top; 
           [0012]      FIG. 3  is a detail side perspective view of a pump system in accordance with one embodiment of the present invention shown without an enclosure top; 
           [0013]      FIG. 4  is a front perspective view of a manifold, air control valves, a pony board and an air pump in accordance with one embodiment of the present invention; 
           [0014]      FIG. 5  is a front perspective view of three configurations of pump systems with enclosure tops; 
           [0015]      FIG. 6  is a top view of the three configurations of pump systems of  FIG. 5 , shown without enclosure tops; 
           [0016]      FIG. 7  is a rear perspective view of a manifold and a faceplate in a two-zone configuration of a pump system; 
           [0017]      FIG. 8  is a rear perspective view of a manifold and faceplate in a six-zone configuration of a pump system; 
           [0018]      FIG. 9  is a front perspective view of a manifold, zone tubing and faceplates of two configurations of pump systems shown without enclosure tops; 
           [0019]      FIG. 10  is a rear view of a manifold with an air control valve and air control plugs in accordance with one embodiment of the present invention; 
           [0020]      FIG. 11  is a top perspective view of an air control valve in accordance with one embodiment of the present invention; 
           [0021]      FIG. 12  is a top view of a platform of a pump system in accordance with one embodiment of the present invention; 
           [0022]      FIG. 13  is an underside view of a top enclosure of a pump system in accordance with one embodiment of the present invention; 
           [0023]      FIG. 14  is a top view of a manifold, a pony board, air valves, and air valve connective wires in accordance with one embodiment of the present invention; 
           [0024]      FIG. 15  is a side perspective view of a manifold and tubing of a pump system in accordance with one embodiment of the present invention; 
           [0025]      FIG. 16  is a side perspective view of a pendant circuit board in accordance with one embodiment of the present invention, shown with the cover removed; 
           [0026]      FIG. 17  is a side perspective view of a pendant attached to a pump system with an enclosure top in accordance with one embodiment of the present invention; 
           [0027]      FIG. 18  is an exploded isometric view of the back of a manifold and solenoid assembly in accordance with one embodiment of the present invention; 
           [0028]      FIG. 19  is a cross-section of a side view of the assembled manifold of  FIG. 18  showing a solenoid assembly engaged in an air control hole; and 
           [0029]      FIG. 20  is an enlarged view of the cross-section of the solenoid assembly shown in  FIG. 19 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0030]    Referring now to the drawings,  FIGS. 1-6  are views of a multiple configuration airbed pump system  10  in accordance with a preferred embodiment of the present invention. The pump system  10  may include a pump casing consisting of a platform  20  and an enclosure top  80 . The system may further include a manifold  30  for controlling airflow and including air valves  35  and a pressure measurement valve  37 , air control valves  34 , air control plugs  36 , zone tubing  38 , a pump mounting area  40  for receiving a pump  42 , an interchangeable faceplate  50 , a primary circuit board  60 , internal tubing  62 , a pressure measurement tube  66 , a pendant  70 , and a pony board  100 . The air valves  35  and pressure measurement valve  37  include air inlets, outlets, or ports. The platform  20 , manifold  30 , mounting base  40 , circuit board  60 , internal tubing  62 , pressure measurement tube  66 , pendant  70 , pump  42 , pony board  100 , and enclosure top  80 , are the shared components of the system, and can be used with mattresses varying from one to six individual inflatable zones. Of course, the system  10  could be used with mattresses having other numbers of zones if desired by modifying the manifold  30  to include additional air valves  35 . The faceplate  50 , number of air control valves  34 , zone tubing  38 , and number of air control plugs  36  are the only components that vary in the use of the system  10  with different mattresses. The software of the circuit board  60  can be programmed to correspond to the number of zones to be inflated. 
