Single Direction Air Pump Assembly with Dual Flowpaths

Abstract

A pump assembly for an inflatable structure comprises a blower unit disposed in a housing configured to move air in a single direction from an inlet in the housing to an outlet in the housing. A connector is in communication with the housing outlet. The connector is adapted to connect the pump assembly to an inflatable structure to allow inflation and deflation of the inflatable structure. A base is provided with first and second valve bodies positionable in the base for selective movement between inflate and deflate positions. The first valve body aligns the housing outlet in communication with the connector and the second valve body aligns the housing inlet with atmosphere in the inflate position. The second valve body aligns the connector in communication with the housing inlet and the first valve body aligns the housing outlet in communication with atmosphere in the deflate position.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The disclosure relates to fluid pumps, and more particularly, the disclosure is directed to an air pump and a control for the air pump for supplying air under pressure to an air mattress and evacuating air from an air mattress.

2. Related Art

Air beds use air mattresses to provide an adjustable level of support and comfort for the user. Air mattresses are often inflated with motor-driven blowers and pumps. Controls on the motors are used to adjust the level of inflation. This disclosure is directed to a simplified construction for a pump for an inflatable structure, such as an air mattress, that allows a user to quickly inflate and deflate the inflatable structure as needed.

SUMMARY OF THE INVENTION

In one aspect of the invention, a pump assembly for an inflatable body is provided. The pump assembly comprises a blower unit disposed in a housing that is configured to move air in a single direction from an inlet in the housing to an outlet in the housing. The pump assembly further comprises a connector in communication with the housing outlet that is adapted to connect the pump assembly to an inflatable body to allow inflation and deflation of an inflatable body. The pump assembly also comprises a base with first and second valve bodies positionable in the base for selected movement between inflate and deflate positions, where the first valve body aligns the housing outlet in communication with the connector and the second valve body aligns the housing inlet with atmosphere in the inflate position, and where the second valve body aligns the connector in communication with the housing inlet and the first valve body aligns the housing outlet in communication with atmosphere in the deflate position. The pump assembly also comprises a control for selectively positioning the first and second valve bodies between inflate and deflate positions.

In another aspect of the invention, an inflatable and deflatable product is provided. The inflatable product has a body with an interior adapted to hold air at pressure. The inflatable body also has a port communicating with the interior that is adapted to receive air into the interior and discharge air from the interior. The inflatable product comprises a blower unit disposed in a housing that is adapted to move air in a single direction from an inlet in the housing to an outlet in the housing. The inflatable product further comprises a base with first and second valve bodies positionable in the base for selected movement between inflate and deflate positions, where the first valve body aligns the housing outlet in communication with the port and the second valve body seals the port from the housing inlet in the inflate position, and where the second valve body aligns the port in communication with the housing inlet and the first valve body seals the port from the housing outlet in the deflate position. The inflatable product further comprises a control for selectively positioning the first and second valve bodies between inflate and deflate positions.

Further features and advantages of the apparatus of the present disclosure, as well as the structure and operation of various embodiments of the apparatus of the disclosure are described in detail below with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the embodiments of the disclosure and together with descriptions, serve to explain the principles of the apparatus of the disclosure. In the drawings:

FIG. 1 illustrates a perspective view of a pump assembly attached to an inflatable and deflatable structure such as an air mattress;

FIG. 2 shows a front view of a blower unit, base and plug of the pump assembly of FIG. 1 removed from a casing of the pump assembly;

FIG. 3 shows a right-side view of the blower unit, base and plug of FIG. 2;

FIG. 4 shows a rear view of the blower unit, base and plug of FIG. 2;

FIG. 5 shows a side view of a solenoid actuated valve removed from a duct in the base;

FIG. 6 shows a top cross-sectional view of the blower unit, base, plug and a portion of the connector taken along lines 6-6 of FIG. 3;

FIG. 7 shows a front-cross sectional view of the blower unit, base, plug and a portion of the connector taken along lines 7-7 of FIG. 3.

