SIMPLICITY BED

Abstract

An adjustable bed is provided that includes a bed frame defined by a pair of side rails, a rear rail, and a front rail. A mattress support is disposed on top of the bed frame and includes a plurality of support panels, coupled in succession using hinges such that at least one support panel can be articulated, causing the panel to pivot about the hinge connection with an adjacent panel. An adjustment mechanism is provided that includes torque tubes that each include a torque shaft and lift links. The torque tubes are removably attachable to the side rails of the bed frame by inserting bushings on the ends of the torque shafts into slots running along the insides of the side rails. A motor is coupled to the torque tubes, locking the torque tubes in place. A set of foot links is provided for supporting a foot panel during articulation of an adjacent leg panel.

Description

BACKGROUND

Adjustable beds are a versatile alternative to conventional beds because they allow the user to position the bed according to various configurations. Typically, adjustable beds allow for at least the head and foot of the bed to be raised and lowered. In adjustable beds, the mattress typically rests on a mattress support that consists of three or four support panels. The support panels are arranged end-to-end and each panel is pivotably connected to adjacent panels using hinges. For example, in the case of a four-section mattress support, the adjustable bed includes a head support panel, a center support panel, a leg support panel, and a foot support panel. The support panels are connected such as to allow pivotal movement between adjacent panels about parallel axes transverse to the length of the bed.

Adjustable beds are typically quite heavy and include a fair amount of hardware, particularly as part of the adjustment mechanisms. Much of the hardware on most adjustable beds is interconnected and requires appropriate experience and tools to assemble. Accordingly, adjustable beds are often shipped partly pre-assembled as one large and heavy package and often must be assembled for a user by a service technician. Moreover, adjustable beds typically include shrouds or other types of covers to hide the operational hardware from view so that an appealing aesthetic appearance can be maintained.

SUMMARY

The invention is defined by the claims below. This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

Embodiments of the present invention relate to an adjustable bed with a break-down feature that allows the adjustable bed to be manufactured and shipped in several pieces and can be reassembled by a consumer with simple tools. The adjustable bed includes a number of support panels arranged end-to-end and interconnected by hinges so that individual panels can be articulated independent from other panels. The adjustable bed also includes a base having a bed frame that includes a pair of parallel opposed side rails, a rear rail, and a front rail. An adjustment mechanism is coupled to the base and adapted to manipulate a support panel. The adjustment mechanism includes a torque tube that is rotatably coupled to the frame and that engages a support panel so that when the torque tube is rotated by a motor coupled thereto, the support panel articulates, thereby adjusting the position of the bed.

Further embodiments of the present invention provide for an adjustable bed with a simple and aesthetically pleasing appearance. In some embodiments, the adjustable bed includes a frame having a pair of parallel opposed side rails, a rear rail, and a front rail. The adjustable bed also includes a mattress support that has a center support panel secured to the side rails. A head support panel is pivotably connected to one side of the center support panel and a leg panel is pivotably connected to the other side of the center support panel. A foot panel is pivotably connected to the other side of the leg panel. The adjustable bed further includes an adjustment mechanism including two torque tubes adapted to articulate the head and leg panels. The torque tubes are removably coupled with the side rails via a bushing on both ends of each torque tube that is configured to fit and slide within a slot that runs along an inside wall of the side rail. The adjustable bed also includes a pair of foot links that provide stability and support to the foot support panel during articulation of the adjacent leg support panel.

According to a further embodiment of the invention, an adjustable bed is provided that includes a mattress support having a head support panel, a stationary center support panel, a leg support panel, and a foot support panel. The head support panel is configured to be articulated using a head panel adjustment mechanism that includes a torque tube slidably coupled to the side rails. The foot support panel is elevated in response to articulation of the leg support panel, which is accomplished using a foot panel adjustment mechanism that includes a second torque tube slidably coupled to the side rails. An electric motor is provided for actuating the torque tubes as well as holding the torque tubes in place. Foot links provide support to the foot panel during articulation of the leg support panel.

