U.S. patent application number 09/873540 was filed with the patent office on 2001-09-27 for check valve for mattress assembly.
This patent application is currently assigned to Hill-Rom, Inc.. Invention is credited to Perez, Timothy W., Romano, James J., Soltani, Sohrab.
Application Number | 20010023512 09/873540 |
Document ID | / |
Family ID | 22359387 |
Filed Date | 2001-09-27 |
United States Patent
Application |
20010023512 |
Kind Code |
A1 |
Perez, Timothy W. ; et
al. |
September 27, 2001 |
Check valve for mattress assembly
Abstract
A check valve adapted for use between first and second fluid
chambers. The check valve is configured to prevent fluid flow from
the second fluid chamber into the first fluid chamber.
Inventors: |
Perez, Timothy W.; (James
Island, SC) ; Soltani, Sohrab; (Charleston, SC)
; Romano, James J.; (James Island, SC) |
Correspondence
Address: |
Intellectual Property Group
Bose McKinney & Evans LLP
2700 First Indiana Plaza
135 North Pennsylvania Street
Indianapolis
IN
46204
US
|
Assignee: |
Hill-Rom, Inc.
|
Family ID: |
22359387 |
Appl. No.: |
09/873540 |
Filed: |
June 4, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09873540 |
Jun 4, 2001 |
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09479353 |
Jan 7, 2000 |
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6240584 |
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60115116 |
Jan 8, 1999 |
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Current U.S.
Class: |
5/713 |
Current CPC
Class: |
A47C 27/10 20130101;
A47C 27/082 20130101; Y10T 137/3584 20150401 |
Class at
Publication: |
5/713 |
International
Class: |
A47C 027/08 |
Claims
What is claimed is:
1. A check valve for use in a mattress assembly including an
inflatable central support portion and a manifold in fluid
communication with the central support portion, the manifold being
configured to be coupled to an air supply to supply air to the
central support portion, the check valve comprising: a top sheet; a
bottom sheet disposed substantially parallel to the top sheet; a
tube positioned intermediate the top sheet and the bottom sheet,
the top sheet and the bottom sheet sealed around the tube to
provide an air inlet located within the manifold; and the top and
bottom sheets cooperating to define at least one air opening
located within the central support portion.
2. The check valve of claim 1, wherein the at least one air opening
is configured to permit air flow in a first direction from the
manifold into the central support portion, while preventing air
flow in a second direction from the central support portion into
the manifold.
3. The check valve of claim 1, wherein the top and bottom sheets
cooperate to define two air openings located within the central
support portion.
4. The check valve of claim 1, wherein the tube has an angled end
surface.
5. A check valve adapted for use between first and second fluid
chambers, the check valve comprising: a first sheet; a second sheet
sealed to the first sheet to define a fluid outlet, the fluid
outlet positioned within the second fluid chamber wherein fluid
pressure within the second fluid chamber forces the first and
second sheets toward the other of the first and second sheets,
thereby preventing fluid flow from the second fluid chamber into
the first fluid chamber; and a tube positioned intermediate the
first and second sheets, the first and second sheets sealed around
the tube to provide an fluid inlet in fluid communication with the
first fluid chamber, wherein fluid supplied from the tube forces
the first and second sheets away from the other of the first and
second sheets, thereby permitting fluid flow from the first fluid
chamber into the second fluid chamber.
6. The check valve of claim 5, wherein the first and second sheets
cooperate to define two fluid openings located within the second
fluid chamber.
7. The check valve of claim 5, wherein the tube has an angled end
surface.
8. The check valve of claim 5, wherein the first fluid chamber
comprises a manifold being configured to be coupled to an air
supply to supply air to the second fluid chamber, and the second
fluid chamber comprises an inflatable central support portion of a
mattress assembly.