DETAILED DESCRIPTION OF THE DISCLOSED EMBODIMENTS

FIG. 1 shows a perspective view of a pump assembly 20. Preferably, the pump assembly is constructed from a flame retardant, light-weight and high-impact type plastic, such as ABS UL-94VO. To simplify construction and assembly, the pump assembly and its associated parts may be injection molded with cooperating and interlocking features that allow the pump assembly to be snap-fit together. Although the pump assembly may be used with a portable air mattress, the pump assembly may also be used in or with more permanent bedding furniture such as adjustable mattress support systems, or with other inflatable products such as inflatable amusements. As shown in FIG. 1, the pump assembly 20 includes a connector 24 to allow connection of the pump assembly to an inflatable structure 26, such as an air mattress. Preferably, the connector 24 is formed on a front side 28 of the pump assembly thereby leaving a rear side 30 of the pump assembly generally unobstructed by the air mattress 26. Preferably, the connector 24 releasably connects the pump assembly to the inflatable body. For instance, the inflatable body 26 may have a port 32 adapted to interlock with the connector 24 to releasably secure the pump assembly 20 directly to the inflatable body. As shown in the drawings, the connector is a threaded connector similar to a union-type connector that threadably attaches to the port. Alternatively, a conduit (not shown) may be interposed between the port and the pump assembly connector. For instance, one end of the conduit may be releasably secured to the connector and the opposite end of the conduit may be releasably secured to the port. Straps may be used to support the pump assembly on the outside of the inflatable structure with the connector connected to the port.

In an alternative construction (not shown), the pump assembly may be formed with a plurality of connectors so that one pump assembly unit may inflate a plurality of inflatable bodies. For instance, the inflatable product may comprise a two-chamber air mattress. Accordingly, the pump assembly may be formed with two connectors for inflation of each chamber of the air mattress. A conduit may extend from each connector to the port associated with each chamber of the air mattress so that one pump unit can inflate and/or deflate both chambers of the air mattress simultaneously and remotely. Alternatively, a single pump unit may be associated with each chamber of an air mattress to allow independent inflation and deflation of each chamber of the air mattress. In such an embodiment, one pump assembly may be dedicated to a specific chamber in an air mattress.

As shown in FIG. 1, the rear side 30 of the pump assembly provides a location for air flow into and out of the pump assembly. Being generally unobstructed by the air mattress 26, the rear side 30 of the pump assembly also provides a convenient location for controls, although the pump assembly controls may be placed anywhere on the exterior surface of the pump assembly. The controls may comprise a pendant control 40. In addition to or in an alternate embodiment, the controls may be arranged directly on an exterior of the pump assembly. Referring to FIG. 1, the control for the pump assembly includes the pendant control 40 and externally mounted controls. Both the pendant and externally mounted controls are similar in that they comprise an “empty” (or deflate) push button 60 and a three-position latch switch 64. The three-position latch switch 64 has an “fill” (or inflate) position 66, an “off” position 68, and a “empty” (or deflate) position 70. In the “fill” (or inflate) position 66, the switch 64 energizes a blower unit of the pump assembly and positions valve bodies in a base of the pump assembly to inflate the air mattress. In the “empty” (or deflate) position 70, the switch 64 energizes a blower unit of the pump assembly and realigns valve bodies in a base of the pump assembly for power-assisted deflation of the air mattress. In the “off” position 68, the blower unit remains de-energized and the valve bodies are aligned in a base of the pump assembly to maintain pressure inside the air mattress. The “empty” (or deflate) push button control 60 on the controller allows the user to fine-tune the level of support and comfort of the air mattress. The “empty” (or deflate) push button 60 is preferably spring return and configured to position the valve bodies to deflate the air mattress as long as the button remains depressed. Preferably, the “empty” (or deflate) push button 60 does not energize the blower unit for power assisted deflation of the air mattress, but rather allows for natural deflation of the air mattress. A further description of the operation of the controls, blower unit and valve bodies follows below.