         [0031]    As seen in  FIGS. 1-3 , the manifold  30  and circuit board  60  can be mounted to the platform  20 , and the platform  20  may have a pump area  40  for holding a pump  42 . The use of a manifold  30  is well-known in the art as a component for regulating air flow pumped from a pump  42  to air chambers. A diaphragm pump is shown, but other types of pumps could be used. The platform  20  can also include a slot  52  for holding an changeable faceplate  50 . The platform  20  may also include screw holes  22  for attaching the manifold  30  and circuit board  60 . The platform  20  may also include screw holes  44  for attaching the pump  42 , as well as screw holes  23  for attaching the enclosure top  80  ( FIG. 11 ). Of course, other means of attaching the enclosure top  80  to the platform  20 , such as adhesives, sonic welding, or snap-fitting, may also be used. 
         [0032]    As seen in  FIG. 2 , the assembled pump system  10  with the enclosure top  80  secured to the platform  20  is identical for pump systems  10  used with, for example, six-, four-, and two-zone mattresses, with the exception of the faceplate  50  and number of zone tubes  38  exiting the faceplate  50 . This allows continuity in the overall product line, in addition to the cost savings, in using such an interchangeable pump system  10 . As the casing platform  20 , enclosure top  80 , and manifold  30  ( FIGS. 12-13 ) are three of the more intricate and therefore expensive components to tool in manufacturing, the standardization provides cost savings by allowing these expensive components to be used across the entire product line, with any mattress model. The standardized platform  20  and enclosure top  80  casing also allow for standardized packing, shipping, and storage of the pump systems  10  to be used with the varying mattress models. The standardized casing also provides brand equity by keeping the same overall look across multiple price points and SKUs, and also provides packaging and advertising cost savings. 
         [0033]    Referring now to  FIGS. 3-4 ,  7 - 8  and  10 , one side of a manifold  30  includes air control holes  32 . In the embodiment shown, seven air control holes  32  are shown. This allows up to seven air control valves  34  to be inserted into the holes  32  of the manifold  30  for a six-zone mattress, with six air control valves  34  used for air flow to the zones, and one air control valve  34  for exhaust. In  FIG. 11 , solenoid valves are shown but other types of air control valves  34  could be used. See, e.g.,  FIGS. 18-20  and related discussion. Of course, manifolds  30  with more or fewer air control holes  32  could be manufactured to accommodate mattresses with more or fewer than six inflatable zones. The manifold  30  includes a cover  31  which can be connected with screws using manifold screw holes  33 . There may also be a manifold gasket  28  between the manifold cover  31  and the manifold  30 . A manifold gasket  28  may help with sealing the manifold and preventing air leaks. In one embodiment, shown in  FIGS. 18-20 , the manifold cover  31  also has a groove  29  to help secure and compress the manifold gasket  28  between the manifold  30  and manifold cover  31 . The inclusion of a groove  29  in the manifold cover  31  creates a substantially more airtight seal between the manifold cover  31  and the manifold  30  because it tolerates molding irregularities better than other types of gasketing options and allows for a lower cost manufacturing and assembly option while still preserving the option for disassembly and repair. Other methods of sealing the manifold cover  31  to the manifold  30  include solvent bonding, heat or sonic welding, and sealing adhesives. 
         [0034]    Having a standardized manifold  30 , the most expensive component due to its complexity and detailed tooling, provides a large cost savings. When fewer than the maximum number of zones are being inflated, the corresponding number of air control valves  34  can be used, and air control plugs  36  can be used to block the empty holes  32  not being used. For example, in the embodiment shown, in a mattress with only two zones, three air control valves  34  would be used (two for air flow to the zones, one for exhaust), and four air control plugs  36  would be inserted into the four unused holes  32 .  FIG. 7  shows a system  10  configured for a two-zone mattress, with the manifold  30  having three air control valves  34  and four air control plugs  36  blocking the unused holes  32 .  FIG. 8  shows a system  10  configured for a six-zone mattress, with the manifold  30  having seven air control valves  34  and therefore no air control plugs  36 . The air control plugs  36  ( FIG. 10 ) fit any hole  32  in the manifold  30  and are very inexpensive to manufacture; having these air control plugs  36  as one of the variable components therefore allows for only a small cost to change the configuration for use with different mattress models. It also allows for volume discounts, in that the same parts can be used across different SKUs. 
