Air Bed Diaphragm Pump

Technical Field

A diaphragm pump adapted for use with an air sleep system equipped with an internal inflation apparatus for controlling the firmness of the air core within the air sleep system.

Background Art

Air beds have become an increasingly popular sleeping system. Thus, it appears that the "Air Sleep System" manufac¬ tured by the Select Comfort Corporation of Minneapolis, Minne¬ sota is purchased by at least about 50,000 consumers per year in the United States. The "Air Sleep System" utilizes an air mattress described in United States patent 4,908,895 of Robert A. Walker.

Similar air mattresses are contained in the air sleep systems sold by other manufacturers. These prior art air sleep systems generally utilize a motor-driven impeller which is disposed outside of said air bed and is connected to the air mattress by tubing. In the use of such air sleep systems, it iε common to locate the impeller beneath the air bed on the floor below it together with the appropriate control mechan¬ isms. When the user wishes to adjust the firmness of the mattress, he may reach to the floor, pick up the control, activate the impeller, and either deliver or release air from he mattress.

The motor driven impeller used in these prior art ar sleep systems is excessively noisy.This often causes a problem wi.er. one user, during the middle of the night, decides to

adjust the firmness of such an "Air Sleep System."

In addition to creating an unseemly amount of noise, it is often difficult to gain access to the relatively large motor driven impeller unit. Furthermore, the location of wires, hoses, and a motor driven impeller under the air bed creates cleaning problems under the bed, is inconvenient to use with certain types of headboard and bed assemblies, and often is aesthetically displeasing.

In many hospital settings, beds are used where the head of the bed is movable from a horizontally up to a verti¬ cal or substantially vertical position. The need for external wires, tubes, and pumps in the "Air Sleep System" renders such system impractical for such a use.

It is an object of this invention to provide a dia¬ phragm pump which can be used to inflate an air mattress and, during such inflation, will operate readily quickly and quiet- iy.

It is another object of this invention to provide a diaphragm pump which can be disposed within and operate suit¬ ably within conventional air mattresses.

It is yet another object of this invention to provide an air sleep system which automatically prevents overinflation of the air core during the time air is being supplied to such core.

Disclosure of the invention

In accordance with this invention, there is provided a diaphragm pump containing a shaft, means for rotating the shaft at a speed less than about 3,300 revolutions per minute, a flange connected to the shaft and disposed thereto at an angle other than 90 degrees, and a pair of connecting rods attached to said flange.

Brief description of the drawings

The present invention will be more fully understood by reference to the following detailed description thereof, when read in conjunction with the attached drawings, wherein like reference numerals refer to like elements, and wherein:

Figure 1 is schematic view of one preferred embodiment of applicant's air sleep system;

Figure 2 is a top view of the air mattress used in the system of Figure 1, with the baffle design of such mattress indicated by dotted lines;

Figure 3 is a side view of the air mattress of Figure

2;

Figure 4 is an end view of the air mattress of Figure

2;

Figure 5 is an enlarged side view of one portion of the air mattress of Figure 2;

Figures 6 and 7 are partial perspective views of the cover rail straps of the system of Figure 1;

Figure 8 is a partial perspective view of the cover rail sleeve of the system of Figure 1;

Figure 9 is an partial enlarged side view of the air sleep system of Figure 1;

Figure 10 is a schematic view of one preferred dia¬ phragm pump used in the sleep system of Figure 1;

Figure 11 is a sectional view of the pump of Figure

10;

Figure 12 is a top view of the pump of Figure 10;

Figure 13 is a sectional view of the diaphragm housing of the pump of Figure 10;

Figure 14 is sectional view of the diaphragm/diaphragm housing combination of the pump of Figure 10;

Figure 15 is a sectional view of the shaft mechanism

of the pump of Figure 10;

Figure 15A is a partial sectional view of a connecting rod/retaining plate/diaphragm assembly in an open position;

Figure 15B is a partial sectional view of a connecting rod/retaining plate/diaphragm assembly in a closed position;

Figure 16 is a partial sectional view of an exhaust port of the pump of Figure 10;

Figure 17 is a partial sectional view of another em¬ bodiment of a diaphragm pump which may be used in the sleep system of Figure 1;

Figure 18 is a top schematic view of one embodiment of applicant's sleep system;

Figure 19 is a side view of the sleep system of Figure

18;

Figure 20 is a top view of one preferred diaphragm pump;

Figure 21 is a side view of the diaphragm pump of Figure 20;

Figure 22 is a side view of a hand-held controller device which can be used with the air mattress assembly of Figure 1;

Figure 23 is a schematic illustration of a flush- raountable controller device disposed within an air mattress assembly;

Figure 24 is a top view of a remote controller device which may be used in conjunction with the air mattress assem¬ bly of Figure 1;

Figure 25 is a perspective view of the foam mattress support system used in the air mattress assembly of Figure 1;

Figure 26 is a sectional view of an air-filled mat¬ tress support system which may be used in place of the foam mattress support system of Figure 25, and also of two air mat

tesses disposed within said system;

Figure 27 is a top view of the air-filled mattress support system of Figure 26;

Figure 28 is a perspective view illustrating how the foam rails of Figure 8 may be disposed within the air mattress assembly of Figure 1;

Figure 29 is a side view of a mattress assembly the elevation of whose head section can be varied;

Figure 30 is a sectional view of the inflatable baffle potion of the head section of the mattress of the assembly 29.

Figure 30 is a perspective view of the mattress assem¬ bly of Figure 28;

Figure 31 is a top view of another preferred embodi¬ ment of a mattress assembly with two head sections, either one of which can be independently raised or lowered;

Figure 32 is a top view of yet another preferred em¬ bodiment of a mattress assembly with two head sections, either one of which can be independently raised or lowered;

Figure 33 is a side view of the mattress of Figure 31; and

Figure 34 is a partial, top sectional view of an air bedding assembly.

