Adjustable Bed with Low Profile Adjustable Foundation

Abstract

The disclosure generally relates to an adjustable foundation and bed, in particular having a low vertical profile while maintaining a full range of motion for articulation of its various deck support sections. In various embodiments, a deck support section of an adjustable bed can include an open area in the deck support surface. The open area is positioned relative to an actuator mounted beneath the deck support section and support surface such that a portion of the actuator occupies the open area during at least some of the normal range of motion of the actuator and corresponding deck support section. The additional space provided by the open area allows inclusion of an otherwise bulky actuator mechanical component in a vertically smaller space, permitting the adjustable bed to have an overall lower vertical profile.

Description

CROSS REFERENCE TO RELATED APPLICATION

Priority is claimed to U.S. Provisional Application No. 62/410,682 filed Oct. 20, 2016 and U.S. Provisional Application No. 62/423,486 filed Nov. 17, 2016, both of which are incorporated herein by reference in their entireties.

STATEMENT OF GOVERNMENT INTEREST

None.

BACKGROUND OF THE DISCLOSURE

Field of the Disclosure

The disclosure generally relates to an adjustable foundation or bed, in particular having a low vertical profile while maintaining a full range of motion for articulation of its various deck support sections. In various embodiments, a deck support section of an adjustable bed can include an open area in its deck support surface. The open area is positioned relative to an actuator mounted beneath the deck support section and support surface such that a portion of the actuator occupies the open area during at least some of the normal range of motion of the actuator and corresponding deck support section.

SUMMARY

In one aspect, the disclosure relates to an adjustable foundation (e.g., for an adjustable bed with a mattress thereon) comprising: (a) a stationary bed frame; (b) a mattress support surface comprising (i) a first deck support section comprising a (generally planar) deck support surface defining a first open area therein, and (ii) a second deck support section pivotally attached to the first deck support section; and (c) a first actuator having (A) a first (or proximal) end mounted to the first deck support section and (B) a second (or distal) end mounted to the stationary bed frame (e.g., at a longitudinal position generally beneath the first deck support section or the second deck support section), wherein: the first actuator is adapted to move the first deck support section between articulated and substantially flat positions relative to the stationary bed frame, and the first end of the first actuator is positioned such that it occupies at least a portion of the first open area at one or more positions of the first deck support section ranging between a fully articulated position and a substantially flat position.

Various refinements of the adjustable bed and foundation are possible.

In a refinement, the first end of the first actuator corresponds to a winding portion of the first actuator, and the second end of the first actuator corresponds to a distal end of a push rod of the first actuator (e.g., where the first end is bulkier and generally occupies a larger volume than the second end).

In another refinement, the adjustable foundation further comprises a first frame support that supports the first deck support section, and a second frame support that supports the second deck support section; the first end of the first actuator is mounted to the first deck support section via the first frame support to which the first end of the first actuator is (pivotally) attached; the first deck support section is pivotally attached to the second deck support section via a pivotable connection between the first frame support and the second frame support; and the stationary bed frame supports the first frame support and the second frame support (e.g., mounted thereto such that the first frame support and first deck support section can correspondingly move/articulate relative to the stationary bed frame).

In another refinement, the first end of the first actuator is pivotally mounted to the first deck support section, and the second end of the first actuator is pivotally mounted to the stationary bed frame at a vertical position that is below that of the first end when the first deck support section is in a substantially flat position.

In another refinement, the first deck support section corresponds to a back and head portion of the mattress support surface, and the second deck support section corresponds to a bottom portion of the mattress support surface. For example, the bottom portion can be stationary/fixed relative to the stationary bed frame. In some embodiments, the bottom portion can extend longitudinally to provide space for legs and feet in a head-up only configuration (i.e., an adjustable foundation where only the back/head portion of the mattress support is adjustable). In some embodiments, the bottom portion can be relatively short longitudinally and be connected to further adjustable/moveable deck support sections for the legs and/or feet, for example.

In another refinement, the first deck support section corresponds to a foot portion of the mattress support surface, and the second deck support section corresponds to a leg portion of the mattress support surface.

In another refinement, the stationary bed frame comprises: a lower longitudinal support member extending longitudinally substantially the length of the mattress support surface on both sides of the stationary bed frame; a lower lateral support member (e.g., two or more members) extending laterally between and mounted to the lower longitudinal support member on each side of the stationary bed frame; an upper longitudinal support member extending longitudinally along both sides of the stationary bed frame and mounted to the lower lateral support member (or members); and an upper lateral support member (e.g., two or more members) extending laterally between and mounted to the upper longitudinal support member on each side of the stationary bed frame. In a further refinement, the second end of the first actuator is mounted to the upper lateral support member of the stationary bed frame; and the upper lateral support member is positioned vertically below the first deck support section or the second deck support section. In another further refinement, a vertical distance between an upper edge of the lower longitudinal support member and a bottom longitudinal edge of the mattress support surface ranges from about 5 cm to about 15 cm.

In another refinement, the stationary bed frame comprises: one or more lift members (e.g., two or more lift members or handles) extending from the stationary bed frame (e.g., a lower longitudinal support member thereof) and being adapted for gripping by a user.