         [0035]    As seen in the embodiment shown in  FIGS. 1-3 , two air valves  35  are connected by internal tubing  62  to the pump  42 , whereby air is pumped from the pump  42  to the manifold  30 . On the opposite side of the manifold  30 , air valves  35  are coupled to each of the seven holes  32 . For each zone of the mattress that is to be inflated, a zone tube  38  is attached to the air valve  35  opposite an air control valve  34  and runs to an inflatable zone of the mattress. The manifold  30  is one of the more difficult and expensive components to tool for manufacturing, but, by simply plugging any unused holes  32  with plugs  36 , the manifold  30  can be used with beds ranging from, in the embodiment shown in the FIGS., one to six inflatable zones without any additional manufacturing or machining costs. 
         [0036]    Referring now to  FIGS. 1 ,  6 , and  9 , the faceplate  50  includes openings  54  through which the zone tubes  38  can pass. In a preferred embodiment, the faceplate  50  fits into a slot  52  in the casing platform  20  and top enclosure  80 . Faceplates  50  can therefore be changed to accommodate the number of zone tubes  38  (and air control valves  34 ) corresponding to the number of inflatable zones in each particular mattress. Where a mattress has four inflatable zones, for example, a faceplate  50  with four openings  54  would be placed in the slot  52 , and four tubes  38  would run from the air valves  35  opposite the air control valves  34 , through the openings  54  and to each zone of the mattress. The faceplates  50  are a small and inexpensive component of the pump  10 , and requiring only this component to be manufactured differently for use of the pump  10  with different mattresses saves time and money. Additionally, the faceplate  50  protects the tube  38  connections to the air valves  35 . Some pump systems currently on the market have the tube connections exposed, which subjects the existing pump systems to a greater risk of breakage. This “hiding” of the internal components in the pump system  10  of the present invention also adds aesthetic value to the system  10  giving it an overall clean, finished look. 
         [0037]    The platform  20  in a preferred embodiment also includes a pump mounting area  40  for supporting a pump  42 . A diaphragm pump is shown, but other types of air pumps could also be used. The mounting area  40  in the embodiment shown in  FIG. 12  includes four pump screw holes  44  by which the pump  42  can be secured. Of course, the mounting area  40  could be configured differently and include a different number and configuration of pump screw holes  44  depending on the pump  42  used. Alternative methods of securing the pump  42  to the mounting area  40  of the platform  20  could also be used. The mounting area  40  is sized such that a variety of types and sizes of pumps  42  can be used with the pump system  10 . Internal tubing  62  connects the pump  42  to the manifold  30  to pump air from the manifold  30  to the mattress zones. 
         [0038]    As seen in  FIGS. 1-3 , a circuit board  60  may also be affixed to the platform  20 . The circuit board  60  contains software programmable for the varying number of zones to be inflated. It also contains all connection assemblies for system power and for the pendant  70  used by the mattress user to control the inflation of the zones. The air control valves  34  can be connected to the circuit board  60  by connective wires  64 , and air flow is controlled by the user selecting desired firmness on the pendant  70  which is connected to the circuit board  60 . This allows the corresponding amount of air to be pumped to each zone based on the firmness level selected by the user on the pendant  70 . A pressure measurement tube  66  connects a pressure measurement valve  37  on the manifold  30  to the circuit board  60  to allow the software to determine the pressure in the manifold  30  to control the proper release of air for the firmness selected by the user. The circuit board  60  can be used for any configuration of air control valves  34  and pump sizes  42  by loading it with the appropriate software program. A power cord  68  may be attached to the circuit board  60  to provide power to the pump system  10 . The power cord  68  may alternatively be attached through a transformer (not shown) depending on circuitry design. In a preferred embodiment, the power cord  68  passes through the top enclosure  80  and/or the platform  20  of the casing. 
