MOVING BED ASSEMBLY

Description

RELATED APPLICATIONS

This application is a continuation of U.S. Application No. 18/436,420 filed February 8, 2024, the contents of which are herein incorporated by reference in their entirety.

TECHNICAL FIELD

The present invention relates generally to bed assemblies configured to provide motion for sleep enhancement, and more particularly to moving bed systems having powered drivetrain mechanisms.

BACKGROUND

While the benefits of high quality sleep have been appreciated since ancient times, modern clinical research continues to expand the scope of that understanding. It is now well recognized that sleep quality affects far more than daily alertness. Poor or fragmented sleep has been linked to increased risks of obesity, type 2 diabetes, hypertension, impaired cognitive function, decreased balance, slowed reaction time, and a wide variety of long term health consequences. As a result, there has been growing interest in technologies aimed at improving sleep onset, sleep continuity, and overall sleep quality.

It has been known for generations that gentle, repetitive rocking or side-to-side motion can promote and maintain sleep. Parents have long relied on rhythmic motion to soothe infants, and research suggests that certain types of repetitive motion may benefit sleepers of all ages. Several devices and systems have been proposed to deliver a rocking, oscillating, or reciprocating motion to a bed or mattress in order to replicate these natural soothing effects and improve sleep quality for adult users.

However, despite these potential benefits, motion-capable beds have not achieved wide commercial adoption. One challenge is that a sleeping user is often highly sensitive to abrupt changes in movement. Any sudden perturbation, interruption, or inconsistency in the motion cycle whether due to mechanical irregularities, uneven loading, or drivetrain transitions can be readily perceived by the user and may disrupt the sleep cycle or awaken the user. The difficulty of providing smooth, continuous, repeatable motion without noticeable perturbations has therefore hindered acceptance of motion enabled sleep systems.

Another significant barrier to adoption relates to safety. A bed that includes moving components such as powered actuators, rotating shafts, and articulated linkages introduces potential pinch, crush, and entrapment hazards, particularly in environments where pets, children, or clutter may be present. Motion beds designed for residential use must therefore incorporate robust safety mechanisms that prevent accidental contact with moving machinery and automatically halt motion if an obstruction or unsafe condition is detected. Conventional systems often fail to address these concerns adequately, creating a need for motion bed assemblies that both deliver smooth, continuous motion and incorporate comprehensive safety systems suitable for everyday home environments.

SUMMARY

In view of the foregoing, it is an object of the present invention to provide an improved moving bed assembly. In one aspect, the invention provides a moving bed assembly configured to generate controlled motion of a bed frame relative to a base frame while incorporating integrated safety systems. The assembly includes a base frame, a bed frame arranged above the base frame, and at least first and second pairs of swing arms pivotably connecting the bed frame to the base frame. A drive shaft mounted to the base frame carries cranks at opposite ends, and first and second drive arms extend between the cranks and corresponding ones of the swing arms. A motor drives the drive shaft to impart reciprocating motion to the bed frame. A protective barrier is mounted to the base frame and is positioned to inhibit access to the motor, the drive shaft, or the swing arms. A crush-detection system includes a compressible sensor tube mounted along a perimeter of the bed frame or base frame, the sensor tube containing a light emitter and a light sensor arranged to detect a transmitted light signal during normal operation. Compression of the sensor tube disrupts the detected light signal and causes the motor to be disabled until the obstruction is removed and a reset action is performed.

In various embodiments of the moving bed assembly, the protective barrier includes an electrical interlock configured to disable the motor when the barrier is removed or displaced, and restoration of operation may require re-establishing the interlock and activating a reset input. The compressible sensor tube may be mounted along a perimeter of the bed frame or along a perimeter of the base frame. The motor remains disabled until the light signal is restored and a control circuit is reset. The assembly may further include a shaft brake engaging the drive shaft, and the braking force applied by the shaft brake may be adjustable. A transmission may be provided through which the motor drives the drive shaft, and the rotational axis of the motor may be perpendicular to the rotational axis of the drive shaft. In some embodiments, the bed frame supports an articulated mattress platform.

In another aspect, the invention provides a safety system for a moving bed assembly. The safety system includes a protective barrier mounted to a frame of the bed assembly and an electrical interlock forming part of a safety circuit. A controller is configured to disable the motor of the bed assembly when the safety circuit is interrupted. The protective barrier may be arranged to enclose the motor, the drive shaft, or a swing arm, and the interlock may comprise a plug-and-receptacle connector. Restoration of operation may require closure of the safety circuit followed by activation of a reset input.