9. A check valve comprising: a first planar sheet; a second planar
sheet disposed substantially parallel to the first sheet; a tube
disposed intermediate the first and second sheets, the first and
second sheets sealed around the tube to prevent fluid flow between
the first and second sheets and the tube; and at least one outlet
formed by the first and second sheets and positioned in spaced
relation to the tube, the at least one outlet configured to permit
fluid flow in a first direction from the tube to the at least one
outlet, while preventing fluid flow in a second direction from the
at least one outlet to the tube.
10. The check valve of claim 9, wherein the tube is in fluid
communication with a first fluid chamber.
11. The check valve of claim 10, wherein the outlet is in fluid
communication with a second fluid chamber, and the first and second
sheets are disposed within the second fluid chamber wherein fluid
pressure within the chamber tends to force the first and second
sheets into sealing engagement.
12. The check valve of claim 9, wherein the tube maintains the
first and second sheets in spaced relation.
13. The check valve of claim 9, wherein the first and second sheets
are formed of a urethane material.
14. The check valve of claim 9, wherein the tube has an angled end
surface.
15. The check valve of claim 9, wherein the at least one outlet
comprises a pair of openings disposed substantially perpendicular
to the tube.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. patent
application Ser. No. 09/479,353 filed Jan. 7, 2000, which claims
the benefit of U.S. provisional application Serial No. 60/115,116,
filed Jan. 8, 1999, the disclosures of which are expressly
incorporated by reference herein.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] The present invention relates to a mattress, a mattress
overlay, or a mattress replacement assembly including an air
cushion having air zones for supporting a person, and to a pressure
control assembly for controlling the pressure of pressurized fluid
contained by the air zones of the air cushion.
[0003] Some mattresses, mattress overlays, or mattress replacement
systems (hereinafter mattresses) are provided with air sacks to
support a person and to provide adjustable firmness
characteristics. These air mattresses include one, or several air
sacks that are inflated to different pressures to adjust the
firmness in selective regions or zones of the mattress. One such
mattress is illustrated in U.S. Pat. No. 5,794,288, entitled
PRESSURE CONTROL ASSEMBLY FOR AN AIR MATTRESS, which is herein
incorporated by reference.
[0004] It is desirable for an air mattress to provide different
pressure zones of support for a person on the mattress while
maintaining sufficient pressure along opposite side edges of the
mattress to provide support when the person sits or rests along one
of the side edges. In the illustrated embodiment, each air zone is
in fluid communication with a manifold having an interior region
that is maintained at a constant pressure. The constant pressure of
the pressurizing fluid within the manifold may be the same as or
may be different from the pressure of pressurized fluid within at
least one of the air zones. The illustrated air cushion also
includes first and second side bolsters filled with air that extend
along opposite sides of the air cushion to help retain a person on
the air cushion.
[0005] In the illustrated embodiment of the present invention, a
mattress assembly comprises an inflatable central support portion
having a head end, a foot end, a first side and a second side, and
first and second side bolsters coupled to the first and second
sides, respectively. The first and second side bolsters each have
at least two chambers extending along a longitudinal axis of the
first and second side bolsters. At least one of the chambers is a
manifold in fluid communication with the central support portion.
The manifold is configured to be coupled to an air supply to supply
air to the central support portion and the other chambers.
[0006] Also in the illustrated embodiment, the inflatable central
support and the first and second side bolsters are formed from a
plurality of separately inflatable zones. The plurality of zones
include a head zone, a shoulder zone, a seat zone, and a foot zone.
The illustrated first and second side bolsters each include a top
chamber, a central chamber, and a bottom chamber. The central
chamber of the first side bolster is illustratively the manifold
extending along the first side of the central support portion. The
central chamber of the first side bolster is in fluid communication
which each of the plurality of zones of the central support
portion. The zones of the top and bottom chambers of the of the
first and second side bolsters are each in fluid communication with
the central support portion through a restricted flow orifice.