These and other aspects of the invention will become apparent to one of ordinary skill in the art upon a reading of the following description, drawings, and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is described in detail below with reference to the attached drawing figures, wherein:

FIG. 1 is a perspective view showing an adjustable bed in accordance with an embodiment of the present invention;

FIG. 2 is a side view of an adjustable bed with a mattress in accordance with an embodiment of the present invention;

FIG. 3 is a bottom view of an adjustable bed having a removably attached adjustment mechanism in accordance with an embodiment of the present invention;

FIG. 4 is an enlarged bottom view showing an exemplary coupling of a torque tube and a side rail of an adjustable bed in accordance with an embodiment of the present invention;

FIG. 5 is an enlarged perspective showing an exemplary coupling of a torque tube using a slot in a side rail of an adjustable bed in accordance with an embodiment of the present invention; and

FIG. 6 is another perspective view of an adjustable bed with a mattress in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION

Referring to the drawings, and particularly to FIG. 1, there is illustrated an adjustable bed 10 in accordance with an embodiment of the present invention. The adjustable bed 10 includes a bed frame 12, a mattress support 14, and an exemplary adjustment mechanism 16 in accordance with an embodiment of the present invention. As illustrated in FIG. 1, the bed frame 12 is roughly rectangular and includes a pair of parallel opposed side rails 18 and 20, a front rail 22, and a rear rail 24. The bed frame 12 can also include legs 26. In the illustrated embodiment, the legs 26 are welded onto the side rails 18 and 20, thereby minimizing noise to due metal parts moving against other metal parts or parts of another material. In another embodiment, the legs 26 can be detachable or adjustable legs. In an embodiment, side rails 18 and 20, front rail 22, and rear rail 24 are hollow tubular structures. In embodiments, the hollow tubular structures are rectangular, and in other embodiments, the tubular structures can be rounded.

As illustrated in FIG. 1, mattress support 14 includes a number of support panels 30, 32, 34, and 36. A center support panel 30 is secured on a first side to one side rail 18 and on a second side to the other side rail 20. The center support panel 30 is pivotably coupled on a third side to one side of a head support panel 32 and pivotably coupled on a fourth side to one side of a leg support panel 34. The other side of leg support panel 34 is pivotably connected to a foot support panel 36. These pivotable couplings are achieved by including a hinge 38 at each interface between two adjacent support panels 30, 32, 34, and 36. In an embodiment, mattress support 14 includes four support panels 30, 32, 34, and 36. In other embodiments, mattress support 14 can include fewer than four support panels, while in still further note, mattress support 14 can include more than four support panels.

As illustrated in FIG. 1, the adjustment mechanism 16 includes a torque tube 40 that is disposed between the two side rails 18 and 20, and is rotatably coupled to each side rail 18 and 20. The torque tube 40 includes a torque shaft 42 extending between the two side rails 18 and 20 and a pair of parallel opposed lift links 44 that include lift wheels 46 that engage the head support panel 32. An electric motor 48 is coupled with the torque tube 40 and is adapted to cause the torque shaft 42 to rotate, thereby moving the lift links 44 to cause articulation of the head support panel 32. For example, rotation of the torque shaft 42 in a first direction (counter-clockwise in FIG. 1) causes the lift links 44 to apply a rotational force in the first direction to the head support panel 32, thereby causing the head of the adjustable bed 10 to articulate. Although not shown in FIG. 1, the adjustable bed 10 may also include a second torque tube used to articulate the leg support panel 34. The adjustable bed 10 includes a pair of parallel opposed foot links 52 (only one of which is shown in FIG. 1) that provide support to the foot support panel 36 such that foot support panel 36 can elevate in response to articulation of the leg support panel 34.

Turning now to FIG. 2, an adjustable bed 10 is shown to include, as illustrated in FIG. 1, a bed frame 12 and a mattress support 14. Additionally, the illustration of FIG. 2 includes a mattress 54 attached to the top of the mattress support 14, an exemplary head panel adjustment mechanism 56, an exemplary leg panel adjustment mechanism 58, and a pair of parallel opposed foot links 52 in accordance with an embodiment of the present invention. In an embodiment, the mattress 54 is attached to the mattress support 14 using mattress retainer clips. In another embodiment, the mattress 54 is attached to the mattress support 14 using mattress retainer brackets such as those described in U.S. Pat. No. 7,047,579 to Piana et al. In a further embodiment, the mattress 54 is attached to the mattress support 14 using an attachment panel such as is described in U.S. application Ser. No. (not yet assigned), filed (date not yet established, Attorney Docket No. LGPL.139922).

As shown in FIG. 2, the head panel adjustment mechanism 56 includes a first torque tube 40 having lift links 44. The lift links 44 are attached to a torque shaft (not shown in FIG. 2) at a first end and include lift wheels 46 rotatably coupled to a second end that engage the head support panel 32. The leg panel adjustment mechanism 58 includes a second torque tube 60 having lift links 62. The lift links 62 are attached to a torque shaft (not shown in FIG. 2) at a first end and include lift wheels 66 rotatably coupled to a second end that engage the leg support panel 34.