In another refinement, the stationary bed frame comprises: one or more extendable support members (e.g., two or more support members or bolts) outwardly extending from the stationary bed frame (e.g., a lower longitudinal support member thereof) and being adapted for mounting within an external furniture frame. In a further refinement, the adjustable foundation further comprises (d) a furniture frame positioned around at least a portion of the stationary bed frame, wherein the one or more extendable support members are extended outwardly to contact the furniture frame and stabilize the adjustable foundation within the furniture frame.

In another refinement, the mattress support surface further comprises (iii) a third deck support section pivotally attached to the second deck support section, and (iv) (optionally) a fourth deck support section pivotally attached to the third deck support section (e.g., with corresponding frame support sections). In a further refinement, the adjustable foundation further comprises (d) a second actuator having (A) a first (or proximal) end mounted to the third deck support section and (B) a second (or distal) end mounted to the stationary bed frame (e.g., at a vertical position below the fourth deck section), wherein the second actuator is adapted move the third and/or fourth deck support sections between articulated and substantially flat positions relative to the stationary bed frame (e.g., where the third deck section optionally can include an open area therein to accommodate the first end of the second actuator therein during some of its range of motion). In another further refinement, the adjustable foundation further comprises (d) a second actuator having (A) a first (or proximal) end mounted to the fourth deck support section and (B) a second (or distal) end mounted to the stationary bed frame (e.g., at a vertical position below the third deck section), wherein the second actuator is adapted move the third and/or fourth deck support sections between articulated and substantially flat positions relative to the stationary bed frame (e.g., where the fourth deck section optionally can include an open area therein to accommodate the first end of the second actuator therein during some of its range of motion).

In another refinement, the adjustable foundation further comprises (d) a mattress positioned above the mattress support surface (e.g., in direct contact with or otherwise indirectly resting on/supported by the mattress support surface).

In another refinement, the stationary bed frame comprises an upper longitudinal support member extending longitudinally along both sides of the stationary bed frame, the upper longitudinal support comprising (i) a fixed bottom portion extending longitudinally along both sides of the stationary bed frame and (ii) a top portion extending longitudinally along both sides of the stationary bed frame which is slidably mounted to the fixed bottom portion; the mattress support surface is mounted to the top portion; the top portion is adapted to slide longitudinally towards a head end of the stationary bed frame when the first deck support section is articulated away from the substantially flat position; and the top portion is adapted to slide longitudinally away from the head end of the stationary bed frame when the first deck support section is articulated towards the substantially flat position.

Additional features of the disclosure may become apparent to those skilled in the art from a review of the following detailed description, taken in conjunction with the drawings, examples, and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the disclosure, reference should be made to the following detailed description and accompanying drawings wherein:

FIG. 1 is a side view of a low-profile adjustable foundation in an articulated position according to the disclosure.

FIG. 2 is a side view of a low-profile adjustable foundation in a substantially flat position according to the disclosure.

FIG. 3 is a bottom perspective view of a low-profile adjustable foundation in a substantially flat position according to the disclosure.

FIG. 4 is a top plan view of a low-profile adjustable foundation in a substantially flat position according to the disclosure.

FIG. 5 is a bottom plan view of a low-profile adjustable foundation in a substantially flat position according to the disclosure.

FIG. 6 is a side view of the head-end of a low-profile adjustable foundation in a substantially flat position according to the disclosure.

FIG. 7 is a top perspective illustration of a mattress according to the disclosure.

FIG. 8 is a top perspective view of a low-profile adjustable foundation including lift and extendable support members according to the disclosure.

FIG. 9 is a side view of a low-profile adjustable foundation including lift and extendable support members according to the disclosure.

FIG. 10 is a partially hidden side view of a low-profile adjustable foundation including lift and extendable support members in combination with a furniture frame according to the disclosure.

FIG. 11 is a top view of a low-profile adjustable foundation including lift and extendable support members in combination with a furniture frame according to the disclosure.

FIG. 12 is a side view of a low-profile adjustable foundation including lift and extendable support members in a wall-hugging embodiment according to the disclosure.

While the disclosed apparatus and methods and are susceptible of embodiments in various forms, specific embodiments of the disclosure are illustrated (and will hereafter be described) with the understanding that the disclosure is intended to be illustrative, and is not intended to limit the claims to the specific embodiments described and illustrated herein.

