US20080052830A1 - Bed foundation with drop-in unit - Google Patents

Abstract

A bed foundation may be retrofitted or otherwise converted in the field to include one or more additional function. In one illustrative embodiment, the bed foundation may be retrofitted or otherwise converted by incorporating a drop-in articulation unit. Such an articulation unit may permit a user to raise and/or lower the head of their bed. In some cases, a second articulation unit may be placed at the foot of a bed foundation to permit the user to independently raise and/or lower the head and the foot of their bed. In other illustrative embodiments, drop-in units may add other functions to existing bed foundations. In some cases, the bed foundation and/or drop-in units may be configured such that it can be easily shipped and assembled in the field by a user.

Description

• This application claims the benefit of U.S. Provisional Application Ser. No. 60/823,940, filed Aug. 30, 2006.
FIELD
• The invention generally relates to beds and more particularly to bed foundations.
BACKGROUND
• Beds that articulate have been widely used in hospitals and other medical facilities for many years. Some bed manufactures have adapted these beds and sold them for home use. Such beds typically allow a user to move a head portion of the bed between a lowered and raised position. In the raised position, the occupant of the bed is in a more sitting position. In some cases, the user is also allowed to move the foot of the bed between a lowered and raised position for increased comfort.
• Such articulating beds are often designed and shipped as articulating beds from the factory, and are not typically convertible from a non-articulating to an articulating bed in the field, or from an articulating bed to a non-articulating bed. Also, the articulating structure of these beds is typically not modular in the sense that individual articulating units cannot be independently selected, purchased and installed, and adapted to only control the articulation of a portion of the bed, such as either the head portion or the foot and/or leg portion of the bed. Instead, the articulating structure of these beds is typically designed into the overall structure of the bed.
• More generally, beds of all kinds are typically delivered to a user with certain pre-designed features. It is often difficult to add or remove functionality at a later date and in the field. What would be desirable, therefore, is bed that can be initially purchased by a user, and if an additional function is desired later, the user may simply purchase one or more drop-in units and relatively easily install them into the existing bed in the field.
SUMMARY
• The following summary is provided to facilitate an understanding of some of the innovative features unique to the present invention and is not intended to be a full description. A full appreciation of the invention can be gained by taking the entire specification, claims, drawings, and abstract as a whole.
• The present invention generally relates to beds and more particularly to bed foundations. In some instances, the present invention provides structural elements that may be employed to convert a flat bed foundation into an adjustable bed foundation using an articulation unit, or from an adjustable bed foundation to a flat bed foundation, as desired. Such an articulation unit may permit a user to raise or lower a portion of a bed, such as a head portion of a bed or a foot and/or leg portion of a bed. In some embodiments, a second articulation unit may be employed, which when used in conjunction with a first articulation unit, may permit the user to independently raise or lower both the head portion of the bed and the foot and/or leg portion of the bed, as desired. In some embodiments, the first and second articulation units may be separate modular units, but his is not required.
• The articulation units may be modular in the sense that each articulating unit may be independently installed into an existing bed foundation in the field, and may only control the articulation of a corresponding portion of the bed, such as either the head portion or the foot and/or leg portion of the bed. This may allow, for example, an existing bed foundation that is already in the field, and that does not have an articulating capability, to be relatively easily retrofitted or converted into an articulating bed having desired characteristics. In some cases, the articulating units may be simply dropped-in to the bed foundation to provide the articulating capability. Likewise, removing the articulating unit may allow a bed with an articulating capability to be relatively easily retrofitted or converted into a non-articulating bed, if desired.
• In some instances, an adjustable bed foundation that is segmented or modularized for easier and less costly shipping may be provided. The articulation units may be sized to permit shipping via common carriers such as U.P.S., FedEx and the like. In some instances, the remaining portions of the adjustable bed foundation may also be configured such that they can be relatively easily broken down into sections that are more easily shippable and then assembled by a user. When so provided, the entire bed foundation, including the drop in articulating unit, may be capable of being shipped relatively inexpensively via common carrier, and then assembled by the user in the field. In addition, and for those that already have an existing bed foundation in the field that does not have an articulating capability, the modular drop-in articulation unit(s) may be ordered and shipped separately, and then installed by the user to convert their existing bed foundation to an articulating bed foundation. Moreover, and in some cases, the entire bed foundation including the drop in articulating unit may be capable of being relatively easily disassembled by the user in the field. This may be useful when, for example, the bed foundation is to be moved for one reason or another.
• More generally, it is contemplated that modular drop-in units may be provided to relatively easily retrofit or otherwise convert an existing bed foundation in the field to include one or more additional functions. In some cases, the bed foundation and/or drop-in units may be configured such that it can be easily shipped and assembled in the field by a user.
BRIEF DESCRIPTION
• The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:
• FIG. 1 is a schematic perspective view of an illustrative but non-limiting example of a bed foundation in accordance with the present invention;
• FIG. 2 is a schematic perspective view of an illustrative but non-limiting example of a bed foundation in accordance with the present invention;
• FIG. 3 is a schematic perspective view of an illustrative but non-limiting example of a bed foundation in accordance with the present invention;
• FIG. 4 is a schematic perspective view of an illustrative but non-limiting example of a bed foundation in accordance with the present invention;
• FIG. 5 is a schematic perspective view of an illustrative but non-limiting example of a bed foundation in accordance with the present invention;
• FIG. 6 is a schematic perspective view of an illustrative but non-limiting example of a bed foundation in accordance with the present invention;
• FIG. 7 is a schematic perspective view of an illustrative but non-limiting example of a bed foundation in accordance with the present invention;
• FIG. 8 is a schematic perspective view of an illustrative but non-limiting example of a bed foundation in accordance with the present invention;
• FIG. 9 is a schematic perspective view of an illustrative but non-limiting example of a bed foundation in accordance with the present invention;
• FIG. 10 is a partially exploded perspective view of another illustrative but non-limiting example of a bed foundation in accordance with the present invention;
• FIG. 11 is a perspective view of the illustrative bed foundation ofFIG. 10 with the head, leg and foot top sections of the platform removed;
• FIG. 12 is a partially exploded perspective view of the illustrative bed foundation ofFIG. 10 with two “drop-in” articulation units;
• FIG. 13 is a perspective view of the bottom of the illustrative bed foundation ofFIG. 12 with the two “drop-in” articulation units installed;
• FIG. 14 is a perspective view of the illustrative bed foundation ofFIG. 13 with the two “drop-in” articulation units partially articulated;
• FIG. 15 is a schematic perspective view of an illustrative but non-limiting example of a bed foundation having a drop-in unit in accordance with the present invention;
• FIG. 16 is a schematic top view of an illustrative but non-limiting example of a drop-in unit, which may be used in conjunction with the bed foundation ofFIG. 15;
• FIG. 17 is a schematic top view of an illustrative but non-limiting example of a drop-in unit, which may be used in conjunction with the bed foundation ofFIG. 15;
• FIG. 18 is a schematic top view of an illustrative but non-limiting example of a drop-in unit, which may be used in conjunction with the bed foundation ofFIG. 15;
• FIG. 19 is a schematic cross-sectional side view of an illustrative but non-limiting example of a drop-in unit, which may be used in conjunction with the bed foundation ofFIG. 15;
• FIG. 20 is a schematic cross-sectional side view of an illustrative but non-limiting example of a drop-in unit, which may be used in conjunction with the bed foundation ofFIG. 15;
• FIG. 21 is a schematic cross-sectional side view of an illustrative but non-limiting example of a drop-in unit, which may be used in conjunction with the bed foundation ofFIG. 15;
• FIG. 22 is a schematic top view of an illustrative but non-limiting example of a drop-in unit, which may be used in conjunction with the bed foundation ofFIG. 15;