         [0039]    As shown in FIGS.  1  and  16 - 17 , a pendant  70  can be connected to the circuit board  60  via a pendant cord  72 . An aperture  74  in the enclosure top  80  allows the pendant cord  72  to pass through the enclosure top  80  for connection to the circuit board  60 . Alternatively, the pendant  70  may be configured with the circuit board  60  for wireless control of the pump system  10  (not shown). The pendant  70  includes a pendant circuit board  76  onto which pendant software is uploaded. The pendant  70  and pendant software are standard and can be can be used in connection with any pump system  10  configuration; the pendant  70  and pendant software are designed such that a pendant  70  can be plugged into the circuit board  60  of any pump system  10  configuration and allow the user to control the number of zones in her or her particular air mattress. The pendant  70  includes an LCD display  78  and control buttons  79  to allow the user to control the amount of air pumped from the pump  10  to each inflatable zone. The size of the LCD display  78  and number of control buttons  79  can of course vary. Alternatively, the LCD display  78  could be a touch screen on which firmless level is selected, or a track wheel or ball could be used for selection by a user. Multiple pendants  70  could also be used depending on the need for individual controllers in the system. 
         [0040]    As seen in FIGS.  4  and  14 - 15 , the air control valves  34  may be connected to the circuit board  60  through a pony board  100  instead of directly to the circuit board  60  itself. In this embodiment, connective wires  64  connect the air control valves  34  to the pony board  100 , which is then connected to the circuit board  60 . The pony board  100  may be attached to the cover  31  of the manifold  30  by screws. This pony board  100  includes connection ports  102  equal to the maximum number of air control holes  32  in the manifold  30  and an output arm  104 . In the embodiment shown in the FIGS., the pony board has seven connection ports  102 , equal to the number of air control holes  32  in the manifold  30  shown. Of course, the pony board  100  could include a different number of ports  102  to accommodate the number of holes  32  in the manifold  30 . The pony board  100  allows each air control valve connective wire  64  to be plugged into the pony board  100  instead of directly into the circuit board  60 , with a single output arm  104  running from the pony board  100  to the circuit board  60 . The output arm  104  provides for a single connection from the valves  34  to the circuit board  60  where multiple valves  34  are used, making connection of the pump  10  components faster and easier. It also provides for faster and simpler external testing of the valves  34  and manifold  30  by allowing connection of the single output arm  104  of the pony board  100  to a separate testing unit. 
         [0041]    Air control holes  32  into which air control valves  34  are inserted can be a source of air leaks, and the system can be optimized using air control valves  34  that form a strong seal with the manifold  30 .  FIGS. 18-20  show an embodiment of a manifold  30  in which the air control valves  34  form a strong seal with the manifold overmolding  99  to avoid such air leaks. The air control valve  34  in  FIGS. 18-20  is a solenoid assembly  82 . The solenoid assembly  82  shown includes a solenoid coil  83 , a solenoid frame  84 , a retaining clip  85 , a first solenoid o-ring  86 , a plunger stop  87 , a carrier sleeve  88 , carrier overmolding  89 , a plunger  90 , a return spring  91 , and a second solenoid o-ring  92 . The solenoid coil  83  is typically an electrical wire coil attached to an electrical source. The solenoid frame  84  can be made from any material permeable to magnetic flux and is preferably made from steel. The carrier sleeve  88  may be made from any non-magnetic metal but is preferably made from copper or brass. The carrier overmolding  89  may be made from any non-magnetic material, and preferably is made from a high temperature resistant thermoplastic. The plunger stop  87  and plunger  90  is preferrably made from a high quality, high magnetically permeable iron with limited residual magnetic retention properties. The first solenoid o-ring  86  and the second solenoid o-ring  92  can be made from a variety of types of temperature resistant rubber or plastic, including nitrile. The retaining clip  85  and return spring  91  could be made from any suitable material including, but not limited to, a variety of metals, plastic, or rubber. The return spring  91  should be made from high temperature, non-magnetic material, such as 302 Stainless Spring Wire. 