Best Mode for Carrying out the Invention

The diaphragm pump of this invention may be used with any conventional air mattress system.

In one especially preferred embodiment, the diaphragm pump may be used in conjunction with the air mattress dis¬ closed and claimed in United States patent 4,394,784 of Gerald R. Swenson et al.; the entire disclosure of this patent is hereby incorporated by reference into this specification.

United States patent 4,394,784 discloses, and claims:

"An air bed system having firmness control of an air bladder confined within a mattress, comprising (a) an air blower having an intake to atmospheric air and having an exhaust to atmospheric air, and having a pressurized air outlet; (b) an air line connected to said pressurized air outlet and connect¬ ed to said air bladder; (c) an air valve for selectively openings and closing air flow therethrough; (d) means for actuating said air valve for opening flow through said air line and for energizing said air blower; and (e)means for actuating said air valve for opening air flow through said air line and for deenegizing said air blower (see claim 1).

In other embodiments, one or more of the airbeds dis¬ closed in the patents cited during the prosecution of United States patent 4,394,784 may be used in conjunction with applicant's diaphragm pump. Thus, by way of further illustra¬ tion but not limitation, one may use one or more of the air¬ beds disclosed in United States patents 3,303,518 of Ingram, 4,078,842 of Zur, 4,224,706 of Young et al. , 4,306,322 of Young et al. and/or in German patent 1529538 may be used in applicant's claimed apparatus. The disclosure of each of these patents is hereby incorporated by reference into this specification.

In another preferred embodiment, the diaphragm pump is used in conjunction with the air mattress assembly described in United States patent 4,908,895; the entire disclosure of such patent is hereby incorporated by reference into this specification.

United States patent 4,908,895 describes an air mat¬ tress which contains a chamber and, located with such chamber, a "...plurality of transverse webs...." In particular, this patent discloses and claims "An air mattress accommodating air under pressure for providing support for a body comprising: a

top wall, a bottom wall spaced from and located below the top wall, side walls and end walls secured to said top and bottom walls, all of said walls comprising flexible air impervious sheet members sealed together along the edge portions thereof to form a chamber for accommodating air under pressure, seam means securing adjacent portions of the sheet members togeth¬ er, a pair of longitudinal first support means located in said chamber extended between said end walls adjacent the side walls and secured to said top and bottom walls providing longitudinal passages accommodating air, a plurality of transverse second support means located in said chamber ex¬ tended between said pair of first support means and secured to said top and bottom walls providing transverse passages for accommodating air, said first and second support means limit¬ ing outward expansion of the top and bottom walls when air under pressure is stored in said chamber; each of said first and second support means having a continuous web section and opposite end portions, an opening adjacent each of said end portions allowing air communication between said transverse and longitudinal passages, the opposite end portions of said first support means longitudinally spaced from said end walls, and the opposite end portions of said second support means laterally spaced from the web sections of the first support means to provide said openings, first tube means mounted in the seam means in one end of the air mattress to facilitate supplying air under pressure to said chamber, an elongated flexible and elastic tube connected to the first tube means and adapted to be connected to a supply of air under pressure to said chamber and retain air under pressure within said tube, and said second tube means mounted in the seam mean s in a second end of the air mattress, and air pressure relief valve means connected to said second tube means in

communication with said chamber and atmosphere whereby air is vented from said chamber through said valve means when the pressure of the air within the chamber exceeds a selected maximum limit."

In other preferred embodiments, one or more of the airbeds disclosed in the patents cited during the prosecution of United States patent 4,908,895 may be used in conjunction with applicant's diaphragm pump. Thus, by way of further illustration but not limitation, one may use one or more of the airbeds disclosed in United States patents Des. 300,194 of Walker, Des. 486,696 of Curlin, 1,282,980 of Takach, 1,730,752 of Withers, 2,000,873 of Arens, 2,236,587 of Williams, 2,237,012 of Sampson, 2,415,150 of Stein, 2,542,781 of Sawyer, 2,549,597 of Harris et al., 2,604,641 of Morner, 2,614,272 of Morner, 2,741,780 of Kimbrig, 2,919,747 of Post, 3,128,480 of Lineback, 3,705,429 of Nail, 3,780,388 of Thomas et al., 3,790,975 of Phillip et al., 3,867,732 of Morrell, 4,225,989 of Corbett et al., 4,306,322 of Young et al., 4,394,784 of Swenson et al., 4,541,135 of Karpov, 4,631,767 of Carr et al., 4,644,597 of Walker, and 4,682,378 of Savenije. The entire disclosure of each of these United States patents is hereby incorporated by reference into this specification.

In yet another preferred embodiment, applicant's dia¬ phragm pump may be used in conjunction with the air bed assem¬ blies disclosed in one or more of United States patents 5,170,522, 4,897,890 4,644,597, 5,144,706, 4,890,344, 4,788,729, 4,991,244, 4,829,612, 4,766,628, Des. 300,194, and Des. 313,973. The disclosure of each of these patents is hereby incorporated by reference into this specification.

In yet another preferred embodiment, applicant's dia¬ phragm pump is used in conjunction with the air bed disclosed

in United States patent 5,105,488, the entire disclosure of which is hereby incorporated by reference into this specifica¬ tion.

In yet another embodiment, the hospital air bed dis¬ closed in United States patent 4,803,744 (the entire disclo¬ sure of which is hereby incorporated by reference into this specification) may be used in conjunction with applicant's diaphragm pump.