• FIG. 23 is a schematic cross-sectional side view of an illustrative but non-limiting example of the drop-in unit ofFIG. 22 taken along line23-23; and
• FIG. 24 is a schematic cross-sectional side view of an illustrative but non-limiting example of a drop-in unit, which may be used in conjunction with the bed foundation ofFIG. 15.
• While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.
DESCRIPTION
• The following description should be read with reference to the drawings, in which like elements in different drawings are numbered in like fashion. The drawings, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of the invention. Although examples of construction, dimensions, and materials are illustrated for the various elements, those skilled in the art will recognize that many of the examples provided have suitable alternatives that may be utilized.
• FIGS. 1 and 2 are schematic perspective views of an illustrative butnon-limiting bed foundation10.Bed foundation10 includes aplatform12 and aframe14. It should be recognized thatbed foundation10 may be configured to support and hold a mattress (not shown). Any suitable mattress may be placed atopbed foundation10. Examples of suitable mattresses include coil spring mattresses, foam mattresses, water beds, air mattresses, etc. In particular instances,bed foundation10 may be configured to support and hold an adjustable air mattress, such as the adjustable air mattresses sold by Select Comfort Corporation, located in Minneapolis, Minn.
• In the illustrated embodiment,platform12 includes threetop sections16,18 and20. In some cases,platform12 may include only one or two sections, or may in some cases include four, five or more sections.Platform12 may be formed of any suitable material. In some cases, one or more ofsections16,18 and/or20 may be injection molded, blow molded or extruded of a lightweight but relatively strong polymer. In some instances, one or more ofsections16,18 and/or20 may be formed of a metal such as steel or aluminum. In other cases, one or more ofsections16,18 and/or20 may be formed of wood. Examples of suitable wood products include plywood, oriented strand board (sometimes referred to as OSB) and particle board.
• In some instances, each oftop sections16,18 and20 may simply rest atopframe14. If desired, one or more oftop sections16,18 and20 may be secured to frame14 using nails, screws, snap or interference fit, or any desired attachment method or technique. In some cases,sections16,18 and20 may be unsecured, relying upon gravity and the weight of the mattress (not illustrated) to holdtop sections16,18 and20 in place.
• In some cases, one or more oftop sections16,18 and20 may include an L-shaped lip or the like that overlaps the outer top edge offrame14. InFIG. 2, for example,section20 can be seen to include ashort edge lip22 and a long edge lip24. While only a singleshort edge lip22 and a single long edge lip24 are visible in this illustration, it will be recognized thatsection20 may, if desired, include a second, opposing short edge lip on the non-visible side of thesection20.Section16 may be similarly configured, although the long edge lip may be on the opposing side.Section18, being positioned betweensection16 andsection20, may include opposing short edge lips but no long edge lips.
• In this, long and short are relative terms that refer to the illustrated embodiment. It will be recognized thatbed foundation10 may be manufactured in differing sizes to accommodate a wide variety of mattress sizes, ranging from twin, long twin, double, queen, king and California king, among others. Depending on the size ofbed foundation10 and the numbers of sections used to formplatform12,section20 may be long and narrow, or may even be close to square.
• In some instances,frame14 may include along side26 and ashort side28. Asbed foundation10 is typically square or rectangular, it will be recognized thatframe14 may include opposinglong sides26 and/or opposing short sides28. In many cases, each of theshort sides28 may have a rectangular shape having a height of perhaps 6 to 12 inches, a thickness of about ½ to about 2 inches, and a length of perhaps about 3 to about 7 feet. The length of eachshort side28 may be determined by the size of mattress thatbed foundation10 is designed to accommodate. These dimensions are only examples.
• In some instances, eachlong side26 may be a single piece having a height of perhaps about 6 to about 12 inches, a thickness of about ½ to about 2 inches, and a length of about 6 to about 8 feet. In some cases, eachlong side26 may be formed of several distinct sections that are short/small enough to be shipped relatively inexpensively, e.g. by UPS at Over-Size Package Category 2 or below. Currently, Over-Size Package Category 2 is defined as the shipped package having a length plus girth greater than 108 inches but not more than 130 inches, and having a weight of less than 70 pounds. The length corresponds to the longest side of the package shipping package, and the girth corresponds to two times the width plus two times the height of the shipping package.
• In the illustrated embodiment,long side26 includessections30,32, and34.Sections30,32 and34 may be individual sections that can be separated for shipping and then rejoined by a homeowner or other users using dowels, pegs, screws, nuts and bolts, or any other attachment method. In some instances, individual sections and/or corners may include complementary dovetail shapes that fit together. If desired, a predrilled hole extending down through the joint may permit a homeowner, for example, to fit a peg into the joint to secure the joint.
• While not expressly illustrated, it is contemplated thatsections30,32 and34 may be hingedly attached to each other. That way,long side26 may be folded together for shipping and then simply straightened out by the homeowner. In some cases, it is contemplated that ashort side28 and along side26 may also be hingedly secured to each other. In some instances, it is possible that theentire frame14 is hinged together.
• Each of the long side(s)26 and the short side(s)28 may be formed of any suitable material. In some cases, one or more of long side(s)26 and the short side(s)28 may be injection molded, blow molded or extruded of a lightweight but relatively strong polymer. In some instances, one or more of long side(s)26 and the short side(s)28 may be formed of a metal such as steel or aluminum. In some cases, one or more of long side(s)26 and the short side(s)28 may be formed of wood. Examples of suitable wood products include plywood and other engineered laminates, oriented strand board (sometimes referred to as OSB) and particle board.
• As can be seen inFIG. 2,frame14 may, if desired, include additional support. In some cases,frame14 may include one, two, three, four ormore cross members36 that may be attached tolong sides26 in any suitable manner. In some instances, thecross members36 may be nailed, screwed or bolted tolong sides26. In some cases, thecross members36 may slide into grooves provided (not illustrated) at appropriate locations along eachlong side26. This may provide a benefit of ensuring that thecross members36 are positioned appropriately. While not explicitly shown, it is contemplated that thecross members36 may be attached toshort sides28, rather than long sides26. It is also contemplated thatvarious cross members36 may be attached toshort sides28 andlong sides26, and/or betweenother cross members36, if desired.
• Thecross members36, if included, may be formed of any suitable material. In some cases, thecross members36 may be injection molded, blow molded or extruded of a lightweight but relatively strong polymer. In some instances, thecross members36 may be formed of a metal such as steel or aluminum. In some cases, on thecross members36 may be formed of wood. Examples of suitable wood products include plywood and other engineered laminates, oriented strand board (sometimes referred to as OSB) and particle board.
• FIGS. 3 through 9 illustrate possible modifications that can, if desired, be made to thebed foundation10. These modifications can include adding one or two articulations units. These articulation units may be added to an existingbed foundation10 in the field. In some cases,bed foundation10 may be constructed to include one or more articulation units directly from the factory. It should be noted that construction details of the bed foundation, aside from elements directly discussed with respect toFIGS. 3 through 9, can be considered as the same or at least substantially the same as that discussed with respect toFIGS. 1 and 2.
• As seen inFIGS. 3 and 4,bed foundation10 is being prepared for insertion of anarticulation unit40.FIG. 5 illustratesarticulation unit40 disposed withinbed foundation10. InFIG. 3,platform section20 has been removed, as well as across member36. In some instances, this can be done by the homeowner in the field. In some cases, depending on the size ofbed foundation10 and the size of thearticulation unit40 to be added, it may be necessary to remove more than one platform section and/or more than onecross member36. It can be seen that removal ofsection20 andcross member36 provides acavity38, defined by thelong sides26 andshort sides28, into which anarticulation unit40 may be inserted.
