U.S. patent application number 13/311614 was filed with the patent office on 2012-06-07 for adjustable contour mattress system.
This patent application is currently assigned to J.T. Labs Limited. Invention is credited to Tit-Shing Wong.
Application Number | 20120137444 13/311614 |
Document ID | / |
Family ID | 46160826 |
Filed Date | 2012-06-07 |
United States Patent
Application |
20120137444 |
Kind Code |
A1 |
Wong; Tit-Shing |
June 7, 2012 |
Adjustable Contour Mattress System
Abstract
An adjustable contour mattress is provided with a multiplicity
of zones each having a mattress height independently adjustable by
a respective electro-mechanical actuator. The actuators are
disposed within the mattress between a lower panel member and an
upper mattress layer. A control unit is connected to the actuators
for operating them to alternately raise and lower respective zones
of the upper mattress layer. A remote control is operatively
connected to the control unit and includes command input elements
enabling an individual user to selectively operate the actuators
independently of other ones of the actuators, whereby the user can
adjust heights of the zones independently of one another.
Inventors: |
Wong; Tit-Shing; (Kowloon,
CN) |
Assignee: |
J.T. Labs Limited
On Lok Tsuen Fanling
CN
|
Family ID: |
46160826 |
Appl. No.: |
13/311614 |
Filed: |
December 6, 2011 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61459047 |
Dec 6, 2010 |
|
|
|
Current U.S.
Class: |
5/722 |
Current CPC
Class: |
A47C 21/006 20130101;
A47C 19/025 20130101; A61G 7/0573 20130101 |
Class at
Publication: |
5/722 |
International
Class: |
A47C 17/00 20060101
A47C017/00 |
Claims
1. An adjustable contour mattress system comprising: a support
frame having at least one lower panel member along a bottom
periphery of said frame; a mattress having an at least partially
resilient upper layer and provided with a multiplicity of
independent height-adjustable zones; a multiplicity of actuators
equal in number to said zones and disposed within said mattress
between said lower panel member and said upper layer; a control
unit operatively connected to said actuators for operating same to
alternately raise and lower respective zones of said upper layer;
and a remote control operatively connected to said control unit,
said remote control having command input elements enabling an
individual user to select heights of said zones independently of
one another.
2. The mattress system defined in claim 1 wherein said actuators
include mechanical linkages.
3. The mattress system defined in claim 2 wherein said actuators
are electrically powered.
4. The mattress system defined in claim 1 wherein each of said
actuators includes a motor with a speed reduction gear box
operatively connected to a screw shaft for alternately rotating
said shaft in opposite directions.
5. The mattress system defined in claim 4 wherein said screw shaft
is linked to the driving gear box and a screw nut at each end.
6. The mattress system defined in claim 1 wherein each of said
actuators includes a scissor linkage
7. The mattress system defined in claim 1 wherein each of said
actuators includes at least one camming member.
8. The mattress system defined in claim 1 wherein each of said
actuators includes a screw jack actuator.
9. The mattress system defined in claim 1 wherein each of said
actuators includes a rack and pinion assembly.
10. The mattress system defined in claim 1 wherein each of said
actuators includes a linear actuator.
11. The mattress system defined in claim 1 wherein said linear
actuator is taken from the group consisting of a hydraulic
cylinder, a pneumatic cylinder, and a motorized ball screw linear
actuator.
12. The mattress system defined in claim 1 wherein said remote
control has command input elements enabling an individual user to
select heights of said zones independently of one another.
13. A method for adjusting a mattress, comprising: providing a
mattress having a multiplicity of height-adjustable zones and a
multiplicity of actuators equal in number to said zones and
disposed in operative relationship with respect to said mattress to
effectuate adjustment of mattress contour; operating said actuators
to elevate said zones to respective heights; and operating a remote
control to select the heights of individual ones of said zones, the
operating of said actuators being in conformity with the heights of
said individual ones of said zones as selected via the operating of
said remote control.
14. The method defined in claim 13 wherein the operating of said
remote control includes generating height-adjustment signals and
automatically modifying stored data encoding the heights of said
individual ones of said zones.
15. The method defined in claim 13 wherein the operating of said
actuators includes operating a control unit to access a memory to
extract mattress height data determined at least in part by the
operating of said remote control.
Description
BACKGROUND OF THE INVENTION
[0001] This invention relates to a mattress having an adjustable
contour.