In yet another patent, the diaphragm pump may be used in conjunction with the air bed systems disclosed in United States patents 4,986,738 and 5,062,169.

Figure 1 is a perspective view of a preferred air bedding system 10 of this invention. Referring to Figure 1, and in the preferred embodiment illustrated, it will be seen that air bed system 10 is comprised of optional foundation 12, mattress edge support 14, first air mattress 16, second air mattress 18, flush-mounted hand control 20, first hand-held hand control 22, second hand-held hand control 24, diaphragm pump 26, air hose 28, hose 30, convoluted foam topper 32, mattress cover 34, and electrical cord 36.

Air bedding system 10 has a foundation 12 such as, e.g., a box spring which may be constructed according to well- known techniques. Thus, e.g., one may use one or more of the box springs disclosed in United States patents 5,083,329, 5,070,556, 5,052,064, 5,009,417, 4,995,125, 4,979,251, and the like. The disclosure of each of these patents is hereby incorporated by reference into this specification.

One may use other mattress foundations or furniture items such, e.g., platform beds, Captains beds, bunk beds, posture foundations, waterbed pedestals, a floor, etc.

In one embodiment, the bed foundation disclosed in United States 5,144,706 may be used as foundation 12. Alter

natively, one may use one or more of the foundations of United States patents 64,175, 1,853,111, 2,518,983, 4,128,907, 4,391,008, 4,402, 097, 4,675,929, 4,679,261, 4,696,071, and 4,734,946. The disclosure of each of these patents is hereby incorporated by reference into this specification.

Referring again to Figure 1, mounted on foundation 12 is mattress edge support 14. As is known to those skilled in the art, the function of mattress edge support 14 is to pro¬ vide support for one sitting or sleeping on the side of the mattress and to confine air core mattresses 16 and 18.

In one embodiment, mattress edge support 14 consists essentially of foam material. Foam materials are materials with a spongelike, cellular structure and include, e.g., sponge rubber, plastic foams, latex foams, polyurethane foams, and the like.

In one embodiment, mattress edge support is made from polyurethane foam. Urethane foams are made by adding a com¬ pound that produces carbon dioxide or by reaction of a diiso- cyanate with a compound containing active hydrogen.

In one preferred embodiment, the polyurethane foam used is a flexible foam with a density of from about 1 pound per cubic foot to about 5 pounds per cubic foot and, prefer¬ ably, has an independent load deflection (ILD) of from about 20 to about 80.

Any conventional foam edge support may be used in the air bedding system of Figure 1. Thus, by way of illustration and not limitation, one may use the "Border for Air Bed" disclosed and claimed in United States patent 4,991,244 and/or the air bed borders disclosed and/or claimed in United States patents 1,730,752, 2,691,179, 3,128,480, 3,735,432, 3,736,604, 4,187,566, 4,224,706, 4,306,322, 4,394,784, 4,637,082, 4,682,378, 4,713,852, 4,879,775, 4,890,344,

4,897,890, and the like. The disclosure of each of these patents is hereby incorporated by reference into this specifi¬ cation.

Referring to Figure 1, it will be seen that mattress edge support 14 is preferably comprised of segment 38, 40, 42, and 44 which may be joined together.

In one embodiment, illustrated in Figure 1, each of segments 38, 40, 42, and 44 is mitered at its edge (such as, e.g., edge 46) and is preferably covered with a flexible fabric material 48.

Daphragm pump 26 is disposed within an opening 50 (whose outlines are shown in dotted line). Because opening 50 cannot exceed the dimensions of segment 42, the diaphragm pump 26 must have a maximum width which is less than the width of segment 42. In practice, it is preferred to have at least about 0.5 inches of foam surrounding each side of diaphragm pump 26. Thus, when as is conventional,the height 52 of segments 40 and 42 are about 6 inches, the maximum height of diaphragm pump 26 must be no more than about 5 inches. It is preferred however, to use a diaphragm pump whose width is no greater than about 4 inches.

Referring again to Figure 1, air flowing from dia¬ phragm pump 26 flow through air hoses 28 and 30 from ports 220 and 222 (see Figure 12) and thence into air cores 16 and 18.

Any of the air cores known to those skilled in the art may be used as air cores 16 and 18. Thus, referring to United States patent 4,908,895 (see column 2), "A plurality of trans¬ verse sheet beams or webs are secured to the top and bottom walls to maintain the air mattress in a box-like shape. A pair of longitudinal sheet beams or webs are secured to the top and bottom walls between the outer ends of the transverse webs and the side walls of the air mattress. The longitudinal

and transverse webs stabilize side to side mattress sway motion and eliminate uneven areas on the top wall of the air mattress. The opposite ends of the transverse and longitudin¬ al webs have openings to allow air to flow into and out of the transverse and longitudinal air chambers. The walls and webs can be nylon fabric and vinyl plastic or cotton fabric and rubber sheet materials sealed together. These sheet materials are air impervious and form seals that do not tear or rip apart in use. "

The air cores 16 and 18 depicted in Figure 1 are similar to the air mattress 20 described in United States patent 4,908,895 with the exception that the latter air mat¬ tress contains transverse webs whereas the former air mat¬ tresses do not.

One may use one or more of the air cores described in United States patents Des. 300,194, 4,788,729, 4,644,597, 4,371,999, 4,986,738, 5,062,169, 4,788,729, 4,394,784, 4,305,425, 4,225,989, 4,224,706, 4,175,297,_ 4,169,295, 4,149,285, 4,129,145, and the like. The disclosure of each of these patents is hereby incorporated by reference into this specification.