• FIG. 4 includes a diagrammatic illustration of thearticulation unit40. It can be seen thatarticulation unit40 may be sized to fit intocavity38 previously discussed.Articulation unit40 is shown as abox structure42 having an articulatingtop surface44. The “box” shape ofbox structure42 is merely schematic in nature, and it is contemplated that the shape of articulatingunit40 may have any desired shape or configuration. It will be recognized thatbox structure42 may represent the mechanics necessary to raise and lowertop surface44. These mechanics, such as an electric or pneumatic motor, struts, a controller, a remote control unit, and the like, are generally known and thus are not illustrated in detail herein. An electric motor, if present, may interact directly with the other mechanical elements such as, arms, struts, shafts, braces, etc., via direct gear drive, chain drive, screw drive, or other suitable methods. In some cases, some of the mechanics may be placed or extend into the cavity underplatform section18, if desired. When the articulatingunit40 includes a remote control for allowing an occupant to control the articulating unit from, for example the bed, it is contemplated that the remote control may include a memory function, whereby the user may store one or more articulated positions of the articulating unit. Subsequently, the user may press one or more buttons on the remote control to return the articulating unit to a selected stored articulated position.
• In some cases, if desired,box structure42 may be sized to simply sit on the floor withincavity38. In other instances, such as in the illustrated embodiment,box structure42 may includehooks46 that are secured to the side ofbox structure42 and that are configured to interact withframe14 to hang thearticulation unit40 from theframe14.Hooks46 may be formed of any suitably strong material, including metals such as steel, plastic or any other suitable material, as desired. In some cases,frame14 may include grooves or indentations (not shown) to accommodate a thickness of thehooks46 so thattop surface44 may lie flush with or below theplatform12 whenarticulation unit40 is in a fully down position.
• Top surface44 may be formed of any suitable material, such as those discussed previously with respect toplatform12. As will be understood,articulation unit40 may include one or more arms that are driven via a motor or other motive force to move between a horizontal or substantially horizontal position corresponding totop surface44 being aligned withplatform12 and an angled or tilted position corresponding totop surface44 being disposed at an acute angle with respect toplatform12. In other instances, it is contemplated thatarticulation unit40 may include other apparatus for raising and loweringtop surface44, such as hydraulic cylinders and the like.
• FIG. 6 is an illustrative but non-limiting schematic perspective view ofbed foundation10aincluding anarticulation unit40a.Articulation unit40aincludes, similar to before, abox structure42 that schematically represents the articulation hardware, and may include hooks46.Articulation unit40aalso includes, as illustrated, a pair of articulatingarms48. The pair ofarms48 may be moved in any suitable manner, such as by electric motor, hydraulics, etc.
• In some cases, top surface44 (seeFIG. 4) may be formed fromplatform section20, as illustrated inFIG. 6.Platform20 may be secured toarms48 viaattachments50. In some instances,attachments50 may be screws or bolts, as desired. In some cases,attachments50 may represent rivets, adhesives or any other attachment mechanism. By utilizingplatform section20 as the top surface ofarticulation unit40a,platform section20 may be recycled, rather than being thrown away when thearticulation unit40ais installed. Moreover,articulation unit40amay have a lighter weight (absent the top surface), which may provide savings particularly in shipping expenses. Another possible advantage is that the top surface ofarticulation unit40amay visibly matchsections16 and18 ofplatform12. This may provide aesthetic advantages, particularly if part ofplatform12 is visible even with a mattress disposed thereon.
• FIGS. 7 and 8 are illustrating but non-limiting schematic perspective views of abed foundation100 that includes aplatform102 and aframe104. Except as described herein,platform102 may be essentially the same in construction, assembly and materials asplatform12. Likewise,frame104 may be essentially the same in construction, assembly and materials asframe14. Whileframe104 is illustrated as having single pieceshort sides106 and single piece long sides108, it is considered that theshort sides106 and/or thelong sides108 may be formed of multiple sections as discussed with respect to frame14.
• As illustrated,platform102 includessections110,112,114 and116. It is contemplated thatplatform102 could include fewer sections, or in some instances could include more than four sections. In some instances,section110 andsection112 may be hingedly secured to each other. In other cases,section110 andsection112 may be a single integral section (not illustrated).
• As best seen inFIG. 8,bed foundation100 may include afirst articulation unit118 that may be considered as being disposed at a foot end ofbed foundation100, and asecond articulation unit120 that may be considered as being disposed at a head end ofbed foundation100. Thus,bed foundation100, with first and second articulation units installed, permits a user to independently raise the foot end or portion and/or the head end or portion of the bed to an articulated position.
• For the most part, each offirst articulation unit118 andsecond articulation unit120 may be constructed similarly toarticulation units40 and/or40adiscussed above. Each offirst articulation unit118 andsecond articulation unit120 may be constructed such that they may be retrofitted or “dropped into” an existing bed foundation simply by removing relevant portions ofplatform102 and perhaps one ormore cross members122, if present.
• As shown,first articulation unit118 is shown having abox structure142 that schematically represents the mechanics necessary to raise andlower platform sections110 and112. These mechanics, such as an electric motor, a controller and the like, are generally known and thus are not illustrated in detail herein. It will be recognized thatplatform sections110 and112 may represent original platform sections that have been recycled by attaching them to arms or a plate (not visible) offirst articulation unit118. In some cases,platform sections110 and112 may represent new top surfaces that are sold and shipped withfirst articulation unit118.
• Likewise,second articulation unit120 is shown having abox structure145 that schematically represents the mechanics necessary to raise andlower platform section116. These mechanics, such as an electric motor, a controller and the like, are generally known and thus are not illustrated in detail herein. It will be recognized thatplatform section116 may represent an original platform section that has been recycled by attaching it to arms or a plate (not visible) ofsecond articulation unit120. In some cases,platform section116 may represent a new top surface that is sold and shipped withsecond articulation unit120.
• FIG. 9 is an illustrative but non-limiting schematic perspective view of abed foundation200 that includes aplatform202 and aframe204. Except as described herein,platform202 may be essentially the same in construction, assembly and materials asplatform12. Likewise,frame204 may be essentially the same in construction, assembly and materials asframe14. Whileframe204 is illustrated as having single pieceshort sides206 and single piece long sides208, it is considered that theshort sides206 and/or thelong sides208 may be formed of multiple sections as discussed with respect to frame14.
• In some instances,platform202 may include afirst section210 and asecond section212 that may fit ontoframe204 in a manner similar to that discussed with respect toplatform12. In the illustrative embodiment, anarticulation unit240 can be “dropped into”cavity238, which is defined byframe204, in a manner similar to that discussed previously. Theillustrative articulation unit240 includes abox structure242 that schematically represents the articulation mechanism. In some cases, thebox structure242 may includehooks46 that may be adapted to hang thearticulation unit240 from theframe204. In other cases, thebox structure242 may be secured relative to theframe204 via one ormore support elements216, which may be near or undersecond section212. Theillustrative articulation unit240 includes atop surface244 that may be moved between a horizontal or substantially horizontal position to a position at whichtop surface244 is at an acute angle with respect toplatform202.
• Platform section212 may includestructure214 that generically represents at least a portion of the machinery needed to raise and lowertop surface244 ofarticulation unit240. In some instances,structure214 may include one ormore support elements216, which may represent hinges, actuating bars moved by a motor or other motive force (not illustrated), or any other machinery that may be used to interact witharticulation unit240 to holdarticulation unit240 in place and/or movetop surface244.
• In one case, supportelements216 may include mounting bars that securely attached toarticulation unit240 and helpsecure articulation unit240 to frame204. In other cases, and as further described below,support elements216 may include hinge mounts that attached toarticulation unit240 to helpsecure articulation unit240 to frame204, yet allow thearticulation unit240 to articulate relative to theframe204. It is contemplated thatstructure214 may include one or more actuators that extend between a motor, which in some cases may be located insecond section212, and mechanics withinarticulation unit240.
• It is contemplated that an existing flat bed foundation may be retrofitted into an adjustable or articulating bed foundation by removing relevant portions ofplatform202 and/orframe204, and installing inplatform section212 some or all of the machinery discussed above, and “dropping in” anarticulation unit240 and securing corresponding elements of thearticulation unit240 to corresponding elements ofstructure214. In some cases, it is contemplated that a bed foundation may be sold already including at least some of the elements ofstructure214 insection212, but this is not required or even desired in some embodiments. If at some point in the future a user wishes to convert their bed into an adjustable bed, they may only need to purchase and install thearticulation unit240, and possible some of the elements ofstructure214. By including some of the mechanics withinsection212, thearticulation unit240 may be produced less expensively and may have a lower shipping cost and/or weight, but this is not required.