Illustratively, the zones of the central chamber of the second side
bolster are coupled to the top chambers of the second side bolster
through a restricted flow orifice. Also illustratively, the bottom
chambers in the shoulder zone of the of the first and second side
bolsters are coupled to the central support portion by check valves
which permit air flow from the central support portion into the
bottom chambers in the shoulder zone.
[0007] Additional features and advantages of the invention will
become apparent to those skilled in the art upon consideration of
the following detailed description of an illustrated embodiment
exemplifying the best mode of carrying out the invention as
presently perceived.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The detailed description particularly refers to the
accompanying figures in which:
[0009] FIG. 1 is an exploded perspective view of a mattress
assembly of the present invention including an air cushion having a
plurality of separate air zones, top coverlet, a bottom cover, and
a blower configured to be coupled to the air cushion;
[0010] FIG. 2 is a sectional view taken through a head zone of the
air cushion;
[0011] FIG. 3 is a sectional view taken through a shoulder zone of
the air cushion;
[0012] FIG. 4 is a sectional view taken through a seat zone of the
air cushion;
[0013] FIG. 5 is a sectional view taken through a foot zone of the
air cushion;
[0014] FIG. 6 is a top plan view of the air cushion of FIG. 1;
[0015] FIG. 7 is a bottom plan view of the air cushion;
[0016] FIG. 8 is a perspective view of a check valve of the present
invention in an open orientation to permit air flow from a manifold
into a central support portion of the air cushion;
[0017] FIG. 9 is a perspective view of the check valve of FIG. 8
illustrating the check valve in a closed position; and
[0018] FIG. 10 is a perspective view of a portion of the air
cushion illustrating a plurality of chambers within a side bolster
located adjacent to a support zone of the air cushion.
DETAILED DESCRIPTION OF THE DRAWINGS
[0019] Referring now to the drawings, FIG. 1 illustrates a mattress
assembly 10 including an air cushion 12 configured to be located
between a top coverlet 14 and a bottom cover 16. Illustratively,
top coverlet 14 includes a top surface 18 and a side flap 20. A
zipper 22 extends around the coverlet 14 beneath the flap 20.
Zipper 22 is configured to be coupled to a zipper 24 of bottom
cover 16 so that the flap 20 extends downwardly over zipper 24.
Zipper 24 is coupled to a side wall 26 of cover 16 which extends
upwardly from a bottom surface 28. Coverlet 14 and bottom cover 16
cooperate to define an interior region 30 for receiving the air
cushion 12. Buckles 32 are coupled to opposite sides of cover 16 to
secure the mattress assembly 10 to a box spring or a support deck.
In addition, bottom cover 16 includes tie straps 34 which may also
be used to secure the mattress assembly 10 to a support deck.
[0020] Air cushion 12 includes a side flap 43 adjacent each side
bolster 42 and 44. Snaps 45 are located on each flap 43. Snaps 45
are configured to mate with snaps 47 on side wall 26 of bottom
cover 16. It is understood that other suitable fasteners, such as
Velcro fasteners, ties, etc. may be used instead of snaps 45 and
47.
[0021] Air cushion 12 includes a central support portion 40 which
provides a sleep surface for a person resting on the mattress. Air
cushion 12 also includes side bolsters 42 and 44 located on
opposite sides of the central support portion 40. Air cushion 12 is
illustratively divided into separate air zones including a head
zone 46, a shoulder zone 48, a seat zone 50, and a foot zone 52. A
hose fitting 54 is coupled to the side bolster 42 in the foot zone
52. Fitting 54 is configured to be coupled to a connector 56 on air
hose 58. A connector 60 on the opposite end of hose 58 is
configured to be coupled to an outlet 62 of a blower 64. Connector
56 extends through an aperture 66 formed in bottom cover 16 and
into the hose fitting 54 to supply air from the blower 64 to the
air cushion 12 as discussed in detail below.
[0022] Each of the air zones 46, 48, 50, and 52 are separated by a
solid divider wall 68, 70, and 72 as best illustrated in FIG. 6.