Air bedding systems comprising air cores 16 and 18, which are similar in configuration to the air bedding system 10, are commercially available and may be purchased from, Dynatech, Inc. of Greenville, South Carolina as the "Comfor- taire Air Bed. "

Referring again to Figure 1, a resilient foam topper 32 is disposed on top of air cores 16 and 18 and within seg¬ ments 38, 40, 42, and 44 to protect such air cores 16 and 18 and increase the comfort of the assembly. It is preferred that topper 32 be comprised of flexible polyurethane foam with a density of from about 1 to about 5 pounds per cubic foot.

It is also preferred that topper 32 be secured within segments 38, 40, 42, and 44 by a friction fit.

A mattress cover 34, which preferably is quilted on its tops and side, is disposed over topper 32, the top surfac¬ es of segments 38, 40, 42, and 44, the outside surfaces (not shown) of segments 38, 40, 42, and 44, the bottom surface (not shown) of segments 38, 40, 42, and 44, and the undersides (not shown) of air cores 16 and 18. The mattress cover 34 may be preferably be closed by conventional means such as, e.g., a zipper 54, "VELCRO" loop and hook fastening means (not shown), a draw string (not shown), permanent sewing (not shown), etc.

Rail straps 58, 60, 62, 64, and 66 are used to fasten cover 34 to one or more of segments 38, 40, 42, and 44.

Hand-held controller 22 may be used to either insert air into or withdraw air from air core 18; and, similarly, controller 24 may be used to control the flow of air into air core 16. Each of these controllers 22 and 24 is comprised of a switch (such as switches 23 and 25). In one position, each of such switches activates diaphragm pump 26 and causes air to flow into the air mattress. In another position, each of such switches activates a solenoid (not shown) and allows air to exhaust from the air mattress.

In the embodiment illustrated in Figure 1, in addition to hand-held controllers 22 and 24, the assembly 10 also is comprised of a controller 20 which is mounted within segment 40 of the edge support system 14. The flush-mounted con¬ troller 20 serves the same function as does the hand con¬ trollers 22 and 24.

In another embodiment, not shown, hand controller 22 is replaced by flush mounted controller 20 and, optionally, hand controller 24 is replaced by a comparable flush-mounted controller (not shown).

Figure 2 is a top view of an air core 17 which, in many respects, is similar to the air core 16 of Figure 1. Referring to Figure 2, air core 17 is comprised of a multi¬ plicity of fabric 68 which extends from front edge 70 to back edge 72, and from side edge 74 to side edge 76.

Within fabric 68 are a multiplicity of air compart¬ ments 78 which are formed by baffles 80 and longitudinally- extending beams 82.

Air may flow into (or out of) air hose 28. For the purpose of illustration, the discussion will relate to air inflow, it being obvious that the reverse process can occur in the reverse direction.

Air may flow through air hose 28 in the directions of arrows 38.

The transversely-extending baffles 80 do not complete¬ ly extend from one side of beam 82 to another. Thus, refer¬ ring to a portion of Figure 2, it will be seen that air may flow around openings 84 formed between the ends of baffles 80 and the interior walls of beams 82. Additionally, air may flow in the direction of arrows 86 and 88. Because air is free to flow past all of the baffles 80 and into each of the air compartments 78, the air pressure in each of said compart¬ ments will be substantially equal once an equilibrium pressure been attained.

Figure 3 is a longitudinal sectional view of air mat¬ tress 17. Figure 4 is a transverse sectional view of air mattress 17. Referring to Figure 4, it will be seen that air may flow in the direction of arrows 84, 86, and 88 (see Figure 2) though openings 90 formed between the ends of baffles 80 and the beams 82.

Figure 5 is an enlarged sectional view of Figure 3. Referring to Figure 5, it will be seen that baffle 80 has a

substantially I-shaped structure (and thus is often referred to as an I beam) and is joined to fabric 68 at its top and bottom. Although not specifically illustrated in Figures 2 through 5, it is preferred that longitudinally-extending beams 82 also have an I-beam structure and also be joined at their tops and bottoms to fabric 68.

Referring again to Figure 5, the seams between the sides, the top, and the bottom of fabric 68 and 72 may be joined by conventional means such as, e.g., vulcanized butt seam 90 and lap seam 92.

In one preferred embodiment, all of the seaming used to form air core 16 is heat-vulcanized, and the fabric 68 is preferably a latex rubber with a fabric outer side to prevent stretching. The fabric outer side may consist, e.g., of cotton, of polyester, of a fabric blend of natural and/or synthetic fiber, a knit fabric, a warp fabric, and/or a nonwo- ven fabric. In one preferred embodiment, such fabric is knit poly(ethylene terephthalate).

Figure 6 is a partial perspective view of cover 34. Referring to Figure 6, it will be seen that cover 34 is com¬ prised of side 35, bottom 37, top rail strap 39, and bottom rail strap 41. Extending from the seam between zipper 54 and mattress cover side 35, fabric 39 is comprised of a loop section of VELCRO (synthetic material which adheres when pressed together) 43. Similarly, extending from the sewn seam between bottom 37 and side 35, fabric section 41 is comprised of a hook section of VELCRO 45. As will be apparent to those skilled in the art, VELCRO sections 43 and 45 can be pressed together to secure an object such as, e.g., support rail 40.

Figure 7, and Figure 1, both depict the rail strap assembly 64 in its closed position, supporting segment 40.

Other fastening means also may be used to secure the mattress edge support system 14. One such alternative means is illustrated in Figure 8. Referring to Figure 8, fabric 49 is joined to fabric 51 by means of zipper 53, thereby enclos¬ ing and securing foam segment 40. Furthermore, yet other fabric fastening means may be used, such as sewing, gluing, friction fit, and the like.