• FIG. 10 is a partially exploded perspective view of another illustrative but non-limiting example of abed foundation300 in accordance with the present invention. Theillustrative bed foundation300 includes aplatform302 and abed frame304. As inFIG. 1, it should be recognized thatbed foundation300 may be configured to support and hold a mattress (not shown). Any suitable mattress may be placed atopbed foundation300. Examples of suitable mattresses include coil spring mattresses, foam mattresses, water beds, air mattresses, etc. In particular instances,bed foundation300 may be configured to support and hold an adjustable air mattress, such as the adjustable air mattresses sold by Select Comfort Corporation, located in Minneapolis, Minn.
• In the illustrated embodiment ofFIG. 10,platform302 includes foursections306,308,310 and312.Section306 may be referred to as the head section,section308 maybe referred to as the center section,section310 may be referred to as the leg section, andsection312 may be considered the foot section. In some cases,platform302 may include only one or two sections, or may in some cases include four, five or more sections, depending on the application.
• It is contemplated thatplatform302 may be formed of any suitable material. In some cases, one or more of thesections306,308,310 and/or312 may include an injection molded, blow molded or extruded portion of a lightweight but relatively strong polymer. In other instances, one or more ofsections306,308,310 and/or312 may include a metal such as steel or aluminum. In other cases, one or more ofsections306,308,310 and/or312 may include wood. Examples of suitable wood products include plywood, oriented strand board (sometimes referred to as OSB) and particle board.
• In some instances, each ofsections306,308,310 and312 may include a relatively planar member that simply rest atopframe304. If desired, one or more ofsections306,308,310 and312 may be secured to frame304 using nails, screws, snap or an interference fit, or any other desired attachment method or technique. In some cases,sections306,308,310 and312 may be unsecured, relying upon gravity and the weight of the mattress (not illustrated) to holdsections306,308,310 and312 in place relatively to frame304.
• In some cases, one or more ofsections306,308,310 and312 may include an L-shaped lip (as discussed above), a bracket, or some other structure that is adapted to overlap the outer top edge offrame304. InFIG. 10, for example,center section308 can be seen to include a number ofbrackets314 that extend over the top edge offrame304. Similar brackets may be provided on the opposing side ofcenter section308, if desired. It is contemplated thatsuch brackets314 may serve to hold thecenter section308 in place relative to theframe304, and also provide support and rigidity to theframe304. While the use ofbrackets314 is shown inFIG. 10 for thecenter section308, it is contemplated that thecenter section308 may be secured relative to theframe304 in any suitable manner, including through the use of bolts, screws, pins, adhesives, and/or any other suitable attachment mechanism.
• In some instances,frame304 may include along side320 and ashort side322. As abed foundation304 is typically square or rectangular, it will be recognized thatframe304 may include opposinglong sides320 and/or opposingshort sides322. In many cases, each of theshort sides322 may have a rectangular shape having a height of perhaps 6 to 12 inches, a thickness of about ½ to about 2 inches, and a length of perhaps about 3 to about 7 feet. The length of eachshort side322 may be determined by the size of mattress thatbed foundation304 is designed to accommodate. These dimensions are only examples.
• In some instances, eachlong side320 may be a single piece having a height of perhaps about 6 to about 12 inches, a thickness of about ½ to about 2 inches, and a length of about 6 to about 8 feet. In some cases, eachlong side320 may be formed of several distinct sections that are short/small enough to be shipped relatively inexpensively, e.g. by UPS at Over-Size Package Category 2 or below. Currently, Over-Size Package Category 2 is defined as the shipped package having a length plus girth greater than 108 inches but not more than 130 inches, and having a weight of less than 70 pounds. The length corresponds to the longest side of the package shipping package, and the girth corresponds to two times the width plus two times the height of the shipping package.
• In the illustrated embodiment ofFIG. 10,long sides320 include twosections320aand320b.Sections320aand320bmay be individual sections that can be separated for shipping and then rejoined by a homeowner or other user using dowels, pegs, screws, nuts and bolts, or any other attachment mechanism. InFIG. 10,sections320aand320bare jointed at a joint326 via complementary dovetail shapes that fit together. If desired, a predrilled hole extending down through the joint may permit a homeowner, for example, to fit a peg into the joint to secure the joint. Corner pieces, such ascorner pieces328, may be used to secure thelong sides320 to theshort sides322, as shown.
• While not expressly illustrated, it is contemplated thatsections320aand320bmay be hingedly attached to each other. When so provided,long sides320 may be folded together for shipping and then simply straightened out by the homeowner. In some cases, it is contemplated that theshort sides322 and thelong sides320 may also be hingedly secured to each other. In some instances, it is possible that theentire frame14 is hinged together.
• Each of the long side(s)320 and the short side(s)322 may be formed of any suitable material. In some cases, one or more of long side(s)320 and the short side(s)322 are injection molded, blow molded or extruded of a lightweight but relatively strong polymer. In some instances, one or more of long side(s)320 and short side(s)322 may be formed of a metal such as steel or aluminum. In other cases, one or more of long side(s)320 and the short side(s)322 may be formed of wood. Examples of suitable wood products include plywood and other engineered laminates, oriented strand board (sometimes referred to as OSB) and particle board.
• Frame304 may, if desired, include additional support. In some cases, and as shown inFIG. 10,frame304 may include one, two, three, four or more cross members that may be attached between theshort sides322 and thecenter section308. InFIG. 10, afirst cross member330ais secured between thecenter section308 and one of theshort sides322, and asecond cross member330bis secured between thecenter section308 and the opposingshort side322. Thecross members330aand330bmay provide additional structural support to theframe304. In some instances, thecross members330aand330bmay be nailed, screwed or bolted to the correspondingshort sides322. Alternatively, or in addition, thecross members330aand330bmay be slid into grooves provided (not illustrated) at appropriate locations along each of the correspondingshort sides322. This may provide a benefit of ensuring that thecross members36 are positioned appropriately. In some cases, thecross members330aand330bmay include hooks that extend over the top of the correspondingshort sides322. As best show inFIG. 13, the other ends of thecross members330aand330bmay be secured to one ormore brackets350aand350bofcenter section308.
• Thecross members330aand330b, if included, may be formed of any suitable material. In some cases, thecross members330aand330bmay be injection molded, blow molded or extruded of a lightweight but relatively strong polymer. In other instances, thecross members330aand330bmay be formed of a metal such as steel or aluminum. In yet other cases, thecross members330aand330bmay be formed of wood. Examples of suitable wood products include plywood and other engineered laminates, oriented strand board (sometimes referred to as OSB) and particle board.
• InFIG. 10, thehead section306,leg section310 andfoot section312 of theplatform302 are shown elevated above theframe304 for illustrative purposes only. During actual use, thehead section306, theleg section310 and thefoot section312 are supported by theframe304 to provide a stable non-articulating bed foundation for a mattress.
• FIG. 11 is a perspective view of the illustrative bed foundation ofFIG. 10 with thehead section306,leg section310 andfoot section312 of theplatform302 removed completely. As can be seen, thelong sides320 and theshort sides322 of theframe304 define acavity338. Thecavity338 may be adapted to accommodate one or more “drop in” articulation units, as further described below.
• As can best be seen inFIG. 11 andFIG. 13, thecenter section308 may include asupport frame340 that extends between theshort sides322 of theframe304. In the illustrative embodiment, andsupport frame340 of thecenter section308 may include one or more hinge brackets. For example, three spaced hinge brackets342a-342care shown facing the foot end of the bed. Likewise, three spaced hinge brackets344a-344care shown facing the head end of the bed. Hinge brackets342a-342cand344a-344cmay be included and sold along with non-articulating bed units. The hinge brackets342a-342cand344a-344cmay serve no functional purpose unless or until a corresponding “drop in” articulation unit is subsequently obtained and installed in the field, as further described below.