[0002] Standard off-the-shelf mattresses and pillows are not
designed to satisfy individual needs for contour and hardness and
accordingly fail to provide adequate support to the spine and neck
of the user. In particular, many elderly people have trouble
finding a mattress and pillow on the market which would fit 100%
their needs for relief from shoulder pain, neck pain, back pain
resulting from improper support to their body because of the
less-than-optimum contour and hardness of their mattresses.
[0003] The prior art includes air-bag-type mattresses for pressure
sore relief and with low contact pressure for comfort. There are
also adjustable bed support frames (like those commonly used in
hospitals) available on the market.
[0004] However, there is no tailor made mattress and pillow
available in the market place for adapting a mattress to fit
individual needs in the manner of tailor made shoes and
clothing.
[0005] Consequently, there is a need for a mass production mattress
and pillow that are cost affordable by the public but also allow
the user to adjust the contour by the user as they wish.
SUMMARY OF THE INVENTION
[0006] The present invention aims to provide an improved mattress.
More particularly, the present invention aims to provide an
improved mattress that enables custom modification of the mattress
contour in accordance with the preferences and needs of the
individual user. The term "contour" is used herein to mean a
profile of an upper surface of a mattress. The contour is variable
in accordance with the operation of multiple mattress height
actuators and is user adjustable. Mattress contour may be
adjustably variable in just one dimension, along the length of the
mattress, or in two dimensions, including both length and
width.
[0007] The present invention aims to provide a manually adjustable
electro-mechanical mattress that allows the user to adjust and
change the contour of the mattress and pillow to get the best
support he or she wishes.
[0008] The present invention particularly contemplates a mattress
system provided with multiple zones along its full length or
partial length (see FIG. 1) starting from the pillow end.
[0009] An adjustable contour mattress system in accordance with the
present invention comprises a support frame, a mattress, a
multiplicity of actuators, a control unit and a remote control. The
support frame has at least one lower panel member along a bottom
periphery of the frame, while the mattress has an at least
partially resilient upper layer and is provided with a multiplicity
of height-adjustable zones. The actuators equal in number to the
mattress zones and are disposed within the mattress between the
lower panel member and the upper layer. The control unit is
operatively connected to the actuators for operating same to
alternately raise and lower respective zones of the upper layer.
The remote control is operatively connected to the control unit and
includes command input elements enabling an individual user to
selectively operate the actuators independently of other ones of
the actuators, whereby the user can adjust heights of the zones
independently of one another. The control of zone height may be
effectuated in real time, that is, while the user is on the
mattress. Alternatively, or additionally, user adjustment of
mattress zone height may be implemented via electronic storage of
user-adjusted mattress contours and subsequent operation of
mattress height actuators pursuant to the stored mattress contour.
Typically, mattress contour adjustment is effectuated while the
user is lying on the mattress. Contour adjustments may be stored as
"canned" contours per user direction.
[0010] The control unit and the remote control may be incorporated
into the same housing, which may be a handheld device or a tabletop
console. The remote control and the control unit may be operatively
connected to the actuators via electrical wires or wireless
transmission links. Where a handheld remote and a control unit are
provided in separate casings, the handheld may be operatively
connected to the control unit via a hard-wired or a wireless
transmission path.
[0011] It is contemplated that the actuators include mechanical
linkages, preferably electrically powered. Each of the actuators
may include a motor with a speed reduction gear box operatively
connected to a screw shaft for alternately rotating the shaft in
opposite directions. The screw shaft is linked to the driving gear
box and a screw nut at each end.
[0012] Alternatively, each of the actuators may include a scissor
linkage, at least one camming member, a screw jack actuator, or a
rack and pinion assembly.
[0013] In another alternative embodiment the actuators are linear
actuator, for instance, hydraulic cylinders, pneumatic cylinders,
or motorized ball screw linear actuators.
[0014] A method for adjusting a mattress comprises, in accordance
with the present invention, providing a mattress having a
multiplicity of height-adjustable zones and a multiplicity of
actuators equal in number to the zones and disposed within the
mattress, operating the actuators to elevate the zones to
respective heights, and operating a remote control to selectively
adjust an individual one of actuators to adjust the height of the
respective mattress zone.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is partially a schematic isometric view, partially
broken away, and partially a block diagram of a mattress system in
accordance with the present invention.
[0016] FIG. 2 is a schematic partial side elevational view of an
actuator assembly in a height adjustment zone of the mattress
system of FIG. 1, said the actuator assembly in a collapsed or
low-elevation configuration.
[0017] FIG. 3 is a schematic partial side elevational view similar
to FIG. 2, showing the actuator in a raised of high-elevation
configuration.