FIGS. 2-4 and 6-7 show a blower unit 80 of the pump assembly. The blower unit is disposed in a cylindrically shaped housing 82 with an impeller compartment 84 separated from a motor compartment 86 by a dividing wall 88. The dividing wall 88 has flow holes 90 so that the motor compartment 86 communicates with the impeller compartment 84. The motor compartment 86 houses a motor 92 for the blower unit 80 and the impeller compartment 84 houses an impeller 94 for the blower unit. As shown in the figures, the impeller 94 of the blower unit comprises a radial fan type impeller. However, the impeller may comprise a spiral vein impeller, or the blower unit itself may comprise a diaphragm type pump. The housing 82 has an inlet 96 into the motor compartment 86 and an outlet 98 leading out of the impeller compartment 84. The blower unit 80 directs air from the inlet 96 into the motor compartment 86 through the flow holes 90 in the divider wall 88 into the impeller compartment 84 and out through the outlet 98. The blower unit is configured to maintain airflow in a single direction through the housing in both inflate and deflate modes as will be explained below in greater detail.

FIGS. 2-4 show a base 110 of the pump assembly positioned on a top surface of the blower unit housing 82 extending across the housing inlet 96 and housing outlet 98. The base 110 is generally a block-shaped structure with first and second ducts 112,114 extending from a rear 116 of the base to a front 118 of the base. The first duct 112 is oriented toward the outlet side of the blower housing (left side in FIG. 6) and the second duct 114 is oriented toward the inlet side of the blower housing (right side in FIG. 6). The rear 116 of the base has a perforated plate 120 with first and second sets of apertures 122,124. The first set of apertures 122 open to the first duct 112 and the second set of apertures 124 open to the second duct 114. The first duct 112 is formed with a passage 130 that communicates with the housing outlet 98 and the second duct 114 is formed with a passage 132 that communicates with the housing inlet 96. Referring to FIG. 6, a shoulder (134, 136) projects from a wall of each duct adjacent the rearward intersection of the passage and the duct forming a rear valve seat (138,140).

Referring to FIG. 6, a rectangular plate 146 extends across the front of the base 110, and a cover 148 extends over the plate to form a chamber 150 across the front of the base. The plate 146 has a first nipple 152 that extends into the first duct 112 and a second nipple 154 that extends into the second duct 114. Each of the nipples 152,154 extends into its respective duct a distance sufficient to intersect with the forward edge of the passage (130,132). A front valve seat (156,158) is formed on the distal edge of each of the nipples 152,154 at the forward intersection of the passage and nipple. The front valve seat (156,158) opposes and is spaced from the rear valve seat (138,140) in each duct.

The connector 24 is preferably integrally formed with the cover 148 for instance as a union-type connector which releasably interlocks with the port by tightening the threaded collar. The connector's attachment to the port secures the pump assembly to the inflatable structure. A wide strap 170 extending from an exterior of the inflatable structure 26 may be lashed around the pump assembly 20 and releasably secured back on the strap 170 with snaps 172 or to the pump assembly itself (not shown) to support the pump assembly against the inflatable structure.

As described in more detail below, a solenoid valve 180 (FIG. 5), having a disk-like valve body 182 with sealing surfaces 184,186 on front and rear faces 188,190 of the disk, is disposed in each of the ducts with the valve body positioned between the front and rear valve seats. The front face of the disk seals against the front valve seat (156,158) and the rear face of the disk seals against the rear valve seat (138,140). The sealing surface on the face of the disk of the valve body of the first and second solenoid valves may be formed from a silicon rubber to provide an adequate seal. The solenoid includes a spring 192 to bias the disk forward against the front valve seat when the solenoid is de-energized. When the solenoid is energized, a stem of the solenoid valve is retracted into the body of the solenoid thereby moving the valve body (up in FIG. 6) to seal against the rear valve seat against the spring 192. The construction of the solenoid valves in each duct is the same, and hereinafter the solenoid valve in the first duct, including its associated subparts, will be denoted with an “a” following the element's reference character and the solenoid valve in the second duct, including its associated subparts, will be denoted with a “b” following the element's reference character.

The operation of the solenoid valves 180a, 180b will be described in greater detail below with reference to FIGS. 6-7. As described previously, the controls associated with the pump assembly has a three-position latch switch 64. In the inflate or fill mode, the latch switch is switched to the “fill” position 66. This energizes the motor 92 and fan 94, and the first solenoid 180a, causing the first valve body 182a to retract (up in FIG. 6) against the rear valve seat 138 thereby sealing the first duct 112 from the passage 130 and placing the housing outlet 98 and first passage 130 in communication with the plug/connector 24 via the first nipple 152 and chamber 150. The second solenoid valve 180b remains in its normal position with the front face 188b of the valve body 182b sealing against the front valve seat 158 in the second duct 114 with pressure from the second solenoid valve spring 192b.