Thus, referring to United States patent 4,991,244 (the entire disclosure of which is hereby incorporated by reference into this specification), the segments 38, 40, 42, and 44 may be joined together at their butt ends by VELCRO fasteners.

Figure 9 is a partial sectional view, similar to Figure 5 but more detailed, illustrating the relationship of several of the components of air bedding system 10.

Figure 10 is a schematic representation of a preferred pump 100 used in applicant's sleep system. In this preferred embodiment, pump 100 is a diaphragm pump.

A diaphragm pump is a metering pump which uses a dia¬ phragm to isolate the pumped parts from pumped air. These pumps are well known to those skilled in the art and are described, e.g., in United States patents 5,104,298, 5,096,392, 5,08\74,763, 5,074,757, 5,073,092, etc.

Referring to Figure 10, and the preferred pump 100 schematically illustrated therein, it will be seen that pump 100 is comprised of a means for rotating shaft 102, such as, e.g. , motor 104.

Motor 104 preferably is an alternating current elec¬ tric motor which, when supplied with 120 volt 60 cycle alter¬ nating current, will rotate at a speed of less than 3,300 revolutions per minute. Thus, the diaphragm pump of this invention is said to be comprised of means for rotating its shaft at a speed of less than 3,300 revolutions per minute.

When said means language is used hereafter in this specification (and in the claims), it describes an apparatus which, when the motor driving the pump is supplied with 120 volt 60 cycle alternating power, will rotate at a speed of less than 3,300 revolutions per minute. It does not describe an apparatus which only is capable of rotating at a speed of less than 3,300 revolutions per minute when the motor driving the apparatus is supplied with a voltage less than 120 volts.

It is preferred that motor 104 rotate at a speed of less than 3,100 revolutions per minute. By comparison, the motor driven impellers used to inflate the Select Comfort Corporations "Air Sleep System" rotate at least about 16,000 revolutions per minute when suppled with 120 volt, 60 cycles alternating current.

It is also preferred that, during its operation, motor 104 will draw at least about 100 watts of power. In general, motor 104 will draw from about 100 to about 200 watts of power during its operation.

One may use direct current motors, 120 volt universal motors, shaded pole induction motors, and the like, as motor 104. Thus, e.g., motor 104 may be a shaded pole motor (a single-phase induction motor having one or more auxiliary short-circuited windings acting on only a portion of the magnetic circuit.)

Shaded pole induction motors are well known to those skilled in the art and are described, e.g., in United States patents 5,043,612, 5,036,237, 4,795,931, 4,689,508, 4,658,692, 4,531,072, 4,496,869, 4,482,832, and the like. The disclosure of each of these patents is hereby incorporated by reference into this specification.

In one preferred embodiment, motor 104 is a shaped

pole induction motor available as model number P-15129 from the Uppco Corporation of 302 North Sixth Street, Monticello, Indiana 47960-1839.

Alternatively, motor 104 may be a universal motor which may be operated at approximately the same speed and output on either direct current or single-phase alternating current. Such motors are described, e.g., in United States patents 5,071,069, 5,063,319, 5,043,594, 5,040,950, 5,039,973, 5,091,928, and the like; the disclosure of each of these patents is hereby incorporated by reference into this specification.

Alternatively, motor 104 may be a permanent magnet, direct current motor such as, e.g., those described in United States patents 5,109,172, 5,109,171, 5,105,113, 5,077,823, 5,072,144, 5,070,269, and the like. The description of each of these patents is hereby incorporated by reference into this specification.

Alternatively, motor 104 may be a solenoid motor such as, e.g., those motors described in United States patent 5,052,792, in United States patents 4,986,738 and 5,062,169, in United States patent 4,897,890 (see Figure 2), and the like. The disclosure of each of these United States patents is hereby incorporated by reference into this specification.

Referring again to Figure 10, it will be seen that shaft 102 is connected to motor 104. Attached to shaft 104 is a first flange 106 and, in one preferred embodiment, a second flange 108. Although the use of two such flanges is pre¬ ferred, and often leads to quieter and/or quicker operation, a shaft with only one such flange also will function well.

Although the remainder of the discussion in this specification will refer to an embodiment in which two such flanges are present, it is to be understood that a device with

only one such flange also is within the scope of the inven¬ tion.

A flange is a projecting rim of a mechanical part, such as shaft 102. In the embodiment illustrated in Figure 10, flanges 106 and 108 each form an obtuse angle with shaft 102. Thus, the center line 110 of shaft 102 forms an obtuse angle 112 with centerline 114 of flange 108 and, similarly, forms an obtuse angle 116 with center line 118 of flange 106.

Flange 106 and flange 108 can also form an acute angle with shaft 102. In fact, either or both of such flanges can form any angle other than 90 degrees with shaft 102, and the angle formed by one flange may (but need not be) identical to the angle formed by the other flange.

In one preferred embodiment, each of flanges 106 and/or 108 forms an acute angle of from about 10 to about 30 degrees (and, more preferably, from about 15 to about 25 degrees) with shaft 102. In one preferred aspect of this embodiment, each of flanges 106 and/or 108 form an identical angle of from about 18 to about 22 degrees with shaft 102.

In one preferred embodiment, each of flanges 106 and/or 108 is part of an integral plastic assembly (not shown) comprised of a central tube and, integrally connected thereto and disposed at an acute angle to the axis of such tube. This plastic assembly may be friction fit onto shaft 102.

As shaft 102 rotates, the angle formed between the top of the shaft and the flange(s) will change from an obtuse angle to an acute angle. Thus, the angles 120 and 122 which are presently formed between the bottom surface of shaft 102 and the flange(s) will be transposed when the shaft rotates 180 degrees. Consequently, as flanges 106 and/or 108 rotate through 360 degrees, the angles they form with shaft 102 continually vary.