DETAILED DESCRIPTION

The disclosure generally relates to an adjustable foundation or bed, in particular having a low vertical profile while maintaining a full range of motion for articulation of its various deck support sections. In various embodiments, a deck support section of an adjustable bed can include an open area in the deck support surface. The open area is positioned relative to an actuator mounted beneath the deck support section and support surface such that a portion of the actuator occupies the open area during at least some of the normal range of motion of the actuator and corresponding deck support section. In particular, the relatively bigger, bulkier end of the actuator (e.g., the winding portion which generally includes a motor and a corresponding housing) suitably is mounted to the deck support section and is appropriately positioned to be able to occupy the open area, while the relatively smaller, more compact end of the actuator (e.g., the distal end of the push rod) suitably is mounted to a stationary bed frame portion beneath the deck support section. This is in contrast to a typical configuration for mounting an actuator to an adjustable bed foundation, where (i) there is no open area in the deck support surface, (ii) the relatively bigger, bulkier end of the actuator is mounted to the stationary bed frame portion at a relatively low vertical position (e.g., where it is generally closer to a power supply, requires less cabling for connection thereto, is further away from the deck support surface than its other end, and does not interfere with other structural elements during its range of motion/rotation), and (iii) the relatively smaller, more compact end of the actuator is mounted to the deck support section at a relatively high vertical position (e.g., where is closer to the deck support surface than its other end, and its small size does not does not interfere with other structural elements during its range of motion/rotation). The additional space provided by the open area allows inclusion of an otherwise bulky actuator mechanical component in a vertically smaller space, permitting the adjustable bed to have an overall lower vertical profile.

FIGS. 1-12 generally illustrate a low-profile adjustable bed 10 or adjustable foundation 20 according to the disclosure. FIG. 1 is a side view of the low-profile adjustable bed 10 or foundation 20 in an articulated position according to the disclosure. The illustrated adjustable foundation 20 can include a mattress support (or deck) 100 mounted to an adjustable frame 200. The adjustable bed 10 further includes a mattress 300 (e.g., as illustrated in FIG. 7 or otherwise, but not shown in FIG. 1) sitting atop the adjustable foundation 20. FIG. 2 is a side view of a low-profile adjustable foundation 20 in a substantially flat position according to the disclosure. FIG. 3 is a bottom perspective view of a low-profile adjustable foundation 20 in a substantially flat position according to the disclosure. FIG. 4 is a top plan view of a low-profile adjustable foundation 20 in a substantially flat position according to the disclosure. FIG. 5 is a bottom plan view of a low-profile adjustable foundation 20 in a substantially flat position according to the disclosure. FIG. 6 is a side view of the head-end of a low-profile adjustable foundation 20 in a substantially flat position according to the disclosure. FIG. 7 is a top perspective illustration of a mattress 300 according to the disclosure. FIG. 8 is a top perspective view of a low-profile adjustable foundation 20 including lift members 232A and extendable support members 232B according to the disclosure. FIG. 9 is a side view of a low-profile adjustable foundation 20 including lift members 232A and extendable support members 232B according to the disclosure. FIG. 10 is a partially hidden side view of a low-profile adjustable foundation 20 including lift members 232A and extendable support members 232B in combination with a furniture frame 400 according to the disclosure. FIG. 11 is a top view of a low-profile adjustable foundation 20 including lift members 232A and extendable support members 232B in combination with a furniture frame 400 according to the disclosure. FIG. 12 is a side view of a low-profile adjustable foundation 20 including lift members 232A and extendable support members 232B in a wall-hugging embodiment according to the disclosure.

The mattress support 100 includes a deck support 110 platform, for example including a plurality of deck support sections 110A-110D as illustrated. A deck support platform 110 formed from a plurality of deck support sections 110A-110D, each having a corresponding upper surface 112A-112D (i.e., the surface which supports the mattress 300) is suitable for the adjustable foundation 20. In the illustrated embodiment, section 110A corresponds to the foot portion of the bed, section 110B corresponds to the leg portion of the bed, section 110C corresponds to the bottom portion of the bed, and section 110D corresponds to the head and neck portion of the bed 10/foundation 20 (i.e., where the sections correspond to the body portion of a user laying on the bed 10/mattress 300 in a normal use orientation). Each section 110A-110D includes longitudinally opposed ends 110A₁ and 110A₂, 110B₁ and 110B₂, 110C₁ and 110C₂, 110D₁ and 110D₂, respectively, where the longitudinal direction Y is generally defined as being perpendicular to the pivot axis P (described below) and/or along the mattress support 100 length or mattress 300 length. Each deck support section 110A-110D can be pivotally attached to one or more adjacent sections (e.g., directly or indirectly via underlying frame 200 structure as described below), thus allowing each section 110A-110D to rotate independently around the lateral pivot axis P (e.g., an axis generally in the lateral direction X and perpendicular to the longitudinal direction Y). The mattress support 100 generally includes at least two deck support sections, for example including a first (foot) support section 110A, a second (leg) support section 110B pivotally attached to the first section 110A, a third (bottom) support section 110C pivotally attached to the second section 110B, and a fourth (head/neck) support section 110D pivotally attached to the third section 110C as shown in FIG. 1. In other embodiments (not shown), the mattress support 100 can have fewer or more support sections (e.g., a first (foot) support section, a second (leg and bottom) support section pivotally attached thereto, and a third (head/neck) support section pivotally attached thereto). In some embodiments the support sections 110A-110D can be formed from a rigid support material such as wood or metal. In other embodiments the support sections 110A-110D can be formed from a flexible fabric or padding material (e.g., alone or in combination with a rigid support material, such as a cover or padding for an underlying rigid support material).