Through action of the blower unit 80, inflation air is drawn into the pump assembly at the rear 30 of the pump assembly and then through the second set of apertures 124 formed in the perforated plate 120 of the rear of the base. Inflation air then flows through the second duct 114 across the second solenoid 180b. Inflation air is then drawn across the rear valve seat 140 into the second passage 132 and into the motor compartment 86 via the housing inlet 96. Inflation air flows through the motor compartment 86 across the motor 92 where it cools the motor. Inflation air then flows through the divider wall flow holes 90 and into the impeller compartment 84. The impeller 94 pressurizes the inflation air, discharging it from the outlet 98, through the first passage 130 across the front valve seat 156 into the first nipple 152 through the chamber 150 and out of the plug 170 and pump assembly connector 24. From the pump assembly connector, inflation air may inflate the air mattress directly via the port of the air mattress or indirectly via a conduit operatively connected to the port of the air mattress.

Once the inflatable body is inflated, the latch switch 64 is returned to the “off” position. Once in the “off” position, the blower unit 80 and first solenoid valve 180a de-energize and the first valve body 182a is returned to its normal position sealing against the front valve seat 156 in the first duct 112. With the first and second solenoid valves 180a, 1 80b in the normal position, the front faces of each of the valve bodies 182a, 1 82b seal against their respective front valve seats 156,158 under spring pressure (down in FIG. 6), thereby allowing pressure to be maintained in the chamber and inflatable body with the pump assembly connected thereto.

For power-assisted evacuation or deflation of the air mattress (deflation using the blower unit), the latch switch 64 is switched from the “off” position 68 to the “empty” position 70. In the empty or deflate mode, the blower unit 80 and the second solenoid valve 180b are energized. The first solenoid valve 180a remains in the normal position with the valve body front face 188a sealing against the front valve seat 156 in the first duct 112. The energized second solenoid valve 180b retracts, sealing the valve body 182b against the rear valve seat 140 in the second duct 114, thereby aligning the inlet 96 and second passage 132 in communication with the plug/connector via the second nipple 154 and chamber 150, and sealing the passage 132 from the second set of apertures 124 formed in the perforated plate 120 of the rear 116 of the base.

Evacuation air is then drawn from the mattress interior through the port 32 through the pump assembly connector 24 into the chamber 150 and into the second nipple 154. Once in the second nipple 154, the evacuation air flows across the front valve seat 156 into second passage 132 through the inlet 96 and into the motor compartment 86 where the air flows across the motor 92 cooling the motor. Evacuation air then flows through the divider wall flow holes 90 and into the impeller compartment 94. In the impeller compartment, the evacuation air is pressurized and directed through the outlet 98 into the first passage 130 and into the first duct 112. Evacuation air then flows over the rear valve seat 138 across the first solenoid 180a and out of the base through the first set of apertures 122 formed in the perforated plate 120 of the rear of the base. Once the inflatable body is deflated as desired, the latch switch 64 is returned to the “off” position 68 thereby returning the second solenoid valve 180b to its normal position with the second valve body front face 188b sealing against the front valve seat 158 in the second duct 114.

The push button control 60 on the controller moves the solenoid valves 180a, 180b to its deflate position as described above. However, pressing the “deflate” push button 60 does not energize the blower unit but only repositions the solenoid valves to allow deflation through a natural pressure differential created through the pump assembly. In an alternate embodiment, a “deflate” push button is provided on the control as well as an “inflate” push button which operates in a manner similar to the “inflate” position of the latch switch, energizing the blower when the push button is depressed.

Although the embodiment described herein uses two solenoids each with its respective valve body, it is contemplated that one solenoid operatively connected to valve stem with two spaced-apart valve bodies may be positionable in the base, for instance in a spool valve arrangement, to align the housing outlet in communication with the connector in the inflate mode and the housing inlet in communication with the connector in the deflate mode.