• As best shown inFIG. 13, thecenter section308 may also include one or more brackets, such asbrackets350aand350b. Thecross members330aand330bmay be coupled tobrackets350aand350bofcenter section308. In some instances, thebrackets350aand350bmay be positioned such that thecross members330aand330bare located within thecavity338 sufficiently far below the top of theframe304 so that an articulation unit can be placed above. When so provided, thecross members330aand330bmay remain in place after one or more articulation units installed, and still provide structural support to theframe304.
• FIG. 12 is a partially exploded perspective view of the illustrative bed foundation ofFIG. 10 with two “drop-in” articulation units. While two “drop in” articulation unit are shown inFIG. 12, it is contemplated that only one of the “drop in” articulation units may be provided and used in the field, depending on the desires of the user.
• To convert thenon-articulating bed foundation300 ofFIG. 10 into an articulating bed foundation, it is contemplated that the one or more “drop in” articulation units may be provided. In one illustrative embodiment, the “drop in” articulation units may be of a size and/or weight that can be shipped relatively inexpensively, e.g. by UPS at Over-Size Package Category 2 or below. As such, a bed foundation, such as that shown inFIG. 10, may be initially purchased by a user, and then if an articulation function is desired later, the user may simply purchase the one or more articulation units and install them into the existing bed foundation in the field. In some cases, the one or more articulation units may be shipped to the user relatively inexpensively, e.g. by UPS at Over-Size Package Category 2 or below, and may be relatively easy to install such that a user can create an articulating bed foundation from a non-articulating bed foundation.
• In the illustrative embodiment ofFIG. 12, thehead section306 of the bed ofFIG. 10 may be removed and lifted from theframe304. Next afirst articulation unit360, which may be ordered and shipped to the user, may be installed in thecavity338 of the non-articulating bed foundation. In the illustrative embodiment, thefirst articulation unit360 includes asupport frame362. Thesupport frame362 may include a support structure that is capable of supporting theoriginal head section306 during articulation. That is, in the illustrative embodiment, theoriginal head section306 is reused and secured to the support structure of thesupport frame362 of thearticulation unit360 using screws, bolts, adhesives or any other suitable attachment mechanism.
• Thesupport frame362 of thefirst articulation unit360 may also include one or more spaced hinge brackets364a-364cthat are in registration with and that can be hingedly attached to the spaced hinge brackets344a-344cof thesupport frame340 of thecenter section308. In one illustrative embodiment, each of the spaced hinge brackets364a-364cmay simply include a hole passing though a tubular bar of thesupport frame362. The tubular bars of thesupport frame362 may then be received by U-shaped hinge brackets344a-344cof thecenter section308. Each of the U-shaped hinge brackets344a-344cmay have corresponding holes in the U-arms of the U-shaped hinge brackets344a-344c. A pin or the like may be provided though the holes in the U-arms of each U-shaped hinge bracket344a-344cand through the hole passing though the corresponding tubular bar of thesupport frame362 to form a hinged connection therebetween.
• As shown, thesupport frame362 of thefirst articulation unit360 may also include alever arm370 for connection to a first end of amotor assembly372. Themotor assembly372 may be part of thefirst articulation unit360. As best shown inFIG. 13, the other end of themotor assembly372 may be attached to a motor mount352bon the opposing side of thesupport frame340 of thecenter section308. Themotor assembly372, when activated, may provide a motive force to leverarm370, which may cause thesupport frame362 of thefirst articulation unit360 to rotate about the hinge formed by the hinge brackets364a-364cof the support frame of thefirst articulation unit360 and the brackets344a-344cof thesupport frame340 of thecenter section308.FIG. 14 shows the bed foundation after thefirst articulation unit360 has been actuated to a partially elevated position. By reversing themotor assembly372, thefirst articulation unit360 may lower thehead section306 of the bed foundation to a flat or substantially flat position.
• In some cases, it may be desirable to provide articulation to theleg section310 andfoot section312 of the bed foundation. In the illustrative embodiment ofFIG. 12, theleg section310 and thefoot section312 of the bed ofFIG. 10 may be removed and lifted from theframe304. Next asecond articulation unit390, which may be ordered and shipped to the user, may be installed in thecavity338 of the bed foundation. In the illustrative embodiment, thesecond articulation unit390 includes asupport frame392. Thesupport frame392 may include a support structure that is capable of supporting theoriginal leg section310 andfoot sections312 during articulation. That is, in the illustrative embodiment, theoriginal leg section310 and theoriginal foot section312 are reused and secured to the support structure of thesupport frame392 of thesecond articulation unit390 using screws, bolts, adhesives or any other suitable attachment mechanism.
• Thesupport frame392 of thesecond articulation unit390 may also include one or more spaced hinge brackets394a-394cthat are in registration with and that can be hingedly attached to the spaced hinge brackets342a-342cof thesupport frame340 of thecenter section308. In one illustrative embodiment, each of the spaced hinge brackets394a-394cmay simply include a hole passing though a tubular bar of thesupport frame392. The tubular bars of thesupport frame392 may then be received by U-shaped hinge brackets342a-342cof thecenter section308. Each of the U-shaped hinge brackets342a-342cmay have corresponding holes in the U-arms of the U-shaped hinge brackets342a-342c. A pin or the like may be provided though the holes in the U-arms of each U-shaped hinge bracket342a-342cand through the hole passing though the corresponding tubular bar of thesupport frame392 to form a hinged connection therebetween.
• As shown, thesupport frame392 of thefirst articulation unit360 may also include alever arm400 for connection to a first end of anothermotor assembly402. Themotor assembly402 may be part of thesecond articulation unit390. As best shown inFIG. 13, the other end of themotor assembly402 may be attached to amotor mount352a on the opposing side of thesupport frame340 of thecenter section308. Themotor assembly402, when activated, may provide a motive force to leverarm400, which may cause thesupport frame392 of thesecond articulation unit390 to rotate about the hinge formed by the hinge brackets394a-394cof the support frame of thesecond articulation unit360 and the brackets342a-342cof thesupport frame340 of thecenter section308.FIG. 14 shows the bed foundation after thesecond articulation unit390 has been actuated to a partially elevated position. By reversing themotor assembly402, thesecond articulation unit390 may lower theleg section310 andfoot section312 of the bed foundation to a flat or substantially flat position.
• As can be seen, thearticulation units360 and390 may be modular in the sense that each articulating unit may be independently installed into an existing bed foundation in the field, and may only control the articulation of a corresponding portion of the bed, such as either the head portion or the foot and/or leg portion of the bed. This may allow, for example, an existing bed foundation that is already in the field, and that does not have an articulating capability, to be relatively easily retrofitted or converted into an articulating bed having desired characteristics. In some cases, the articulatingunits360 and390 may simply be dropped-in to the bed foundation to provide the desired articulating capability.
• It is contemplated that one or more other functions may be added to a bed foundation that are in addition to, or in place of, the articulation capability discussed above. In some cases, this may allow, for example, an existing bed foundation that is already in the field, and that does not have one or more desired functions, to be relatively easily retrofitted or converted into a bed foundation that does provide the desired functions. Like the drop-in articulating units discussed above, these one or more other functions may, in some cases, be provided by a drop-in unit that may be separately selected, ordered and then dropped into an existing bed foundation.
• FIG. 15 is a schematic perspective view of an illustrative but non-limiting example of a drop-inunit400 that may add one or more desired functions to an existingbed foundation402. Thebed foundation402 shown inFIG. 15 is similar to that shown and described with respect toFIG. 4 above. As seen inFIGS. 15,bed foundation402 is first prepared for insertion of the drop-inunit400, and then the drop-inunit400 is dropped into at least part of the void orcavity404 formed by the side walls of thebed foundation402. In some instances, this can be done by the homeowner in the field. In some cases, and depending on the size ofbed foundation402 and the size of the drop-inunit400 to be added, it may be necessary to remove more than one platform section and/or one or more cross members, as described above.
• The drop-inunit400 may provide one or more desired functions that the existingbed foundation402 currently does not yet provide. For example, the drop-inunit400 may provide one or more of articulation (as described above), heating, cooling, massage, magnetic therapy, adjustable lumbar support, sound, light, aromatherapy, air purifier/filtration, fold-out tray/table capability, on-board bed controls, on board TV and other controls, TV-A/V-phone connections and/or mounts, air pump holder for air beds, storage, as well as any other suitable function or functions, as desired.