The adjustable frame 200 generally provides the mechanical, electrical, and electronic support and articulation components for the adjustable foundation 20 and bed 10. As illustrated, the adjustable frame 200 includes a frame support 210, for example including a plurality of frame support sections 210A-210D as illustrated and corresponding to the deck support sections 110A-110D. Each deck support section 110A-110D can be fixedly or removably mounted (e.g., via bolts, screws, or other fastener or adhesive components) to its underlying frame support section 210A-210D such that when one or more frame support sections 210A-210D are articulated, the deck support sections 110A-110D are correspondingly articulated. As illustrated, each frame support section 210A-210D can be pivotally attached at a pivot axis P to one or more adjacent sections (e.g., directly as illustrated and providing an indirect pivotal attachment for corresponding deck support sections), thus allowing each section 210A-210D to rotate independently around the lateral pivot axis P. The adjustable frame 200 generally includes at least two frame support sections, for example including a first (foot) support section 210A, a second (leg) support section 210B pivotally attached to the first section 210A, a third (bottom) support section 210C pivotally attached to the second section 210B, and a fourth (head/neck) support section 210D pivotally attached to the third section 210C as shown in FIG. 1. In other embodiments (not shown), the adjustable frame 200 can have fewer or more frame support sections (e.g., a first (foot) support section, a second (leg and bottom) support section pivotally attached thereto, and a third (head/neck) support section pivotally attached thereto).

As illustrated, the adjustable frame 200 further includes a subframe or stationary bed frame 230, for example a rigid, non-articulatable stationary frame structure which sits on a floor or within a decorative bed frame common in the furniture industry such as a platform bed (e.g., via various leg elements, not shown) and provides stability for the bed foundation 20 as the adjustable frame 200 is articulated to various different positions. The adjustable frame 200 can further include one or more support members 220 connecting structure between the subframe 230 and the frame support 210 and sections 210A-210D thereof. In some embodiments, one or more of the frame sections 210A-210D can be fixed in position relative to the subframe 230 (e.g., bottom section 210C as illustrated) and be unable to rotate or articulate relative to the subframe 230, although other frame sections pivotally attached thereto are able to rotate or articulate. As further illustrated, the adjustable frame 200 can include one or more actuators 240 (e.g., a first actuator 240A and a second actuator 240B as shown) variously mounted to one or more of the subframe 230, a support member 220, a frame support section 210A-210D, and a deck support section 110A-110D (e.g., directly mounted thereto or indirectly via the corresponding frame support section 210A-210D). In some embodiments, the subframe 230, the support members 220, and the frame support sections 210A-210D can be formed from metal such as steel. The actuators 240 can be any of those commonly known in the art, such as linear actuators. The actuators 240 and, correspondingly, the configuration or position of the adjustable frame 200, mattress support 100, and mattress 300 can be controlled and adjusted by a suitable power supply 250, an adjustable bed controller 260 (illustrated as a combined unit with the power supply 250; e.g., programmable logic controller or otherwise), and a remote control to deliver repositioning commands (not shown).

As generally illustrated in FIGS. 1-6, the adjustable foundation 20 can include two actuators 240, including a first actuator 240A and a second actuator 240B for moving various bed 10/foundation 20 deck support 100 sections. In order to accommodate typical expected loads on the bed 10 (e.g., including common weight ranges for various mattresses 300 and users thereon), an individual actuator suitably has a lift capacity of at least about 500, 750, 1000, or 1250 pounds and/or up to 1250, 1500, 2000, or 2500 pounds, such as about 750 to 2000 pounds or about 1000 to 1500 pounds. Each actuator has a first (or proximal) end 242 (242A and 242B as shown) which generally corresponds to a winding portion of the actuator (e.g., including a motor and associated housing for driving the actuator movement) and a second end 244 (244A and 244B as shown) which generally corresponds to a distal end of a push rod (e.g., which extends from the housing to articulate/move its corresponding deck support section). As illustrated particularly in FIGS. 3, 5, and 6, the first actuator 240A first end 242A is pivotally attached to the head deck support section 110D via the head frame support section 210D, and the first actuator 240A second end 244A is pivotally attached via bracket 239 to the subframe 230 (e.g., at an upper lateral support member 238 as illustrated and described below). Similarly, the second actuator 240B first end 242B is pivotally attached to the leg deck support section 110B via the leg frame support section 210B, and the second actuator 240B second end 244B is pivotally attached via bracket 239 to the subframe 230 (e.g., at a different upper lateral support member 238 as illustrated and described below).