The two torque tubes 40 and 60 are connected to, and operated by, an electric motor 48. One example of an electric motor suitable for use with embodiments of the present invention includes the OKIN OKIMAT 2, available from OKIN of Gummersbach, Germany. As illustrated, the first torque tube 40 engages the head support panel 32 such that when the first torque tube 40 is rotated in a first direction (e.g., counter-clockwise), the head support panel 32 is rotated in the first direction (e.g., counter-clockwise) around the hinge 41, thereby actuating the head of the adjustable bed 10 to cause the same to be oriented in an upright position. It should be understood by those of ordinary skill in the art that the various adjustable portions of adjustable bed 10 can be adjusted by varying degrees into a multitude of positions. Similarly, FIG. 2 also illustrates that the second torque tube 60 engages the leg support panel 34 such that when the second torque tube 60 is rotated in a second direction (e.g., clockwise), leg support panel 34 is rotated in the second direction (e.g., clockwise) around the hinge 43, thereby actuating the foot of the adjustable bed 10 to cause the same to be oriented in an upright position.

Adjustable bed 10 further includes at least one foot link 52 that is rotatably coupled on one end to a foot support panel 36 and rotatably coupled at the other end to frame 12. The foot link 52 acts as a lever to guide foot support panel 36 into an elevated position with respect to frame 12 when support panel 34 is rotated into an upright position. The foot support panel 36 rotates in the first direction (e.g., counterclockwise) about hinge 45 when leg support panel 34 is rotated in the second direction (e.g., clockwise) about hinge 43. It will be understood by those of ordinary skill in the art that this configuration provides for adjusting bed 10 into traditional positions associated with an adjustable bed 10.

Turning now to FIG. 3, the adjustable bed 10 is shown from underneath. As illustrated, the adjustable bed 10 includes a bed frame 12, a mattress support 14 and adjustment mechanisms 56 and 58. The bed frame 12 includes a pair of opposed side rails 18 and 20, a rear rail 22, and a front rail 24 that generally form a rectangular base. In embodiments, the rails 18, 20, 22, and 24 can be tubular rails and in some embodiments, the rails 18, 20, 22, and 24 are rectangular. The mattress support 14 is shown to comprise a center support panel 30 that is fixably attached at one or more attachment points 70 on each side to the side rails 18 and 20. Attachment points 70 can include, for example, screws or bolts. The mattress support 14 further includes a head support panel 32, a leg support panel 34, and a foot support panel 36, with adjacent panels coupled by a hinge 38. A pair of parallel opposed foot links 52 are pivotably attached to the side rails 18 and 20 at a first end 72 and pivotably attached to the foot support panel 36 at a second end 73. The attachments 72 can include bolts in combination with bearings, or other hardware adapted for creating a pivotable connection and the attachments 73 can include, for example, screws or bolts.

The head adjustment mechanism 56 includes, as illustrated in FIG. 3, a torque tube 40 having a torque shaft 42 extending between the two side rails 18 and 20 and a pair of parallel opposed lift links 44 attached to the torque shaft 42 at a first end and extending away from the torque shaft 42. The lift links 44 each include a lift wheel 46 rotatably coupled to a second end that engages the head support panel 32. Similarly, the leg panel adjustment mechanism 58 includes a second torque tube 60 having lift links 62. The lift links 62 are attached to a torque shaft 64 at a first end and include lift wheels 66 rotatably coupled to a second end that engage the leg support panel 34.

The torque shafts 42 and 64 each extend between the side rails 18 and 20 and are rotatably coupled to the side rails 18 and 20 such that the torque tubes 40 and 60 can be removed from the frame 12 without the use of tools. This removable coupling is achieved by configuring the torque shafts 42 and 64 to slide into and along slots 74. Further, the torque shafts 42 and 64 each include a fitting 76 for attaching an electric motor (not illustrated in FIG. 3) thereto. The electric motor can rotate the torque shafts 42 and 64, thereby actuating the lift links 44 and 66, causing the head support panel 32 and the leg support panel 34 to articulate, respectively.