• In some cases, if desired, drop-inunit400 may be sized to simply sit on the floor withincavity404. In other instances, such as in the illustrated embodiment shown inFIG. 15, drop-inunit400 may includehooks406 or the like that are configured to interact with the side walls of thebed foundation402 to hang the drop-inunit400 from the side walls of thebed foundation402. The illustrative hooks46 may be formed of any suitably strong material, including metals such as steel, plastic or any other suitable material, as desired. In some cases, the side walls of thebed foundation402 may include grooves or indentations (not shown) to accommodate a thickness of thehooks406 so that atop surface408 may lie flush with, above, or below the top of the side walls of thebed foundation402 as desired. In some cases, the drop-inunit400 may include a laterally extending portion that extend laterally out past the side walls of thebed foundation402, and may sit in a recess formed in the top side of the side walls of thebed foundation402. More generally, it is contemplated that the drop-inunit400 may be secured to thebed foundation402 in any suitable manner, including screws, bolts, adhesives or any other suitable connector.
• FIG. 16 is a schematic top view of an illustrative but non-limiting example of a drop-inunit400a, which may be used in conjunction with thebed foundation402 ofFIG. 15. InFIG. 16, the drop-inunit400aincludes atop surface410 that is adapted to support a mattress. A number ofsensors412, indicated by a “+” sign may be provided. Thesensors412 may be any type of sensors including, for example, pressure sensors, strain sensors, temperature sensors, vibration sensors, sound sensors, humidity sensors, gas and/or particulate matter sensors, or any other suitable sensor for sensing any suitable parameter(s). It is contemplated that thesensors412 may all be of a single sensor type, or may include multiple sensor types, depending on the application. Although not explicitly shown nFIG. 16, it is contemplated that one or more of the sensor(s)412 may be positioned to sense ambient conditions at or near thebed foundation402, rather than conditions under the mattress. Example ambient conditions may include, for example, temperature, humidity, sound, gas and/or particulate matter concentrations, and/or any other suitable condition or parameter, as desired.
• Acontroller414 may be coupled to and receive signals from thesensors412. Using the outputs from the sensors, thecontroller414 may detect, for example, if an occupant of the bed is uncomfortable. For example, if pressure or strain sensors are provided under the mattress, movement of the occupant may be detected by noting changes in pressure or strain over time, which can correspond to movement and thus discomfort of the occupant in the bed. Once detected, thecontroller414 may take corrective action, such as activate or make adjustments to one or more functions of the bed foundation (e.g. articulate, massage, vibration, alarm, and/or any other function, some or all of which might be provided by the drop-inunit400a), and/or the mattress (e.g. change the air pressure in an air mattress), as desired.
• In another example, sound sensors may detect noise, which through signal processing viacontroller414, may detect movement and thus discomfort of the occupant in the bed. In some cases, it is contemplated that signal processing techniques may be used to detect different noises and classify them into different categories. Such signal processing techniques are known. One illustrative signal processing technique is shown and described in U.S. Pat. No. 5,956,463 to Patrick et al. In one example, thecontroller414 may use such signal processing techniques to classify detected noises among, for example, an occupant discomfort category, an occupant snoring category, an occupant sleep apnea event category, and/or any other desired category or categories as desired. Depending on the identified category or categories, thecontroller414 may take appropriate corrective action, such as activating or making adjustments to certain functions of the bed foundation (e.g. articulate, massage, vibration, alarm, and/or any other function, some or all of which might be provided by the drop-inunit400a) and/or the mattress (e.g. change the air pressure in an air mattress), as desired. In some cases, thecontroller414 may record the detected event(s), and report the event(s) to the user of the bed at a later time.
• In yet another example, thesensors412 may include one or more temperature sensors. When so provided, thecontroller414 may be programmed to function as a thermostat, and may active a heating and/or cooling feature. In some cases, the drop-inunit400amay include a heating and/or cooling pad, which when activated, may heat and/or cool the mattress and thus the occupant of the bed. In some cases, the occupant of the bed may provide a desired temperature set point to thecontroller414 to control the temperature of the bed.
• In yet another example, a gas sensor may sense the concentration of a gas (e.g. CO₂) in or around the bed. If the gas concentration exceeds some threshold, thecontroller414 may be programmed to activate a fan, a ventilation system of the occupant's house, or turn on an air purifier or the like. The above examples are only illustrative of the types of conditions that can be detected by thesensors412, and some illustrative corrective actions that may be taken by thecontroller414.
• FIG. 17 is a schematic top view of an illustrative but non-limiting example of a drop-inunit400b, which may be used in conjunction with thebed foundation402 ofFIG. 15. The drop-inunit400bincludes a number ofmassage elements420. In some cases, themassage elements420 may vibrate or otherwise move to provide a massage sensation to the occupant of the bed. Acontroller422 may be used to control the massage elements.
• In some cases, themassage elements420 may be constructed to provide a “shiatsu-type” massage. In such cases, some or all of themassage elements420 may be formed as balls, fingers, and/or any other suitable structure to help produce the massage sensation. In some cases, each of themassage elements420 may be moved in a pattern by a motor or the like to produce the overall massage sensation. Alternatively, or in addition, one or more of themassage elements420 may produce an acoustical wave of a certain frequency or frequency pattern over time to produce an acoustical massage, if desired.
• In some cases, and rather than providingmassage elements420 or in addition to providing massage elements, a number of magnets may be provided. In some cases, the magnets may be permanent magnets, and may be positioned to provide a desired magnet therapy to the occupant(s) of the bed. In other cases, the magnets may be electromagnets. The polarity, strength and/or frequency of the magnetic fields produced by the electromagnets may be controlled bycontroller422 to provide a desired magnetic therapy.
• FIG. 18 is a schematic top view of an illustrative but non-limiting example of a drop-inunit400c, which may be used in conjunction with thebed foundation402 ofFIG. 15. In the illustrative embodiment, the drop-inunit400cincludes alumbar support430. The lumbar support may be controlled by acontroller432. In some cases, thelumbar support430 may include, for example, a leftlumbar support430aand a rightlumbar support430b, both of which are adjustable. The leftlumbar support430amay provide an adjustable lumbar support for a first occupant of the bed, and the rightlumbar support430bmay provide an adjustable lumbar support for a second occupant of the bed. Although not required, the use oflumbar support430 may be particularly useful when the drop-inunit400calso includes an articulation capability. When so provided, thelumbar support430 may provide increased comfort when, for example, the drop-inunit400craises the head of the bed in an upright position for reading. This, however, is just one example.
• FIG. 19 is a schematic cross-sectional side view of an illustrative but non-limiting example of a drop-inunit400d, which may be used in conjunction with thebed foundation402 ofFIG. 15. In the illustrative embodiment, the drop-inunit400dmay include a heating and/orcooling pad440, which when activated, may heat and/or cool the mattress and thus the occupant of the bed. The heating and/orcooling pad440 may be controlled by a controller (not explicitly shown inFIG. 19).
• In some cases, the controller may be programmed to function as a thermostat, and may active the heating and/orcooling pad440. In some cases, one or more sensors may be provided to sense the temperature of the mattress and/or the temperature of the ambient air near the bed. When so provided, the occupant of the bed may provide a desired temperature set point to the controller to control the temperature of the bed via the heating and/orcooling pad440.
• FIG. 20 is a schematic cross-sectional side view of an illustrative but non-limiting example of a drop-inunit400e, which may be used in conjunction with thebed foundation402 ofFIG. 15. In this illustrative embodiment, the drop-inunit400eincludes apump storage module450 to store one or more pumps, such as air pumps forair mattresses452aand452b. Theair mattresses452aand452bmay be supported by a top surface of the drop-inunit400e, as shown. Themodule450 may, in some cases, include sound and/or vibration insulation to help reduce the noise and/or vibration produced by the air pumps to increase the comfort of the occupants of the bed. In some cases, the drop-inunit400emay include integrated tubing, such asintegrated tubing454aand454b, which can be used to help deliver pressurized air between the air pumps and theair mattresses452aand452b. This may help reduce and/or eliminate the length of separate tubing that is required.