Referring again to Figure 10, flange 106 is connected to connecting rods 124 and 126, and flange 108 is connected to connecting rods 128 and 130. In the position shown in Figure 10, as flange 106 and flange 108 rotate clockwise, connecting rods 124 and 128 depress diaphragms 132 and 134 in the direc¬ tion of arrows 133 and 135 while, simultaneously, connecting rods 126 and 130 pull open diaphragms in the directions of arrows 137 and 139. During this portion of the cycle, air will flow in the directions of arrows 140, 142, 144, 145, 146, 148, and 150. The air flow during this cycle will cause flapper valves 152, 154, 156, 165, and 167, to open.

As the shaft 102 rotates 180 degrees, the flanges will assume the position depicted in dotted lines 160 and 162, and air will flow through flapper valves 170, 161, 172, 163 156, 148, and 150 and cause such valves to open.

Referring again to Figure 10, each of flanges 106 and 108 is connected to both an upper diaphragm (such as dia¬ phragms 132 and 134, respectively) and a lower diaphragm (such as diaphragms 136 and 138, respectively). In one embodiment, not shown, only one of flanges 106 and 108 is used. In either case, regardless of whether one flange and two diaphragms, or two flanges and four diaphragms, are used, applicant's pump during its operations continuously is delivering a specified volume of air to the air mattress through one of the dia¬ phragms connected to each such flange while, simultaneously, intaking air at the same rate through the other of the dia¬ phragms connected to each such flange.

In one embodiment, pump 100 preferably delivers from about 110 to about 150 cubic inches of air per second and, more preferably, delivers from about 130 to about 150 cubic inches of air per second.

Figure 11 is a sectional view of another preferred

embodiment of pump 100. Referring to Figure 11, it will be seen that each of flanges 106 and 108 is a three-piece assem¬ bly which is comprised of a sleeve 174 integrally connected to inner flanges 176 (not shown in Figure 11) which forms an angle other than ninety degrees with sleeve 174.

Sleeve 174 is comprised of an orifice (not shown) which allows it to fit over shaft 102. Sleeve 174 is connect¬ ed to shaft 102 by means of fasteners 180 and 182. In another embodiment, now shown, sleeve 174 is connected to shaft 102 by means of a friction fit.

Referring again to Figures 11 and 15, it will be seen that outer flanges 184 and 186 are connected to connecting rods 124,126 and 128,130, respectively. Connecting rods 124, 126, 128, and 130 are connected to diaphragms 132, 136, 134, and 138, respectively.

Each of the connecting rods 124, 126, 128, and 130 is connected to the flange assembly 106 or 109 by means of a ball and socket assembly 127 which allows the outer flange to pivot around the connecting rod (see Figure 15).

As shaft 102 (not shown) rotates, sleeve 174 rotates at the same speed, thereby causing inner flange 176 (see Figure 15) to rotate at the same speed.

The outer flange 184 is attached to the inner flange 176 so that, during the rotation of inner flanges 176 the outer flange is caused to produce reciprocating linear motion with the connecting rods to which it is attached. One pre¬ ferred means of such attachment is illustrated in Figure 15.

Referring again to the preferred embodiment depicted in Figure 11, it will be seen that diaphragm pump 100 prefer¬ ably is comprised of a pressure relief valve 171 which, in this embodiment, is provided with a spring 173 mounted on a shaft 175. As the air pressure within the housing 234 exceeds

a certain predetermined value, then pressure relief valve 171 will open and exhaust air to atmosphere.

In one embodiment, the pressure relief valve opens when the pressure within housing 234 exceeds a pressure of from about 1 to about 1.25 pounds per square inch in excess of atmospheric pressure.

Oher pressure relief valves in addition to the one depicted in Figure 11 may be used in the apparatus. Thus, by way of illustration, one may use the pressure relief valves disclosed in United States patents 4,644,597, 4,995,173, 4,991,317, 4,977,891, 4,954,051, 4,920,971, and the like. The disclosure of each of these patents is hereby incorporated by reference into this specification.

Referring again to Figure 15, inner flange 176 is disposed within outer flange 184 and separated therefrom by roller bearings. Thus, as inner flange 176 rotates and chang¬ es its angular disposition vis-a-vis shaft 102, outer flange 184 is free to slide over the outer surface of inner flange 176.

Outer flange 184 is connected by rods 190 and 192 to diaphragms 134 and 138 (not shown in Figure 15). Rods 190 and 192 are disposed within guides 194 and 196 which confine their motion to linear motion. Thus, the forces transmitted from inner flange 176 to outer flange 184 result in recipro¬ cating linear motion of rods 190 and 192.

Each of retaining rods 190 and 192 are preferably connected to diaphragms 134 and 138 by means of connecting disks (not shown in Figure 15). These connecting disks are illustrated in Figures 15A and 15B.

Figure 15A is an exploded view of the retaining rod assembly before it is constructed and used. As connecting rod 190 is moved in the direction of arrow 198 because of the

sliding motion of outer flange 186 (not shown in Figure 15A), disc 200 is also moved in the direction of arrow 198. Disk 200 is integrally connected to rod 190. As disk 200 approaches the front face 202 of diaphragm 134, it causes such front face 202 to move towards retaining disk 204 and eventually causes back face 206 of diaphragm 134 to contact and be deformed by retaining disk 204.

Figure 15B illustrates the situation which occurs when the retaining rod 190 has reached the limit of its linear travel in one direction and the assembly is ready for use. The front face 202 and the back face 206 of diaphragm 134 have been sandwiched between disk 200 and disk 204 and caused to conform to the contours of such disks.