In the illustrated embodiment, the first deck support section 110D includes an open area 114D in its deck support surface 112D. The open area is illustrated as a complete opening in the first deck support section 110D in the form of a hole or gap. The first actuator 240A first end 242A is positioned such that it occupies at least a portion of the first open 114D area at one or more positions of the first deck support section 110D ranging between a fully articulated position (e.g., maximum articulation extent) and a substantially flat position For example, as the first deck support section 110D is articulated between different positions, more or less of the first actuator 240A first end 242A can rotate into/out of the first open area 114D. In some cases, the first open area 114D might be occupied to the greatest extent by the first actuator 240A first end 242A in the substantially flat position of the first deck support section 110D, and then less so as the first deck support section 110D rotates to the fully articulated position, or vice versa. As particularly illustrated in FIGS. 3, 4, and 6 for example, a portion of the first actuator 240A first end 242A occupies the open area 114D when the first deck support section 110D is in a substantially flat position. This permits a relatively larger downward angle between the first actuator 240A first end 242A and second end 244A, because the first actuator 240A first end 242A can be mounted (e.g., pivotally attached as shown) to the frame section 210D at a relatively higher position compared to the relatively lower position for mounting (e.g., pivotally attached as shown) the first actuator 240A second end 244A to the subframe 230 (e.g., an upper lateral support member 238 as illustrated). Without the open area 114D, the first deck support section 110D would need to be mounted at a relatively lower position on the frame section 210D in order to avoid collision between the first actuator 240A first end 242A and the first deck support section 110D during actuation. Such a relatively lower mounting position for the first deck support section 110D reduces the downward angle of the first actuator 240A axis to its mounting position for the second end 244A, which in turn reduces the mechanical efficiency of the first actuator 240A and its ability move the first deck support section 110D under a given load (e.g., ability to move under the combined weight of a mattress 300 and user(s) thereon). Thus, by maintaining a relatively larger downward angle of the first actuator 240A axis, the open area 114D improves the mechanical efficiency of the first actuator 240A and also provides a lower profile for the overall adjustable foundation 20 apparatus.

In other embodiments (not shown), the open area 114D can be in the form of a recess on the bottom surface of the first deck support section 110D but which is closed or bounded by the top surface of the first deck support section 110D. A recess open area 114D which is not a completely open hole or gap can be suitable in a low-profile adjustable foundation 20 or bed 10 according to the disclosure if it nonetheless provides sufficient open area to accommodate the first actuator 240A first end 242A as a portion thereof enters into the open area 114D during the normal range of motion of the first actuator 240A during movement of the first deck support section 110D.

As further illustrated in the figures, the deck support 110 can include other holes or open areas 116 to accommodate components or structure other than an actuator component, for example a cooling or heating fan (not shown) adapted to provide a convective flow of air through the deck support 110 and a mattress 300 thereon or a massage motor (not shown) adapted to provide a massage or vibration effect through the deck support 110 and a mattress 300 thereon to a user positioned on the mattress 300.

As further illustrated, the subframe or stationary bed frame 230 includes a variety of upper and lower support structures. The deck support 110 can be mounted directly or indirectly (e.g., via the frame support 210) to the various support structure of the stationary bed frame 230. As shown particularly in FIGS. 3 and 5, two lower longitudinal support members 232 extend longitudinally for substantially the length of the mattress support surface 110 on both sides of the stationary bed frame 230. As further shown, the lower longitudinal support members 232 can have lateral positions corresponding to the width of mattress support surface 110, for example to help conceal interior mechanical and electronic components (e.g., actuators, other frame elements, control box, power supply, cabling, etc.) from external view when the mattress support 100 and deck support sections 110A-D have vertical rails or boards extending downward therefrom (not shown). In some embodiments, a fabric cover (e.g., as a decorative or aesthetic cover) can be wrapped over and around the mattress support surface 110 as well as any rails or boards extending downward therefrom (e.g., providing the appearance of a rectangular shaped box for the upper portion of the adjustable foundation 20 in the flat configuration). In this case, in a flat bed configuration, the lower longitudinal support members 232 have a relatively small gap between the vertical rails (e.g., whether covered or uncovered). Three lower lateral support members 234 (e.g., where more or fewer are possible) extend laterally between and mounted to the lower longitudinal support member 232 on each side of the stationary bed frame 230. As illustrated, two upper longitudinal support members 236 extend longitudinally along both sides of the stationary bed frame (e.g., at an interior width/lateral position and not necessarily extending the full length of the mattress support surface 100) and are mounted to the lower lateral support members 234. Two upper lateral support members 238 (e.g., two or more members) extend laterally between and are mounted to the upper longitudinal support member 236 on each side of the stationary bed frame 236.

The low-profile nature of the adjustable foundation 20 or bed 10 can be characterized in terms of a vertical distance D between an upper edge 232U of the lower longitudinal support member 232 and a lower longitudinal edge 100L of the mattress support surface 100 (e.g., as illustrated in FIG. 2). Preferably, the vertical distance D ranges from about 5 cm to about 15 cm, for example at least about 5 cm, 7.5 cm, or 10 cm and/or up to about 10 cm, 12.5 cm, or 15 cm, such as about 7.5 cm to 12.5 cm (e.g., equivalently at least about 2, 3, or 4 inches and/or up to about 4, 5, or 6 inches). This vertical distance reflects the low-profile aspect of the adjustable foundation 20 or bed 10, as it reflects the minimum vertical thickness of the adjustable foundation 20 apparatus needed to contain bulky mechanical and electronic components therein while providing full mechanical functionality (e.g., range of motion and/or weight load capacity). Of course, the actual height of a fully assembled adjustable bed 10 includes additional height from a mattress 300 as well as possibly legs or other structure to stand the adjustable bed 10 at a desired height above the floor (e.g., height as a clearance space between the floor and the bottom of the adjustable foundation 20 or bed 10 as represented by the lower longitudinal support member 232).