• FIG. 21 is a schematic cross-sectional side view of an illustrative but non-limiting example of a drop-inunit400f, which may be used in conjunction with thebed foundation402 ofFIG. 15. In this illustrative embodiment, the drop-inunit400fprovides built-indrawers460aand460b, cabinets, and/or lock boxes that can provide the consumer with desirable storage locations for clothes, valuables, and other items within thecavity404 formed by the side walls of thebed foundation402. In the illustrative embodiment, thedrawers460aand460bextend through the side walls of thebed foundation402. In some cases, the existing side walls of thebed foundation402 can include removable sections that can be removed by the user prior to installing the drop-inunit400fto accommodate thedrawers460aand460b. In other cases, new side walls may be provide along with the drop-inunit400fthat include openings to receive thedrawers460aand460b.
• FIG. 22 is a schematic top view of an illustrative but non-limiting example of a drop-inunit400g, which may be used in conjunction with thebed foundation402 ofFIG. 15. The illustrative drop-inunit400gis used to show a variety of functions that may be added to a bed foundation. As shown inFIG. 22, the drop-inunit400gmay include one ormore speakers470aand470b. Thespeakers470aand470bmay be used to play music or other audio, sound an alarm, create white noise to counter or drown out background noise, and/or produce any other suitable sound, as desired.
• The drop-inunit400gmay include a number of features generally shown at472aand472b. These may include, for example, an integrated MP3 docking station to receive an MP3 player, connections or mounts for a TV, a phone, other AN connections, and/or one or more remote controls, etc., as desired. In some cases, the drop-inunit400gmay include hardwired remote controls to give a more streamlined look to the bed.
• In some cases, the drop-inunit400gmay provide air purification and/or air filtration. One of thefeatures472aand472bmay include an air inlet and an air outlet for an air purification and/or air filtration system that may be incorporated into the drop-inunit400g. In one illustrative embodiment, cleaned air may be provided from anair outlet472aalong the left side of the bed, and dirty air may be drawn into anair inlet472balong the right side of the bed, creating a pressure differential cross the top of the bed. This pressure differential may help create an envelope of pure, pollutant-free air around the occupant of the bed.
• In some cases, the drop-inunit400gmay provide aromatherapy. One or more of thefeatures472aand472bmay provide a discharge of an aroma into the room that is pleasing to the occupant of the bed. A controller (not shown) may be used to allow, for example, continuous or manual control of the aromatherapy.
• FIG. 23 is a schematic cross-sectional side view of an illustrative but non-limiting example of the drop-in unit ofFIG. 22 taken along line23-23. As can be seen inFIG. 23, the drop-inunit400gmay include lights, such as underbed lights476aand476b. Under bed lighting may provide safer movement around the bed at night, or may provide mood lighting to enhance the bedroom environment. In some cases, the drop-inunit400gmay also include a motion sensor to detect when an occupant of the bed gets out of bed at night, and in response, a controller may turn on theunder bed lights476aand476b, if desired.
• Whilelights476aand476bprovide under bed lighting, it is contemplated that the drop-inunit400gmay provide other lighting. For example, the drop-inunit400gmay include one or more retractable or directional light sources that can be used for reading. In some cases, the drop-inunit400gmay interface with the lighting controls for the bed room. This may allow the occupant and/or a controller of the drop-inunit400gto turn the lights of the room on and/or off. In some cases, a controller of the drop-inunit400gmay turn the lights in the room “on” at a programmed time in the morning to function as a “sunrise” type waking alarm.
• InFIG. 23, part of the drop-inunit400gextends laterally out past the side walls of thebed foundation22. In some cases, one or more recesses in the top of the side walls may allow that laterally extending portion of the drop-inunit400gto extend laterally out past the side walls of the bed foundation. Although not shown in the schematic diagram ofFIG. 23, it is contemplated that the part of the drop-inunit400gthat extends laterally out past the side walls of thebed foundation402 may extend in an upward direction to provide easier user access to functions and/or controls provided by the drop-in unit.
• FIG. 24 is a schematic cross-sectional side view of an illustrative but non-limiting example of a drop-inunit400h, which may be used in conjunction with thebed foundation402 ofFIG. 15. Drop-inunit400hmay include a fold-out tray or table. The fold-out tray or table may provide a surface for working, reading, eating or engaging on other activities. It is contemplated that the fold-out table may swing or slide out from underneath or alongside the bed, or may swing or slide down from the head of the bed. In some cases, the fold-out table may include integrated wiring to for electrical, phone, internet, AV, lighting, etc.
• In the illustrative embodiment ofFIG. 24, the drop-inunit400hmay include a left fold-out table500aand a right fold-out table500b. The left and right fold out tables500aand500bare shown similarly constructed, and both swing or slide out from alongside the bed foundation. As shown inFIG. 24, in the folded away position, the left fold-out table500ahangs down from a pivot502 adjacent to the left side wall of thebed foundation402, and out of the way. To use the left fold-out table500a, the user may simply rotate the left fold-out table500ain an upward direction, and then tilt the table to a horizontal direction, as shown generally at504. In the position shown at504, the long dimension of thetable top506 may extend into the page for a distance. The user may rotate thetable top506 in a horizontal plane, until the long dimension of thetable top506 extends across the bed, and assumes the general configuration shown for the right fold-out table500b. This is just one example of a drop-inunit400hthat may be configured to provide a fold-out tray or table to the occupant of a bed. More generally, it is recognized that any suitable structure may be used to provide a drop-inunit400hthat can provide a fold-out tray or table to the occupant of a bed.
• In some cases, special purpose drop-in units that provide one or more of the functions described above, and/or other functions, may be provided to address certain situations, such as medical conditions. For example, a drop-in unit may be provided for addressing sleep apnea. Such a drop-in unit may include one or more sensors to detect an apnea event, and a controller that can take corrective action such as articulating the head of the bed, sounding an alarm to wake the occupant, turn on a massage feature, and/or take some other corrective action. Alternatively, or in addition, such a drop in unit may include a mask for an occupant, and a discretely placed oxygen source within a storage compartment of the drop-in unit.
• In another example, a drop-in unit may be provided for addressing acid reflux. Such a drop-in unit may manually or automatically elevate the head of the occupant and/or perform some other corrective action. In yet another example, a drop-in unit may be provided for addressing pregnancy. Such a drop-in unit may manually or automatically elevate the head and/or foot of the bed, provide heating and/or cooling on demand or automatically, and/or perform some other corrective action.
• In some cases, a drop-in unit may be provided that includes a formed top surface, rather than a simple flat surface. Such a formed top surface may provide additional comfort and benefit to the occupant(s) of the bed. The formed top surface may include, for example, an elevated or depressed portion at a location that corresponds to the pillow location on the bed. In another example, an integrated lumbar support may be provided in the formed top surface. It is contemplated that the formed top surface may have any desired topology, and in some cases, may be customized or fit to the body of a particular occupant, if desired.
• In some cases, a drop-in unit may include a lifting or other capability. While an articulating head portion of the bed may help some individuals get out of bed, other degrees or motion may be added to allow for elderly or handicapped individuals to more easily get in/out of the bed. For example, a drop-in unit may be provided that articulates the head area about a rotational axis, but also moves the head area of the bed in an up and down direction. In another example, a drop-in unit may be provided that moves the hip area of the bed up and down. In some cases, a drop-in unit may provide a railing on the side of the bed foundation for additional assistance and support.
• It is contemplated that any number of functions can be selected and incorporated into a drop-in unit. In some cases, the drop-in unit may be shipped to a user in the field, and installed by the user. Such drop-in units may allow an existing bed foundation that is already in the field, to be relatively easily retrofitted or converted into bed that has the selected function(s) of the drop-in unit.
• The invention should not be considered limited to the particular examples described above, but rather should be understood to cover all aspects of the invention as set out in the attached claims. Various modifications, equivalent processes, as well as numerous structures to which the invention can be applicable will be readily apparent to those of skill in the art upon review of the instant specification.