The central support portion 40 further includes baffles 74 located
within each zone. Baffles 74 include apertures 76 which permit air
flow through the baffles 74.
[0023] First side bolster 42 includes a top chamber 80, a bottom
chamber 82, and a central manifold 84. Second side bolster 44
includes a top chamber 86, a bottom chamber 88, and a central
chamber 90. Top and bottom chambers 80 and 82 of side bolster 42
are divided into separate zones by dividers 68, 70, and 72 shown in
FIG. 6. Manifold 84 extends continuously through the first side
bolster 42 so that manifold 84 supplies air from the blower 64 to
each of the separate air zones 46, 48, 50, and 52 of the air
cushion 12. A split corrugated hose 92 extends through the manifold
84 to prevent opposite side walls of the manifold 84 from
collapsing together to block air flow through one of the air
zones.
[0024] As shown in FIG. 5, inlet air from blower 64 passes through
hose 58 and hose fitting 54 into bottom chamber 82 of foot zone 52.
Bottom chamber 82 is in fluid communication with manifold 84 within
foot zone 52. Therefore, air flows through the manifold 84 along
the entire side bolster 42.
[0025] Referring now to FIG. 2, the configuration of the head zone
46 of the air cushion 12 is illustrated. The central support
portion 40 has a thickness illustrated by dimension 94. Side
bolsters 42 and 44 have a thickness illustrated by dimension 96
which is greater than the thickness of the support portion 40. The
increased thickness of side bolsters 42 and 44 helps to maintain a
person on the air cushion 12. The top and bottom chambers of the
side bolsters 42, 44 simulate a rectangular shape and provide an
increased sleep surface area compared to a single round side
bolster chamber.
[0026] In head zone 46, air from manifold 84 passes into central
support portion 40 through a check valve 98 in the direction of
arrow 100 to supply the central support portion 40 with air from
the blower 64. Air from central support portion 40 passes through a
restricted flow orifice 102 into top chamber 80 and through a
restricted flow orifice 104 into bottom chamber 82 of side bolster
42. In addition, air from central portion 40 passes through a
restricted flow orifice 106 into top chamber 86 of side bolster 44
and through restricted flow orifice 108 into bottom chamber 88 of
side bolster 44. Air also passes from top chamber 86 to central
chamber 90 of side bolster 44 through a restricted flow orifice
110. Illustratively, orifices 102, 104, 106, 108, and 110 all have
a size of 1/8 inch. A dump valve 112 is coupled to central portion
40 to permit the head zone 46 to be deflated quickly. A test port
114 is also coupled to central support portion 40. Test port 114 is
configured to receive a needle to check the pressure within zone
46.
[0027] FIG. 3 illustrates the configuration of the air cushion 12
in the shoulder zone 48. Air from the manifold 84 passes through a
check valve 116 into central support portion 40 in the direction of
arrow 118. Air from central support portion 40 flows into top
chamber 80 of side bolster 42 through an orifice 120. Air from
central support portion 40 also passes through a check valve 122
into bottom chamber 82 of side bolster 42 in the direction of arrow
124. In addition, air from central support portion 40 passes into
top chamber 86 of side bolster 44 through a restricted flow orifice
126. Air from chamber 86 passes into central chamber 90 through
orifice 128. Air also passes from central support portion 40
through a check valve 130 into bottom chamber 88 of side bolster 44
in the direction of arrow 132. Illustratively, orifices 120, 126,
and 128 have a dimension of 1/8 inch. Dump valves 131 and 133 are
coupled to bottom chambers 82 and 88, respectively, of shoulder
zone 48.
[0028] Check valves 122 and 130 permit air to enter bottom chambers
82 and 88, respectively. However, air cannot pass back through
check valves 122 and 130 into the central support portion 40.