The mattress 300 is not particularly limited, and it can be a conventional mattress 300 (e.g., a spring or coil mattress, memory foam mattress, air mattress) with a base 310 (e.g., a continuous fabric material) suitable for use on a mattress support structure such as a fixed bed frame or an adjustable bed frame. In the illustrated embodiment in FIG. 7, the mattress 300 includes a mattress containment frame 305 including a plurality of foam cells (or foam springs) 340 positioned in the frame 305 to provide the sleeping support surface for the mattress. The mattress containment frame 305 includes a lower/bottom base 310, sidewalls 320, and endwalls 330 which generally define the interior frame 305 volume housing the foam cells 340. The sidewalls 320 and endwalls 330 suitably are formed from a foam material. The base 310 can be a generally continuous fabric material (e.g., a non-woven fabric material). The mattress 300 is generally positioned above the mattress support 100 surface 112, for example sitting directly atop the deck support sections 110A-110D. In other embodiments, other structure between the mattress 300 and mattress support 100 surface 112 can be present, for example a padding or cushion material (e.g., which can be continuous or include openings).

FIGS. 8-12 illustrate further embodiments of a low-profile adjustable bed 10 or adjustable foundation 20 including lift members 232A and/or extendable support members 232B which can assist with installation of the adjustable foundation 20 into a furniture frame 400.

In some embodiments, the stationary bed frame 230 includes the lift members 232A (e.g., handles; such as at least two lift members or handles 232A on two or more sides of the stationary bed frame 230) extending (e.g., upwardly and/or substantially vertically extending) from the stationary bed frame 230 and being adapted for gripping by a user's hand (e.g., for lifting, carrying, and/or installation of the adjustable foundation 20). The lift members 232A can be mounted on one or both longitudinal sides of the stationary bed frame 230 (e.g., on the lower longitudinal support members 232 as illustrated; such as two or more lift members 232A on both opposing sides) and/or one or both lateral sides of the stationary bed frame (e.g., the lower lateral support members 234; not shown). As illustrated, the lift members or handles 232A can be inverted U-shaped elements, such as steel elements welded or otherwise fastened to the stationary bed frame 230/lower longitudinal support 232.

In some embodiments, the stationary bed frame 230 includes the extendable support members 232B (e.g., bolts) outwardly extending from the stationary bed frame 230 and being adapted for mounting within an external furniture frame 400. The extendable support members 232B can be mounted on one or both longitudinal sides of the stationary bed frame 230 (e.g., on the lower longitudinal support members 232 as illustrated; such as two or more support members 232B on both opposing sides) and/or one or both lateral sides of the stationary bed frame (e.g., the lower lateral support members 234; not shown). As illustrated, the extendable support members 232B can be bolt elements having a threaded connection to the stationary bed frame 230/lower longitudinal support 232 (e.g., with a threaded nut mounted thereto as illustrated).

As noted, the lift members 232A and extendable support members 232B can assist with installation of the adjustable foundation 20 into a furniture frame 400, which can provide a foundational (ground or floor) support for the adjustable foundation 20 as well as an aesthetically pleasing outward appearance (e.g., which also partially or completely conceals the electromechanical structure of the adjustable foundation 20). FIGS. 10 and 11 illustrate the adjustable foundation 20 in combination with the furniture frame 400, where the furniture frame 400 is positioned around at least a portion of the stationary bed frame, such as where the adjustable foundation 20 is at least partially within a cavity defined by the furniture frame 400 and is vertically supported therein at a desired height by any suitable support element (e.g., leg elements attached to the adjustable foundation 20 (not shown), other support elements as part of the frame 400 (not shown)). As illustrated, the lift members 232A permit easy installation of the adjustable foundation 20 into the frame 400 and removal therefrom (e.g., during disassembly for moving). The lift members 232A can be accessible via a gap between the deck support 110 and furniture frame 400 wall 410 (e.g., gap as shown in FIG. 11), and the lift members 232A can extend above a top surface of the furniture frame 400 (e.g., as shown in FIG. 10). Both structural aspects provide easy gripping access to the adjustable foundation 20 for workers who are installing or removing the adjustable foundation 20. The extendable structure of the support members 232B (e.g., as a threaded connection or otherwise equivalent structure) permits the support members 232B to have their degree of outward extension relative to the stationary bed frame 230 adjusted and selected such that the distal ends of the support members 232B provide a stabilizing force. For example, the support members 232B can stabilize against lateral movement when mounted to a longitudinal support member (e.g., the lower longitudinal support member 232 as illustrated) or against longitudinal movement when mounted to a lateral support member (not shown). For example, the adjustable foundation 20 can be placed within the furniture frame 400 with the support members 232B in an at least partially retracted configuration such that they are not touching the frame 400 and provide suitable clearance for insertion therein. After placement within the frame 400, the support members 232B can be extended (e.g., with a wrench for a threaded connection) until they contact the furniture frame 400 wall 410. Such contact can stabilize the adjustable foundation 20 from (lateral) movement, in particular when there are two or more support members 232B on both opposing sides of the adjustable foundation 20.