Claims (25)

1. A method of converting a flat bed foundation located at a customer site, wherein the bed foundation includes side walls that define a cavity, the side walls supporting a platform, and the platform adapted to support a bed mattress, the method comprising:

removing a portion of the platform; and

installing an articulation unit that is adapted to articulate only a portion of the bed mattress, the articulation unit extending into at least part of the cavity.

2. The method ofclaim 1, wherein the removing step includes removing only a portion of the platform.

3. The method ofclaim 1, further comprising a step of having the articulation unit shipped to the customer site.

4. The method ofclaim 1, further comprising attaching at least part of the removed platform portion to the articulation unit to form a top surface of the articulation unit.

5. The method ofclaim 1 wherein the portion of the platform that is removed corresponds to a head portion of the platform.

6. The method ofclaim 1 wherein the portion of the platform that is removed corresponds to a foot and/or leg portion of the platform.

7. The method ofclaim 1 wherein the articulation unit is a self-contained articulation unit.

8. A bed foundation having at least a head section and a foot section, comprising:

a frame having one or more side walls that define a cavity therebetween;

a platform supported by the frame, the platform having at least a head section and a foot section; and

a drop-in articulation unit that is configured to be dropped into at least part of the cavity defined by the side walls, and once installed, capable of articulating only one of the head section or foot section of the bed foundation.

9. The bed foundation ofclaim 8 wherein the head section of the platform is secured to the drop-in articulation unit, wherein the drop-in articulation unit causes the head section of the platform to be moveable between a horizontal position and an angled position.

10. The bed foundation ofclaim 8 wherein the foot section of the platform is secured to the drop-in articulation unit, wherein the drop-in articulation unit causes the foot section of the platform to be moveable between a horizontal position and an angled position.

11. The bed foundation ofclaim 8 wherein the drop-in articulation unit includes one or more support members that secure the drop-in articulation unit relative to the frame.

12. The bed foundation ofclaim 11 wherein the one or more supports include one or more hooks that extend over one or more of the side walls of the frame.

13. The bed foundation ofclaim 8 further comprising one or more cross-members that extend between opposing side walls of the frame, and wherein the drop-in articulation unit includes a motor that is coupled to one or more of the cross-members.

14. The bed foundation ofclaim 8 further comprising one or more cross-members that extend between opposing side walls of the frame, and wherein the drop-in articulation unit is hinged relative to one or more of the cross-members.

15. A bed foundation comprising:

a frame;

a platform supported by the frame; and

an articulation unit for articulating only a portion of the platform, the articulation unit having the one or more supports that hang the articulation unit from the frame.

16. The bed foundation ofclaim 15, wherein the frame comprises one or more sections that are sized for shipping by UPS at OS2 or below.

17. The bed foundation ofclaim 15, wherein the one or more supports of the articulation unit comprise one or more hooks that interact with the frame to hang the articulation unit from the frame.

18. The bed foundation ofclaim 17, wherein the frame comprises indentations to accommodate the hooks.

19. The bed foundation ofclaim 17, wherein at least one of the platform sections comprises indentations to accommodate the hooks.

20. A method of converting an existing bed foundation located at a customer site, wherein the bed foundation includes side walls that define a cavity, the side walls supporting a platform, and the platform adapted to support a bed mattress, the method comprising:

removing a portion of the platform; and

installing a drop-in unit that is adapted to add at least one function to the bed foundation, the drop-in unit extending into at least part of the cavity.

21. The method ofclaim 20 wherein the at least one function includes one or more of articulation, temperature control, massage, lumbar support, lighting, aromatherapy, air filtration, sound, storage, and magnetic therapy.

22. The method ofclaim 20 wherein the drop-in unit includes one or more sensors with sensor outputs and a controller, wherein the controller is configured to detect the presence of one or more conditions based on the sensor outputs, and in response, take a corrective action.

23. The method ofclaim 22 wherein the corrective action includes articulating the bed.

24. The method ofclaim 22 wherein the corrective action includes activating a heating or cooling element of the bed.

25. A method of converting an existing bed foundation located at a customer site, the platform adapted to support a bed mattress, the method comprising:

removing a portion of the platform; and

installing a drop-in unit that is adapted to add at least one function to the bed foundation, wherein the at least one function includes one or more of lighting, aromatherapy, air filtration, sound, and storage.

Images