FIG. 4 illustrates an enlarged bottom view showing an exemplary attachment of a torque tube 40 to a side rail 18. As illustrated in FIG. 4, the torque shaft 42 includes a bushing 80 attached to the end. The bushing 80 includes a first cylindrical portion 82, a narrower second cylindrical portion 84, a ridge 86, and a third cylindrical portion 88. It is apparent from the the illustration of FIG. 4 that the components 82, 84, 86, and 88 of the bushing 80 generally form a key structure configured to fit within a key-hole structure defined by an opening 92 to a slot 94 that runs along an inside surface of the side rail 18. The opening 92 is oriented on a bottom surface of the side rail 18 and includes a lower portion 96 of the slot 94. The slot 94 is slightly wider than the second cylindrical portion 84 of the bushing 80 but narrower than the first cylindrical portion 82 and the ridge 86, such that the slot 94 receives and supports the bushing 80. Turning to FIG. 5, after inserting the bushing 80 into the opening 92, the torque shaft 42 slides up the lower portion 96 of the slot 94 and then onto an upper, roughly horizontal portion 98 of the slot 94. The torque shaft 42 can be slid along the upper portion 98 of the slot 94 until the torque shaft 42 is oriented in an assembled position 100, as illustrated in FIG. 4.

The present invention has been described in relation to particular embodiments, which are intended in all respects to be illustrative rather than restrictive. In embodiments, an adjustable bed is described that is configured such that the frame, adjustment mechanisms, motor and mattress support can be manufactured and shipped disassembled. In some embodiments, the adjustable bed can be assembled by a consumer with relative ease and simple tools. Moreover, as illustrated, for example, in FIG. 6, an adjustable bed 10 is presented that includes simple adjustment mechanisms 110 and other construction such that the adjustable bed has a simple and sleek appearance. In some embodiments, the adjustable bed doesn't include a complex assembly of mechanisms, thus limiting the necessity of attaching a shroud to the adjustable bed to mask such an assembly. Alternative embodiments will become apparent to those of ordinary skill in the art to which the present invention pertains without departing from its scope.

From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects set forth above, together with other advantages which are obvious and inherent to the system and method. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.

Claims

1. An adjustable bed comprising:

a mattress support comprising a plurality of support panels arranged end-to-end, wherein each pair of consecutive support panels are pivotably connected to each other by a hinge;

a base comprising a pair of parallel opposed side rails, a front rail, and a rear rail such that the side rails, front rail, and rear rail generally extend about the perimeter of the mattress support, wherein a first support panel is attached on one side to one of the pair of side rails and on an opposite side to the other side rail; and

an adjustment mechanism coupled to the base and adapted to manipulate at least one support panel, the adjustment mechanism comprising at least one torque tube extending between the side rails and engaging the at least one support panel, each side rail having a slot configured to receive and hold in place one side of the torque tube.

2. The adjustable bed of claim 1, wherein the slot comprises an L-shaped slot disposed along the side rail.

3. The adjustable bed of claim 2, wherein the L-shaped slot comprises a void disposed within the rail having a first portion running along the rail parallel to the rail and a second portion perpendicular to the first portion, the second portion extending between a first end of the first portion and a lower surface of the rail.

4. The adjustable bed of claim 3, wherein the at least one torque tube comprises:

a torque shaft extending between the two side rails;

a first lift link perpendicular to the torque shaft and extending between a first end of the torque shaft and a first support panel; and

a second lift link perpendicular to the torque shaft and extending between a second end of the torque shaft and the first support panel.

5. The adjustable bed of claim 4, wherein the at least one torque tube further comprises a bushing attached to each end of the torque shaft, the bushing comprising a cylinder having a channel running along a diameter of the cylinder, thereby defining an inner cylindrical portion situated between the end of the torque shaft and a first edge of the channel, and an outer cylindrical portion adjacent to a second edge of the channel, wherein the channel is adapted to fit within the slot.

6. The adjustable bed of claim 5, wherein the side rails comprise generally rectangular hollow tubes, and the outer cylindrical portion of the bushing is adapted to be positioned within the tube when the channel is disposed within the slot.