FIG. 12 illustrates an embodiment of a low-profile adjustable foundation 20 according to the disclosure which also incorporates wall-hugging sliding/moveable structure as part of the stationary bed frame 230. As illustrated, the upper longitudinal support 236 generally includes a bottom (or fixed) portion 236A of the upper longitudinal support 236 and a top (or slidable) portion 236B of upper longitudinal support 236. The bottom portion 236A of the support 236 is mounted to the lower lateral support 234 as shown in the previous figures, while the top portion 236B of the support 236 is mounted to the upper lateral support 238 and the frame support 210 (e.g., to the mattress and/or deck support 100, 110 alternatively or additionally) as shown in the previous figures. The bottom portion 236A has a fixed position, and it provides a track for the top portion 236B to slide longitudinally back and forth via rollers 236C (e.g., mounted to the top portion 236B as shown). A further rod or member 237 of fixed length is pivotally attached to both the deck support 110 and/or frame support 210 at one end and the stationary bed frame 230 (e.g., the lower lateral support 234 or other fixed portion thereof) at the other end. In the illustrated embodiment, when the actuator 242A moves the head deck section 110D between a substantially flat configuration and an articulated configuration, the slidable mount between the top and bottom portions 236B, 236A combined with the pivotable mount for the rod or member 237 causes the top portion 236B and the corresponding deck 110 to slide forward (direction A in FIG. 12) or backward (direction B in FIG. 12), thus tending to keep the head end of the head deck section 110D at a longitudinal position generally corresponding to the head end of the stationary bed frame 230.

Rawls-Meehan U.S. Pat. Nos. 7,321,811, 7,465,280, 7,805,785, 7,930,783, 7,933,669, 7,979,169, 8,019,486, 8,032,263, 8,032,960, 8,046,114, 8,046,115, 8,046,116, 8,046,117, 8,050,805, 8,069,512, 8,078,336, 8,078,337, 8,150,562, 8,375,488, 8,565,934, and 8,682,457 as well as Rawls-Meehan U.S. Publication No. 2012/0057685 are incorporated herein by reference in their entireties and variously disclose mattresses including foam springs or foam cells and materials/configurations therefor, adjustable bed assemblies including adjustable mattress frames, electrical, mechanical, and electronic components associated therewith, and remote controls for use therewith, all of which may be used individually or collectively in combination with the adjustable bed described herein.

Because other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the disclosure is not considered limited to the example chosen for purposes of illustration, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this disclosure.

Accordingly, the foregoing description is given for clearness of understanding only, and no unnecessary limitations should be understood therefrom, as modifications within the scope of the disclosure may be apparent to those having ordinary skill in the art.

All patents, patent applications, government publications, government regulations, and literature references cited in this specification are hereby incorporated herein by reference in their entirety. In case of conflict, the present description, including definitions, will control.

Throughout the specification, where the compositions, processes, or apparatus are described as including components, steps, or materials, it is contemplated that the compositions, processes, or apparatus can also comprise, consist essentially of, or consist of, any combination of the recited components or materials, unless described otherwise. Component concentrations can be expressed in terms of weight concentrations, unless specifically indicated otherwise. Combinations of components are contemplated to include homogeneous and/or heterogeneous mixtures, as would be understood by a person of ordinary skill in the art in view of the foregoing disclosure.

PARTS LIST

• 10 adjustable bed (including mattress support 100, adjustable frame 200, and mattress 300)
• 20 adjustable foundation (including mattress support 100 and adjustable frame 200)
• 100 mattress support (or deck) surface
• 110 deck support (sections 110A-D as foot, leg, bottom, and back/head portions; longitudinally opposed ends 110A₁ and 110A₂, 110B₁ and 110B₂, 110C₁ and 110C₂, 110D₁ and 110D₂)
• 112 top surface of deck support (sections 112A-D as for deck support)
• 114 open area such as hole, gap, or recess (areas 114A-D possible as for deck support)
• 116 other holes or open areas
• 200 adjustable (bed) frame
• 210 frame support (sections 210A-D as for deck support)
• 220 support member
• 230 subframe or stationary bed frame
• 232 lower longitudinal support
• 232A lift member or handle
• 232B extendable support member or bolt
• 234 lower lateral support
• 236 upper longitudinal support
• 236A bottom (or fixed) portion of upper longitudinal support
• 236B top (or slidable) portion of upper longitudinal support
• 236C rollers
• 237 rod or member
• 238 upper lateral support
• 239 bracket
• 240 actuator or movement/articulation means
• 242 first/proximal end of actuator (e.g., winding)
• 244 second/distal end of actuator (e.g., distal end of push rod)
• 250 power supply
• 260 adjustable bed controller
• 300 mattress (300A: foot end; 300D: head end)
• 305 containment frame
• 310 base
• 320 sidewalls
• 330 endwalls
• 340 foam cells or foam springs
• 400 furniture frame
• 410 furniture frame wall
• D vertical distance
• P pivot axis
• X lateral direction
• Y longitudinal direction
• Z vertical/normal direction
• Θangle of articulation between adjacent sections

Claims

1. An adjustable foundation comprising:

(a) a stationary bed frame;

(b) a mattress support surface comprising (i) a first deck support section comprising a deck support surface defining a first open area therein, and (ii) a second deck support section pivotally attached to the first deck support section; and

(c) a first actuator having (A) a first end mounted to the first deck support section and (B) a second end mounted to the stationary bed frame, wherein: the first actuator is adapted to move the first deck support section between articulated and substantially flat positions relative to the stationary bed frame, and the first end of the first actuator is positioned such that it occupies at least a portion of the first open area at one or more positions of the first deck support section ranging between a fully articulated position and a substantially flat position.