[0018] FIG. 4 is schematic a longitudinal cross-sectional view of
the mattress of FIG. 1, showing a contoured mattress upper
layer.
[0019] FIGS. 5A-5D are schematic partial side elevational views of
alternative mattress-height actuators in accordance with the
present invention.
[0020] FIG. 6 is a schematic isometric view, partially broken away,
of a mattress in another adjustable mattress-height system in
accordance with the present invention.
[0021] FIG. 7 is a schematic isometric view of a linear
mattress-height actuator utilizable in the mattress of FIG. 6.
[0022] FIG. 8 is a block diagram of components of a control unit
and a remote control shown in FIG. 1.
[0023] FIG. 9 is a block diagram of components of a central
processing unit shown in FIG. 8.
DETAILED DESCRIPTION
[0024] As depicted in FIG. 1, an adjustable contour mattress system
comprises a support frame 10, a mattress 12, a multiplicity of
actuators 14, a control unit 16 and a remote control 18. Support
frame 10 has at least one lower panel member 20 along a bottom
periphery of the frame. Mattress 12 has an at least partially
resilient upper layer 22 made of padded or foam material and is
provided with a multiplicity of height-adjustable zones 24.
Actuators 14 are equal in number to mattress zones 24 and are
disposed within mattress 12 between lower panel member 20 and upper
layer 22. Control unit 16 is operatively connected to actuators 14
for operating the actuators independently of one another to
alternately raise and lower respective zones 24 of upper layer 22.
Remote control 18 is operatively connected to control unit 16 and
includes command input elements 26 (e.g., keypads, FIG. 4) enabling
an individual user USR (FIG. 4) to selectively or separately
operate actuators 14 so that the user can adjust the heights of
zones 24 independently of one another. Typically, mattress contour
adjustment is effectuated while the user is lying on the mattress.
Contour adjustments may be stored as "canned" contours per user
direction. Accordingly, a direct adjustment of mattress contour in
response to user operation of remote control 18 may occur only
during a calibration phase. Subsequent changes to mattress contour
may then occur only in response to user selection of a particular
stored mattress contour. Of course, once the user selects a stored
mattress contour, regardless of whether that contour is a
preprogrammed contour pursuant to factory specifications or
includes user-selected mattress-height adjustments, the user may
operate remote control 18 to adjust or "fine tune" the various
mattress zone heights per preferences of the moment.
[0025] Control unit 16 and remote control 18 may be incorporated
into the same housing 28, which may be a handheld device casing or
a tabletop console cabinet. Alternatively, remote 18 and control
unit 16 may be provided in separate casings, the handheld may be
operatively connected to the control unit via a hard-wired or a
wireless transmission path 34 (FIG. 4). Remote control 18 and
control unit 16 may be operatively connected to actuators 14 via
electrical wires 30 or wireless transmission links 32 (FIG. 2).
[0026] As shown in FIGS. 2 and 3, actuators 14 include pairs of
mechanical linkages 36 each connected via a respective screw nut 38
to a drive shaft 40. Each actuator 14 further includes an
electrical motor 42 with an incorporated speed reduction gearbox
operatively connected to drive or screw shaft 40 for alternately
rotating the shaft in opposite directions. In response to
instructions from the user USR via remote control 18, control unit
16 activates each motor 42, as required, to rotate the respective
screw shaft 40 in one direction or the other to raise or lower the
respective zone 24 of mattress upper layer 22.
[0027] Linkages 36 elevate the respective height-adjustable zone 24
when the screw nuts 38 are moved inward (towards each other, see
FIG. 3) or lower the adjustable zone base when the screw nuts are
moved outwards (away from each other). Linkages 36 are pivotably
connected at their lower ends to lower frame panel 20 and at their
upper ends to respective substantially rigid upper panel sections
43. Each upper panel section 43 holds a respective foam mattress
under section 45 atop which mattress upper layer 22 is
disposed.
[0028] FIG. 4 shows upper layer 22 of mattress 12 contoured
pursuant to the preferences and needs of user USR.
[0029] As illustrated in FIG. 5A, each actuator 14 may include a
scissor linkage 44. Each scissor linkage 44 includes a pair of arms
46 pivotably connected to one another at a pin 48, respectively
connected to lower panel 20 and an upper panel section 50 at pivot
pins 52, and slidably connected to upper panel section 50 and lower
panel 20 at sliders 54. A linear force 56 applied to linkage 44
results in an upward translation of upper panel section 50 and an
overlying mattress zone 24, as indicated by an arrow 58.