7. An adjustable bed comprising:

a frame comprising a pair of parallel opposed side rails, a front rail, and a rear rail;

a mattress support comprising a stationary center panel attached on a first side to one of the side rails and on a second side to the other side rail and pivotably coupled by a hinge on a third side to an articulating head support panel and pivotably coupled by a hinge on a fourth side to one side of an articulating leg panel, wherein the articulating leg panel is pivotably coupled by a hinge on an opposite side to an elevating foot panel;

an adjustment mechanism comprising a first and a second torque tube adapted to articulate the head panel and leg panel, respectively, each torque tube having a torque shaft that comprises a bushing at either end configured to slide into and be supported by an L-shaped slot disposed within the adjacent side rail and a pair of parallel lift links extending away from the torque shaft, wherein the lift links of the first torque tube engage the head panel and the lift links of the second torque tube engage the leg panel; and

a pair of parallel opposed foot links rotatably coupled to the frame at a first end and rotatably coupled to the foot panel at a second end, wherein the foot links support the foot panel as the foot panel is elevated in response to articulation of the leg panel.

8. The adjustable bed of claim 7, further comprising an electric motor extending between the first and second torque tubes and adapted to rotate the torque shafts of each torque tube to articulate the head and leg panels, respectively, wherein the electric motor is coupled at one end to the first torque tube and at an opposite end to the second torque tube, thereby locking the first and second torque tubes in place.

9. The adjustable bed of claim 8, wherein the bushing comprises a cylinder having a channel running along a diameter of the cylinder, thereby defining an inner cylindrical portion situated between the end of the torque shaft and a first edge of the channel, and an outer cylindrical portion adjacent to a second edge of the channel, wherein the channel is adapted to fit within the slot.

10. The adjustable bed of claim 7, wherein the side rails comprise generally rectangular hollow tubes, and the outer cylindrical portion of the bushing is adapted to be positioned within the tube when the channel is disposed within the slot.

11. The adjustable bed of claim 7, wherein the stationary center panel is attached to the side rails using fasteners.

12. The adjustable bed of claim 11, wherein fasteners comprise at least one of screws and bolts.

13. An adjustable bed comprising:

a frame comprising a pair of parallel opposed side rails, a front rail, and a rear rail;

a mattress support comprising a stationary center panel attached on a first side to one of the side rails and on a second side to the other side rail and pivotably coupled by a hinge a third side to an articulating head support panel and pivotably coupled by a hinge on a fourth side to one side of an articulating leg panel, wherein the articulating leg panel is pivotably coupled by a hinge on an opposite side to an elevating foot panel;

a head panel adjustment mechanism comprising a first torque tube adapted to articulate the head panel, the first torque tube comprising a first torque shaft having a bushing at each end that is adapted to fit into and slide along an L-shaped slot extending along an adjacent side rail and a pair of parallel lift links attached to and extending away from the first torque shaft, wherein the lift links of the first torque tube engage the head panel such that the lift links cause the head panel to articulate in response to a rotation of the first torque shaft;

a leg panel adjustment mechanism comprising a second torque tube adapted to articulate the leg panel, the second torque tube comprising a second torque shaft having a bushing at each end that is adapted to fit into and slide along an L-shaped slot extending along an adjacent side rail, and a pair of parallel lift links attached to and extending away from the second torque shaft, wherein the lift links of the second torque tube engage the leg panel such that the lift links cause the leg panel to articulate in response to a rotation of the second torque shaft;

an electric motor coupled to the first torque tube at one end and to the second torque tube at an opposite end, thereby holding the first and second torque tubes in place, wherein the electric motor is adapted to causing rotation of the first and second torque shafts; and

a pair of parallel opposed foot links pivotably coupled to the frame at a first end and pivotably coupled to the foot panel at a second end, wherein the foot links support the foot panel as the foot panel is elevated in response to articulation of the leg panel.

14. The adjustable bed of claim 13, the bushing comprises a cylinder having a channel running along a diameter of the cylinder, thereby defining an inner cylindrical portion situated between the end of the torque shaft and a first edge of the channel, and an outer cylindrical portion adjacent to a second edge of the channel, wherein the channel is adapted to fit within the slot.

15. The adjustable bed of claim 13, wherein the side rails comprise generally rectangular hollow tubes, and the outer cylindrical portion of the bushing is adapted to be positioned within the tube when the channel is disposed within the slot.

16. The adjustable bed of claim 13, wherein the bushing comprises bronze.

17. The adjustable bed of claim 13, wherein the frame, the head adjustment mechanism, the leg adjustment mechanism, the motor, and the mattress support can be assembled and disassembled using simple tools.

18. The adjustable bed of claim 13, wherein the stationary center panel is attached to the side rails using fasteners, the fasteners comprising at least one of bolts and screws.

19. The adjustable bed of claim 13, further comprising a plurality of legs attached to a lower side of the frame.

20. The adjustable bed of claim 19, wherein each of the plurality of legs is welded to the lower side of the frame.