Therefore, these bottom chambers 82 and 88 within shoulder zone 48
remain at relatively high pressure to provide additional support in
bolsters 42 and 44 within the shoulder zone. As the weight of the
patient increases, the pressure within bottom chambers 82 and 84
within shoulder zone 48 also increases.
[0029] FIG. 4 illustrates the configuration of the air cushion 12
within the seat zone 50. Air manifold 84 is coupled to central
support portion 40 by an orifice 134. Illustratively, orifice 134
has a dimension of 3/8 inch. Therefore, the pressure within central
support portion 40 of seat zone 50 is maintained at substantially
the air manifold pressure. Air passes from central support portion
40 into top chamber 80 and bottom chamber 82 of side bolster 42
through restricted flow orifices 136 and 138, respectively. Air
also passes from central support portion 40 into top chamber 86 and
bottom chamber 88 of side bolster 44 through restricted flow
orifices 140 and 142, respectively. Air passes from top chamber 86
to central chamber 90 of side bolster 44 through a restrictive flow
orifice 144. Illustratively, orifices 136, 138, 140, 142, and 144
each have a dimension of 1/8 inch. Dump valves 146 and 148 are
coupled to bottom chambers 82 and 88, respectively. A test port 114
is coupled to central support portion 40.
[0030] A configuration of foot zone 52 of air cushion 12 is
illustrated in FIG. 5. Air manifold 84 is coupled to central
support portion 40 of foot zone 52 by a check valve 150 so that air
flows from manifold 84 into central support portion 40 in the
direction of arrow 152. Air passes from central support portion 40
into top chamber 80 of side bolster 42 through restricted flow
orifice 154. Air also passes into top chamber 86 and the bottom
chamber 88 of side bolster 44 through restrictive flow orifices 156
and 158, respectively. Air flows from top chamber 86 to central
chamber 90 of side bolster 44 through restricted flow orifice 160.
Illustratively, orifices 154, 156, 158, and 160 have a dimension of
1/8 inch. A dump valve 162 is coupled to central support portion 40
within foot zone 52. A test port 114 is also coupled to central
support portion 40 within foot zone 52.
[0031] Air pressure within each of the air zones 46, 48, 50, and 52
is controlled by the number of micro holes 172 formed in a top
surface 170 of each zone of the central support portion 40.
Illustratively, head zone 46 includes 12-16 micro holes 172,
shoulder zone 48 includes 20-24 micro holes, seat zone 50 includes
12 micro holes, and foot zone 52 includes 36-48 micro holes. The
number of micro holes 172 in each zone 46, 48, 50, and 52 controls
the pressure within the zone since the same manifold pressure from
air manifold 84 is supplied to each zone. Therefore, pressure
within the zones 46, 48, 50, and 52 can be established at a desired
level by altering the size or number of micro holes 172 formed in
top surface 170 of central support surface 40. In another
embodiment, a separate orifice is coupled to the central support
portion 40 in each zone to adjust the air flow out of the zone
without micro holes being formed in the top surface 170. As shown
in FIG. 7, bleeder valves 174, 176 are coupled to a bottom surface
178 of air cushion 12 in communication with the head zone 46 and
foot zone 52. Bleeder valves 174, 176 further reduce the pressure
in head zone 46 and foot zone 52. When bleeder valves 174, 176 are
used, micro holes 172 are not used to vent head zone 46 and foot
zone 52.
[0032] The side bolsters 42 and 44 help retain a person on the
central support portion 40 as the person moves toward an edge of
the mattress. Since air flow out of the side bolsters 42, 44 is
restricted, air cannot rush to an opposite side of the air cushion
12 as the person moves toward a side of the air cushion 12. The
number of micro holes 172 is illustratively selected so that the
seat zone 50 has the highest pressure. Shoulder zone 48
illustratively has the next highest pressure. Head zone 46 and foot
zone 52 have the lowest pressures.