[0030] As shown in FIG. 5B, each actuator 14 may alternatively
include a pair of camming members 60, 62 mounted on respective
sheaves or gears 64, 66 in turn entrained to an endless belt or
chain 68 that is movable in alternate directions 70 by a motor
72.
[0031] As depicted in FIG. 5C, each mattress height actuator 14 may
alternatively take the form of a screw jack actuator including a
screw 74 fixed at an upper end to an upper panel section 76. Screw
74 threadingly engages a drive gear 78 that is rotatably held at a
fixed vertical location by a support panel 80 and that drivingly
meshes with a pinion 82 of an electrical motor 84. Upper panel
section 76 carries a pair of guide pins that slidably traverse
openings (not shown) in support panel 80. Other operative
configurations of a screw jack actuator will occur to those skilled
in the art.
[0032] FIG. 5D shows a rack and pinion assembly 86 that may serve
as a mattress height actuator 14. Rack and pinion assembly 86
includes two racks 88, two pinions 90, and a guide panel 92.
[0033] In FIG. 1, height adjustment zones 24 are elongate areas
each extending across the main portion of the mattress width. FIG.
6 shows a mattress 94 with a grid of height adjustment zones 96 in
a central region, as well as elongate zones 98 and 100 at a head
region and a foot region (not separately labeled), respectively. In
the grid area, mattress 94 incorporates linear actuators 102 (see
also FIG. 7) in the form of hydraulic cylinders, pneumatic
cylinders, or motorized ball screw linear actuators. Each linear
actuator 102 includes a body 104 and a plunger 106. Body 104 is
fastened to a lower (substantially rigid) panel 108 of mattress 94,
while an upper end of plunger 106 is fixed to a substantially rigid
upper panel section 110 that supports a portion of a soft mattress
under layer section 112.
[0034] Remote control 18 and/or a console (not separately shown) of
control unit 16 may be provided with a display (not shown) that
provides menu selections or options, instructions, messages and
recommendations to the user USR. Control unit 16, via a keypad or
touch screen interface 114 of the remote control 18 (see FIG. 6),
may provide the user USR with the option of selecting from a
plurality of "canned" or preprogrammed sets of mattress zone
heights. Further selections may be made from among user-generated
or user-modified sets of mattress zone heights. Upon selection of
such a preexisting mattress zone height array, the user has the
ability to adjust the height of each zone 24, 96, 98, 100 to suit
the user's contemporaneous requirements and preferences. Such
modifications may be stored in control unit 16 as separate mattress
contours for selection and deployment at a later time.
[0035] Control unit 16 typically stores mattress contours or sets
of zone heights for the following basic sleep postures: flat on the
stomach, flat on the back, on the left side, on the right side.
Modifications of these may include respective tilts for the head
and inclinations of the thigh. A modification of the back-flat pose
is a bend at the waist that approximates a sitting posture to a
greater or lesser extent.
[0036] The widths "W" of the zones 24, 96, 98, 100 may vary and
typically range from 1 inch to 24 inches. The length "L" of the
"grid" zones 96 (FIG. 6) may have a value between 3 inches and 12
inches.
[0037] The vertical displacement ranges of each zone 24, 96, 98,
100 may vary and range from 1 inch to 10 inches. Control unit 16
may be programmed to limit height differences between adjacent
zones where large differences in height would be impractical or
impose undue stress on the mattress upper layer 22 and the user
USR.
[0038] Height adjustment of mattress zones underneath a pillow 116,
118 (FIGS. 1, 4, 6) changes the contour of the pillow as well and
providing head and neck support as the user USR wishes.
[0039] Any desired pillow and mattress contour could be achieved by
the combined position of the individual zones 24, 96, 98, 100 (see
FIG. 4).
[0040] A mattress 12 as described herein may incorporate stuffed or
foam sections 120 that are not adjustable in height.
[0041] As depicted in FIG. 8, control unit 16 may comprise a
central processing unit (CPU) 124 that accesses a memory 126
containing program instructions for directing and enabling
communications with a user via remote control 18 and for operating
various height-adjusting actuators 128. A first data store 130
contains preprogrammed sets of mattress zone heights constituting a
number of "canned" sleep postures. A second data store 132 contains
sets of mattress zone heights that have been modified in accordance
with input from a user. CPU 124 communicates with remote control 18
via a transmitter 134 and a receiver 136 of control unit 16 and via
a receiver 138 and a transmitter 140 of remote unit 18. Remote unit
18 further includes a CPU 142 operating under instructions from a
resident program memory 143 to control a display 144 and field user
instructions from a command input 146 in the form of a keypad. The
functions of display 144 and keypad 146 may be combined in a touch
screen.