         [0042]    Further detail of the solenoid assembly  82  is shown in  FIG. 19 . In the solenoid assembly  82  shown, the plunger stop  87  is positioned partially within the carrier sleeve  88 . There are two grooves around the mid-section of the plunger stop  87  that form two moats, namely the first moat  94  and second moat  95 , between the plunger stop  87  and the carrier sleeve  88 . These moats are filled with a sealant to provide a strong seal between the plunger stop  87  and the carrier sleeve  88 . Whatever sealant is used should be able to withstand high temperatures since temperatures in the solenoid assembly  82  may be significant, for example, around 85-90° C., depending on the frequency and duration of the operation of the system. Many suitable sealants could be used, but a particularly effective sealant is Loctite® branded 620, a selant from Henkel Corporation, which is specifically designed for high temperature environments. During assembly, the carrier sleeve  88  is dipped in the sealant and swaged onto the plunger stop  87 ; this causes the sealant to fill the moats, sealing the assembly. 
         [0043]    The plunger  90  also fits partially inside the carrier sleeve. The plunger  90  has a plunger head  93  that is screwed or otherwise attached into the end of the plunger that is opposite the plunger stop. The plunger head  93  is shaped such that it blocks the valve seat  96  into which it is inserted when the plunger  90  is in a closed position. The return spring  91  surrounds the plunger  90  and is compressed when the plunger  90  is in a closed position so that no air can pass when the solenoid assembly  82  is not energized. 
         [0044]    A carrier overmolding piece  89  surrounds the outside of the carrier sleeve  88  on the end of the carrier sleeve that surrounds the plunger  90 . The carrier overmolding  89  is threaded such that it can be screwed into or connected to the air control hole  32 , which is threaded or otherwise shaped to receive the carrier overmolding and solenoid assembly  82 . The first solenoid o-ring  86  and second solenoid o-ring  92  are positioned on each side of the carrier overmolding  89  and compressed to form seals that prevent air leaking from the air control hole pathway. The first solenoid o-ring  86  is compressed between the carrier overmolding  89 , carrier sleeve  88 , and the solenoid frame  84 . The second solenoid o-ring  92  is compressed between the air control hole  32  and the carrier overmolding  89 . This system of employing moats, sealant between the carrier tube and plunger stop, and compressed o-rings  86 ,  92  on either side of the carrier overmolding  89  creates a reinforced seal between the carrier sleeve and the plunger stop  87 . The default position for the solenoid assembly and in particular the plunger head  93  is that the return spring  91  will be compressed and the plunger head  93  will be blocking the air control hole  32  due to pressurized contact between the plunger head  93  and the valve seat  96 . When the solenoid coil  83  is energized, the plunger  90  will be retratcted until stopped by the plunger stop  87 , therefore opening the valve seat  96  and allowing air to pass through the manifold chamber  27 , through the interior space of the air valve  39 , and through the zone tubing  38 . Other sealing methods and air control valves and devices could be used to seal air pathway around the air control valves  34  and control the flow of air into the manifold as well. 
         [0045]    The combination of compressed first and second soleinoid o-rings  86 ,  92 , compressed manifold gasket  28 , and sealant-filled first and second moats  94 ,  95  creates a reinforced sealed manifold. This reinforced sealing isolates the manifold chamber  27  from outside of the manifold, which acts as a redundant seal for zone tubing  38 , even in the event of a leak at the seal created by plunger head  93  and valve seat  96 . 
         [0046]    Although the invention has been herein described in what is perceived to be to most practical and preferred embodiments, it is to be understood that the invention is not intended to be limited to the specific embodiments set forth above. Rather, it is recognized that modifications may be made by one of skill in the art of the invention without departing from the spirit or intent of the invention and, therefore, the invention is to be taken as including all reasonable equivalents to the subject matter of the appended claims and the description herein.