2. The adjustable foundation of claim 1, wherein the first end of the first actuator corresponds to a winding portion of the first actuator, and the second end of the first actuator corresponds to a distal end of a push rod of the first actuator.

3. The adjustable foundation of claim 1, wherein:

the adjustable foundation further comprises a first frame support that supports the first deck support section, and a second frame support that supports the second deck support section;

the first end of the first actuator is mounted to the first deck support section via the first frame support to which the first end of the first actuator is attached;

the first deck support section is pivotally attached to the second deck support section via a pivotable connection between the first frame support and the second frame support; and

the stationary bed frame supports the first frame support and the second frame support.

4. The adjustable foundation of claim 1, wherein the first end of the first actuator is pivotally mounted to the first deck support section, and the second end of the first actuator is pivotally mounted to the stationary bed frame at a vertical position that is below that of the first end when the first deck support section is in a substantially flat position.

5. The adjustable foundation of claim 1, wherein the first deck support section corresponds to a back and head portion of the mattress support surface, and the second deck support section corresponds to a bottom portion of the mattress support surface.

6. The adjustable foundation of claim 1, wherein the first deck support section corresponds to a foot portion of the mattress support surface, and the second deck support section corresponds to a leg portion of the mattress support surface.

7. The adjustable foundation of claim 1, wherein the stationary bed frame comprises:

a lower longitudinal support member extending longitudinally substantially the length of the mattress support surface on both sides of the stationary bed frame;

a lower lateral support member extending laterally between and mounted to the lower longitudinal support member on each side of the stationary bed frame;

an upper longitudinal support member extending longitudinally along both sides of the stationary bed frame and mounted to the lower lateral support member; and

an upper lateral support member extending laterally between and mounted to the upper longitudinal support member on each side of the stationary bed frame.

8. The adjustable foundation of claim 7, wherein:

the second end of the first actuator is mounted to the upper lateral support member of the stationary bed frame; and

the upper lateral support member is positioned vertically below the first deck support section or the second deck support section.

9. The adjustable foundation of claim 7, wherein a vertical distance between an upper edge of the lower longitudinal support member and a bottom longitudinal edge of the mattress support surface ranges from about 5 cm to about 15 cm.

10. The adjustable foundation of claim 1, wherein the stationary bed frame comprises: one or more lift members extending from the stationary bed frame and being adapted for gripping by a user.

11. The adjustable foundation of claim 1, wherein the stationary bed frame comprises: one or more extendable support members outwardly extending from the stationary bed frame and being adapted for mounting within an external furniture frame.

12. The adjustable foundation of claim 11, further comprising:

(d) a furniture frame positioned around at least a portion of the stationary bed frame, wherein the one or more extendable support members are extended outwardly to contact the furniture frame and stabilize the adjustable foundation within the furniture frame.

13. The adjustable foundation of claim 1, wherein the mattress support surface further comprises (iii) a third deck support section pivotally attached to the second deck support section, and (iv) a fourth deck support section pivotally attached to the third deck support section.

14. The adjustable foundation of claim 13, further comprising:

(d) a second actuator having (A) a first end mounted to the third deck support section and (B) a second end mounted to the stationary bed frame, wherein the second actuator is adapted move the third and/or fourth deck support sections between articulated and substantially flat positions relative to the stationary bed frame.

15. The adjustable foundation of claim 13, further comprising:

(d) a second actuator having (A) a first end mounted to the fourth deck support section and (B) a second end mounted to the stationary bed frame, wherein the second actuator is adapted move the third and/or fourth deck support sections between articulated and substantially flat positions relative to the stationary bed frame.

16. The adjustable foundation of claim 1, further comprising:

(d) a mattress positioned above the mattress support surface.

17. The adjustable foundation of claim 1, wherein:

the stationary bed frame comprises an upper longitudinal support member extending longitudinally along both sides of the stationary bed frame, the upper longitudinal support comprising (i) a fixed bottom portion extending longitudinally along both sides of the stationary bed frame and (ii) a top portion extending longitudinally along both sides of the stationary bed frame which is slidably mounted to the fixed bottom portion;

the mattress support surface is mounted to the top portion;

the top portion is adapted to slide longitudinally towards a head end of the stationary bed frame when the first deck support section is articulated away from the substantially flat position; and

the top portion is adapted to slide longitudinally away from the head end of the stationary bed frame when the first deck support section is articulated towards the substantially flat position.