In view of the foregoing, it will be seen that the several advantages of the invention are achieved and attained. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. As various modifications could be made in the constructions and methods herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents.

Claims

1. A pump assembly for an inflatable structure comprising:

a blower unit disposed in a housing and configured to move air in a single direction from an inlet in the housing to an outlet in the housing;

a connector in communication with the housing outlet, the connector being adapted to connect the pump assembly to an inflatable structure to allow inflation and deflation of an inflatable structure;

a base with first and second valve bodies positionable in the base for selected movement between inflate and deflate positions, where the first valve body aligns the housing outlet in communication with the connector and the second valve body aligns the housing inlet with atmosphere when in the inflate position, and where the second valve body aligns the connector in communication with the housing inlet and the first valve body aligns the housing outlet in communication with atmosphere when in the deflate position; and

a control for selectively positioning the first and second valve bodies between the inflate and deflate positions.

2. The pump assembly of claim 1 further comprising a chamber arranged in communication with the base in a manner such that the first valve body seals the chamber from the housing outlet and the second valve body aligns the connector in communication with the housing inlet via the chamber in the deflate position, and the first valve body aligns the connector in communication with the housing outlet via the chamber and the second valve body seals the chamber from the housing inlet in the inflate position.

3. The pump assembly of claim 1, wherein the control positions the valve bodies in the deflate position without energizing the blower.

4. The pump assembly of claim 1, wherein the connector is a releasably securable connector.

5. The pump assembly of claim 1, wherein the control comprises a control pendant.

6. The pump assembly of claim 5, wherein the control is arranged on an exterior of the pump assembly.

7. The pump assembly of claim 5, wherein the control selectively energizes or de-energizes the blower unit with the first and second valve bodies in the deflate position.

8. The pump assembly of claim 1, wherein the base comprises first and second solenoids operatively connected to the first and second valve bodies.

9. The pump assembly of claim 8, wherein the first and second solenoids seal the connector from the housing outlet when de-energized.

10. The pump assembly of claim 1, wherein the blower unit comprises a single rotational direction impeller to move air from the housing inlet through the housing outlet.

11. The pump assembly of claim 1, wherein cooling air is directed over a motor for the blower unit when the blower unit motor is energized with the first and second valve bodies in either the inflate position or the deflate position.

12. An inflatable device comprising:

an inflatable structure having an interior adapted to hold air at pressure, the structure having at least one port communicating with the interior, the at least one port being adapted to receive air into the interior and discharge air from the interior;

a blower unit disposed in a housing and being adapted to move air in a single direction from an inlet in the housing to an outlet in the housing;

a base with first and second valve bodies positionable in the base for selected movement between inflate and deflate positions, where the first valve body aligns the housing outlet in communication with the at least one port and the second valve body seals the at least one port from the housing inlet when in the inflate position, and where the second valve body aligns the at least one port in communication with the housing inlet and the first valve body seals the at least one port from the housing outlet when in the deflate position; and

a control for selectively positioning the first and second valve bodies between inflate and deflate positions.

13. The inflatable device of claim 12, wherein the inflatable structure is a portable air mattress.

14. The inflatable device of claim 12, further comprising a chamber arranged in communication with the base in a manner such that the first valve body seals the chamber from the housing outlet and the second valve body aligns the at least one port in communication with the housing inlet via the chamber in the deflate position, and the first valve body aligns the chamber in communication with the housing outlet via the chamber and the second valve body seals the chamber from the housing inlet in the inflate position.

15. The inflatable device of claim 14, wherein the chamber further comprises a connector that releasably secures to the at least one port.

16. The inflatable device of claim 15, wherein the connector connects directly to the at least one port.

17. The inflatable device of claim 15, wherein the connector is a threaded connector.

18. The inflatable device of claim 12, wherein the control comprises a control pendant.

19. The inflatable device of claim 12, wherein the blower unit comprises a single rotational direction impeller to move air from the housing inlet through the housing outlet.

20. The inflatable device of claim 12, wherein the base comprises first and second solenoids operatively connected to the first and valve second bodies.