[0033] The mattress assembly 10 of the present invention may be
used as a mattress overlay or as a mattress replacement. Typically,
the thickness of the mattress overlay is less than the thickness
for a mattress replacement air cushion. If desired, such as in a
mattress replacement situation, the orifices 138 and 142 of seat
zone 50 may be replaced with check valves such as illustrated by
check valves 122 and 130 in FIG. 3 so that air is forced into
bottom chambers 82 and 88 based on the weight of the patient. If
such check valves are used, air cannot return from bottom chambers
82 and 88 of the seat zone 50 to the central portion 40 as
discussed with regard to FIG. 3. Therefore, this embodiment would
provide additional stiffness for the side bolsters 42, 44.
[0034] FIGS. 8 and 9 illustrate a check valve 180 of the present
invention. Check valve 180 is illustratively formed from two sheets
181, 183 of high temperature urethane material having a thickness
of about 0.008 inch. The thickness may be less if desired. The
sheets are seam sealed to an air zone surface around a tube 182 by
seams 184. Tube 182 includes an angle cut end 185 to reduce the
likelihood that the tube 182 will be sealed by a portion of
manifold 84. Seals such as RF welds are also provided at locations
186 and 188 to provide a generally T-shaped open region 190 between
the sheets 181, 183 of the valve 180. Open region 190 has air
outlet openings 191 which are not sealed by seams. Air can flow
through the tube 182 in the direction of arrow 192. Air the passes
into region 190 as illustrated by arrows 194 in FIG. 8 and exits
the valve 180 through openings 191 as illustrated by arrows 196.
The sheets 181, 183 of valve 180 collapse and block air flow
through the region 190 in the direction of arrows 197 to provide a
check valve as shown in FIG. 9. Dimension 198 of valve 180 is
illustratively 3.250 inches. Dimension 200 of valve 180 is
illustratively 2.375 inches. Dimension 204 of valve 180 is
illustratively 1.000 inch.
[0035] Additional details of the air cushion 12 are illustrated in
FIG. 10. Air cushion 12 includes a top sheet of material 210 and a
bottom sheet of material 212 which extend across the entire width
of the air cushion 12. Baffles 74 are coupled to top sheet 210 and
bottom sheet 212 by seams 214 and 216, respectively. Air cushions
212 further include upper and lower interior sheets of material 218
and 220 which form the side bolsters 42 and 44. Only one side
bolster 42 is illustrated in FIG. 10.
[0036] Upper sheet 218 is coupled to top sheet 210 by seam 222.
Sheet 218 is also coupled to top sheet 210 at a spaced-apart
location 224 to define the top chamber 80 of bolster 42. Sheets
210, 212, 218, and 220 are all coupled together by seam 222
adjacent flap 43. Lower sheet 220 is coupled to bottom sheet 212 by
seam 228. Lower sheet 220 is also coupled to upper sheet 218 by
seam 184. Illustratively, the check valve 180 is coupled to the top
and bottom sheets 218 and 220 as shown in FIG. 10.
[0037] Lower sheet 220 is also coupled to bottom sheet 212 at a
location 230 spaced apart from seam 228 to define bottom chamber 82
of bolster 42. Manifold 84 is formed between upper and lower sheets
218 and 220 between seams 184, 224, 226, and 230.
[0038] Hose 92 extends through manifold 84 as shown in FIG. 10 to
prevent the sheets 218 and 220 which form manifold 84 from
collapsing against each other to seal the manifold 84. Tube 92 is
split along its length as shown by split 232. Therefore, air can
flow through the tube 92 and through the split portion 232. In
other words, tube 92 provides structural support within the
manifold 84 to hold the manifold 84 open. It is understood that
other structural support members such as springs, etc. which permit
air flow through the support member may be used in accordance with
the present invention.
[0039] Although the invention has been described in detail with
reference to certain illustrated embodiments, variations and
modifications exist within the scope and spirit of the invention as
defined by the following claims.
* * * * *