Figure 12 is a sectional view of one preferred pump assembly 100 from which some detail regarding flanges and diaphragms have been omitted for the sake of clarity. Refer¬ ring to Figure 12 the air flow produced by diaphragms 132 and 135 can only escape through tube 208 after first having flowed into chamber 210, thence through flapper valve 152 into cham¬ ber 212 and thence in the direction of arrows 144 and 145 (see Figure 10) and through flapper valve 156 into solenoid valve chamber 214. By comparison, the air flow produced by dia- phragrms 134 and 138 escapes through flapper valves 154 and 172 into solenoid chamber 214.

Disposed within solenoid chamber 214 are solenoids which, upon actuation, allow air to flow into either tube 220 and/or tube 222.

Each of solenoids 216 and 218 are preferably connected to a separate control means (not shown) which preferably controls the flow to one portion of the air mattress; said control means is also connected to electrical motor 104. When either of solenoids 216 or 218 is connected to the "soft"

setting of the control means, the solenoid is activated to open either rubber valve 224 or 226, thereby allowing air to escape from the air mattress (not shown in Figure 12) back through the pump and through an upper port (not shown in Figure 12). When either of solenoids 216 or 218 is connected to the "hard" setting of the control means, the rubber valves 224 or 226 are opened and, simultaneously, motor 104 is acu- tated, thereby pumping air through said valves into the air core.

When the the control means is neither in the "soft" or the "hard" settings, then power to the solenoids ceases to be delivered, springs 228 and/or 230 cause rubber valves 224 and/or 226 to close, and air does not flow into or out of the mattress.

Figure 13 is a partial inner view of a diaphragm hous¬ ing 230. Figure 14 is a partial outer view of the diaphragm housing 230, illustrating the side facing motor 104.

Referring again to Figure 12, it will be seen that, in the embodiment depicted, rubber valves 224 and 226 allow the passage of air through the front side 232 of the pump housing 234. The location of the air flow ports may be varied. Thus, in the embodiment depicted in Figure 16, from which certain detail has been omitted from the sake of simplicity, port 220 extends thorugh the mattress side of the pump. Thus, e.g., in the embodiment depicted in Figure 17, from which certain detail has been omitted for the sake of simplicity, the ports 220 and 222 extend through the top 238 of pump housing. Other suitable porting arrangements will be readily apparent.

Figure 18 is partial top view of bed assembly 10 in which foam side rails 250, 252, and 254 are joined by VELCRO fasteners (not shown) at junctions 256 and 258. In this em¬ bodiment, the ends of the foam side rails are not mitered

(compare the embodiment of Figure 1), and air hoses 28 and 30 are disposed somewhat differently within the assembly.

Figure 19 is a longitudinal sectional view of the air bed assembly of Figure 18.

Figure 20 is a top sectional view of another embodi¬ ment of pump assembly 100 in which ports 220 and 220 extend through wall 236 rather than through wall 232 (compare this embodiment with the embodiment of Figures 16 and 12)

Referring to Figure 20, pump 100 has a length 250 of at least about 10 inches and, preferably, has a length of from about 10.75 to about 12.75 inches. The width 252 of pump 100 is preferably less than about 4.0 inches and, in one embodi¬ ment, is less than about 3.7 inches. The height 254 of pump 100 is preferably less than about 5.0 inches and, in one embodiment, less than about 4.75 inches (see Figure 21).

Figure 21 is a side view of the pump 100 of Figure 20 in which the flanges 106 and 108 have been exploded to better illustrate their consturction (also see Figure 15).

It is preferred that pump 100 have a substantailly rectilinear shape.

When pump 100 operates at 3,000 revolutions per minute, it produces less than 60 decibels of sound when meas¬ ured with a standard decibel meter located 3.0 feet away from pump 100; by comparison, the pump used in the Select Comfort unit produces at least 80 decibels.

The decibel level of a pump may be determined with conventional sound meters such as, e.g., the sound meters sold as catalog numbers 332055 and 332050 by Radio Shack of, e.g., Panorama Plaza, Penfield, New York 14625.

In one embodiment, not shown, the pump 100 is powered by a battery pack which also is preferably disposed within the air mattress.

Figure 22 is a side view of a hand-held controller device 22 which can be used with the air mattress assembly of Figure 1. Controller 22 is comprised of a switch 23 which, when depressed or otherwise activated, sends a signal (not shown) through electrical wire 260 to diaphragm pump 26 (not shown in Figure 22, but see Figure 1).

Other control units may also be used which are capable of causing air to either flow into or out of air cores 16 and/or 18. Thus, e.g., one may use the control units de¬ scribed in United States patents 4,394,784, 4,435,864, 4,489,297, 3,935,604, 4,998,939, 4,644,597, and Des. 313,973; the disclosure of each of these patents is hereby incorporated by reference into this specification.

Figure 23 is a schematic illustration of how a flush- mounted controller device may be disposed within an air mat¬ tress assembly. Referring to Figure 23, a top view of a bedding assembly 10 (see Figure 1) which contains a left and right flush-mounted controller 20 is shown. Each of such con¬ trollers is functionally similar to controller 22 (see Figure 22) but differs in that controllers 23 are disposed within foam segments 40 and 44. Each of controllers 20 is connected via electrical wiring 264 to male/female connectors 266 (which may be, e.g., a standard three-pronged connector) and thence via wires 268 to diaphragm pump 26. Because segments 38, 40, 42, and 44 are independent and may be removed from each other, it is desirable to have disconnectable male/female connectors between wiring 264 and 268 so that such connection can be readily disconnected when one desires to remove one segments 38, 40, 42, or 44.