[0042] Control unit 16 and remote control 18 may incorporate or
comprise one or more microprocessors. Thus, CPU 124 may be
implemented by a microprocessor. In that case, CPU 124 comprises
generic digital processing circuits modified by programming from
instruction memory 126 to execute the height adjustment functions
described herein. Alternatively, control unit 16 and/or remote 18
may comprise integrated circuits with component parts hard-wired
for processing user selections of mattress zone heights, storing
encoded mattress contour data incorporating user height adjustments
(e.g., in data store 132), and issuing signals to actuators 128 for
controlling mattress contour pursuant to user input. A combination
of hard-wired and generic program-modified circuits is yet another
alternative. Such alternative control unit embodiments are well
within the ken of those skilled in the art.
[0043] As depicted in FIG. 9, CPU 124 comprises functional modules
including a contour selection module 148, an actuator activation
module 150, and a height adjustment module 152. Contour selection
module 148 is connected at inputs to data stores 130 and 132 and
memory 126 and at outputs to actuator activation module 150 and
height adjustment module 152. Actuator activation module 150 is in
turn connected to instruction or program memory 126 and at outputs
to actuators 128 (FIG. 8). Height adjustment module 152 is
connected to memory 126 and to remote control 18 via transmitter
134 and a receiver 136.
[0044] In response to a user's contour selection (e.g., back, right
side, etc.), received from remote control 18 via height adjustment
module 152, contour selection module 128 extracts the appropriate
contour data from store 130. Contour selection module 128 checks
whether the user previously modified the contour data for the
selected posture, by accessing data store 132. Contour selection
module 128 forwards the contour information, with adjusted height
data if available, to actuator activation module 150 for operation
of actuators 128. Actuator activation module 150 periodically
inquires with height adjustment module 152 as to whether any
mattress zone height is to be modified from the stored value.
Height adjustment module 152 communicates with remote control 18 to
field any requests from the user for adjustment of the current
mattress profile, as well as requests to store adjustments. In the
event of the latter type of request, height adjustment module 152
accesses store 132 to change the appropriate height or contour
information stored therein. CPU 142 of remote control 18 includes
modular components for energizing display 144 and collecting
requests input by the user via keypad 146.
[0045] As indicated above, contour selection module 148, actuator
activation module 150, and height adjustment module 152 may be
implemented by generic digital processing circuits modified by
programming from instruction memory 126 to execute the height
adjustment functions described herein. Or contour selection module
148, actuator activation module 150, and height adjustment module
152 may comprise hard-wired integrated circuits or a combination of
hard-wired and generic program-modified circuits.
[0046] Although the invention has been described in terms of
particular embodiments and applications, one of ordinary skill in
the art, in light of this teaching, can generate additional
embodiments and modifications without departing from the spirit of
or exceeding the scope of the claimed invention. For example, the
control unit and the remote controller may be pre-programmed with
different zone height arrays each corresponding to a respective
sleep posture or position of an average user. During an initial use
of the mattress system, a user selects a zone height array of
prospective interest and lies down on the bed (not necessarily in
that order). The user then selectively adjusts the zone heights in
accordance with the user's preferences. Upon discovering a
comfortable configuration, the user may instruct the control unit
via the remote control (or a separate console or keypad) to store
the configuration for future use.
[0047] Adjustment of mattress zone heights may be accomplished by
other types of actuators, different from the electromechanical
actuators discussed hereinabove. For instance, a mattress may
incorporate multiple pressurized compartments operatively connected
via respective valves to a source of compressed air, as described
in U.S. Pat. No. 7,107,642 the disclosure of which is hereby
incorporated by reference. Pursuant to the present invention, the
individual user interacts with a control unit to adjust the heights
(or pressures) of individual mattress compartments to thereby
construct a customized mattress contour, which is stored in encoded
format in a memory. During subsequent use of the mattress
adjustment apparatus, the control unit operates the valves to
increase or decrease the pressures in the individual compartments
pursuant to the stored customized mattress contour data.
[0048] Accordingly, it is to be understood that the drawings and
descriptions herein are proffered by way of example to facilitate
comprehension of the invention and should not be construed to limit
the scope thereof.
* * * * *