Wiring 264 and 268 is disposed within the foam which comprises segments 40, 42, and 44. In another embodiment, not shown, wiring 264 and 268 is disposed outside of such foam.

Figure 24 is a top view of a remote controller device which may be used in conjunction the air mattress assembly of Figure 1. Referring to Figure 24, controller 270 comprised of a "soft" switch 272 to allow air to exhaust from the air core (not shown) and a "firm" switch 274 to force air into the air core (not shown). Any of many conventional remote control devices for controlling the flow of air may be used as member 270. Thus, for example, one may use the remote controllers disclosed in United States patents 4,989,280, 5,105,488, and 5,052,894, the disclosure of which is hereby incorporated by reference into this specification.

Figure 25 is a perspective view of the foam mattress support used in the air mattress assembly of Figure 1.

Figure 26 is a sectional view of an air-filled mat¬ tress support system 300 which may be used in place of the foam mattress support system 14 (see Figure 1). Referring to Figure 26, it will be seen that air cores 302 and 304 are nested within support system 300. Each of air cores 302 and 304 are comprised of walls which extend inwardly from their top 306 to their bottom 308 and thus are adapted to mate with upwardly extending wedge 310 and upwardly and outwardly ex¬ tending walls 312 and 314 and thus securely fit within the support system 300.

Referring to Figure 27, which is a top view of support system 300, the entire top perimeter 316 of support system 300 is comprised of air-pervious baffles 318 which, preferably, are perforated and which allow air to flow completely around the perimeter of such support system 300.

In the embodiment illustrated in Figure 26, baffles 318 are comprised of openings 320 to allow the passage of air through them.

Figure 28 is a perspective view illustrating how the

foam rails of Figure 8 may be disposed in the air mattress assembly of Figure 1. Foam rail segments 38, 40, 42, and 44 are disposed on foundation 12.

Figure 29 is a side view of a adjustable bed assembly 310 comprised of a mattress 312 whose head portion 314 and/or whose foot portion 316 may be raised to any desired extent by the insertion of air into air wedge 318 and/or into a compar¬ able air wedge (not shown) disposed under foot portion 316. Mattress 312 preferably is comprised of at least two portions (such as head portion 314 and foot portion 316) which may be raised or lowered independently of each other. In the pre¬ ferred embodiment depicted, this independent movement is allowed by the presence of gusset-shaped opening 320. Other means may be utilized to allow head portion 314 to fold up¬ wardly substantially independently of foot portion 316. Thus, by way of illustration, head portion 314 might be hingably attached to foot portion 316.

Referring again to Figure 29, diaphragm pump 26 is preferably disposed entirely within mattress 312. The dia¬ phragm pump 26 is connected by an external hose 322 to air wedge 318. In another embodiment, not shown, hose 322 is primarily disposed within mattress 312.

The air wedge 318 is comprised of a multiplicity of vertically-extending air passages 326 (also see Figure 30) which, when the wedge is fully inflated, causes it to attain its full triangular shape and, thus, increase its height. When air wedge 318 is deflated, the distance 328 between its top 330 and its bottom 332 is substantially decreased.

Referring again to Figure 29, and also to Figure 30, air wedge 318 is comprised of solid wall 324, and solid wall 334. The expansion of air compartments 326 causes solid wall 324 to raise upwardly and diagonally; and, because gravity

causes head portion of mattress 312 to rest upon wall 324, such head portion 314 is also raised upwardly and diagonally. Conversely, as air is allowed to exhaust from wedge 318 (by means of controller 22), the air wedge 318, and the head portion 314 of mattress 312, is caused to move downwardly until the head portion 314 is substantially parallel to the foot portion 316.

In another embodiment, not shown, the foot portion 316 is itself divided into at least two sections which are movably connected to each other so that the distal end of foot portion 316 can be raised or lowered independently of the proximal end of portion 316.

Figure 31 is a top view of an air mattress 312 which can be used with the air wedges 318 (not shown in Figure 31). Air mattress 312 has two separate head sections 314 and 314a, each of which can be independently raised or lowered without substantially affecting foot section 316 and/or the other head section 314. Thus, in this embodiment, separate air wedges 318 (not shown) may be disposed under each head section 314, which then can be raised and/or lowered to different degrees and/or at different rates.

In the embodiment of Figure 31, mattress 312 is a substantially integral structure. By comparison, in the embodiment of Figure 32, two separate mattresses 312 are utilized and are joined together, e.g., by conventional means such as, e.g., a zipper 340. In this embodiment, each of the mattresses 312 is also comprised of means allowing its head section 314 to be raised or lowered independently of its foot section 316; and each of such head sections has an air wedge 318 disposed under it.

Figure 33 is a side view of the mattress of Figure 31, illustrating one of such mattresses (with head section 314) in

the reclining position, and the other of such mattresses (with head section 314a) in a diagonal position, being supported by air wedge 318. The air wedge 318 under head section 314 is shown in its deflated condition.

Figure 34 is a partial, top sectional view of air bedding assembly 10 illustrating how air hoses 28 and 30 may be connected to inport ports 400 and 402 of air cores 16 and 18 by means of preferred couplings 404 and 406.

As will be apparent to those skilled in the art, different hydraulic couplings may be used as couplings 404 and 406. In preferred embodiment, couplings 404 and 406 are APC ("all plastic couplings) produced by the Colder Products Company of 1001 Westgagte Drive, St. Paul, Minnesota; thus, e.g., couplings APC-06 may be used.

It is to be understood that the aforementioned de¬ scription is illustrative only and that changes can be made in the apparatus, in the ingredients and their proportions, and in the sequence of combinations and process steps, as well as in other aspects of the invention discussed herein, without departing from the scope of the invention as defined in the following claims.