In a further aspect, the invention provides a crush-detection system for a moving bed assembly. The system includes a compressible sensor tube mounted along a perimeter of the assembly, a light emitter arranged to transmit a light signal within the tube, and a light sensor arranged to detect the transmitted signal. A control circuit disables the motor when compression of the sensor tube disrupts the light signal. The sensor tube may be formed from a soft elastomeric material, and may be positioned along a perimeter of the bed frame or the perimeter of the base frame. Motor operation may remain disabled until the light signal is restored and the control circuit is reset.

These aspects may be implemented individually or in combination to provide a motion-capable bed platform with enhanced safety, obstruction detection, protection against access to moving components, and improved motion stability and control. In addition, these aspects and advantages of the present invention will be better appreciated in view of the drawings and following detailed description of preferred embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is lower perspective view of a moving bed assembly, according to an embodiment of the present invention;

FIG. 1A is a perspective view of the moving bed assembly illustrating the arrangement of the base frame, bed frame, drive components, and protective barriers positioned around the lower frame to restrict access to internal moving mechanisms;

FIGS. 2 and 3 are upper perspective views of the moving bed assembly of FIG. 1;

FIG. 4 is a top view of the moving bed assembly of FIG. 1;

FIG. 5 is a partial sectional view taken along line 5-5 of FIG. 4, with a engagement of a bed frame mounting block within a bed frame cross member;

FIG. 6 is a partial sectional view taken along line 6-6 of FIG. 4, with an side view a representative swing arm;

FIG. 7 is a sectional view taken along line 7-7 of FIG. 4, with an end view of a representative pair of swing arms;

FIG. 8 is a detail view of a representative drive shaft end bearing of the moving bed assembly of FIG. 1;

FIG. 9 is a detail view of a representative crank at an end of a drive shaft of the moving bed assembly of FIG. 1;

FIGS. 10 and 11 are end views of the moving bed assembly of FIG. 1, with a bed frame thereof at opposite extremes of movement;

FIG. 12 is a detail perspective view of a shaft brake of the moving bed assembly of FIG. 1;

FIG. 13 is a detail perspective view of the shaft brake of FIG. 12, with a nut and spring thereof removed to show internal details;

FIG. 14 is a side view of the shaft brake of FIG. 12 with a brake housing thereof removed to show internal details;

FIG. 15 is a detail perspective view of a representative swing arm having an alignment pin therein;

FIG. 16 is a perspective view of a modular moving bed assembly, according to another embodiment of the present invention, incorporating the moving bed assembly of FIG. 1 as a base unit thereof; and

FIG. 17 is a perspective view of a moving bed assembly, according to a further embodiment of the present invention, including a bed frame with an articulated mattress arrangement thereon.

DETAILED DESCRIPTION

The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

According to an embodiment of the present invention, referring to FIG. 1, a moving bed assembly 10 includes a base frame 12 with a bed frame 14 movably supported thereabove by a plurality of swing arms 16. A drive motor 20 is mounted to the base frame 12 and drives the bed frame 14 through a reciprocating motion via a drive shaft 22 and one or more drive arms 24. As described herein, the moving components, including the drive motor 20, drive shaft 22, swing arms 16, and associated linkages, may optionally be equipped with a safety system configured to prevent user contact with the moving machinery or to automatically halt motion upon detection of an obstruction.

The base frame includes a pair of lower base side members 26 with a plurality of lower base cross members 30, 32, 34 extending therebetween. The lower base side and cross members 26, 30 collectively define a lower base frame that supports the base frame 12 on an underlying surface. Outermost lower base cross members 30 collectively define a perimeter of the lower base frame 32 together with the pair of lower base side members 26.

In some embodiments, one or more protective barriers 200 are mounted around portions of this perimeter as depicted in FIG. 1A, to shield the drive motor 20, drive shaft 22, transmission 132, and swing arms 16 located internally within the lower frame. Each protective barrier 200 may be secured by fasteners or latches and may include an electrical interlock connector 202 that forms part of a safety loop as depicted in FIG. 1A. If any protective barrier 200 is removed, displaced, or tampered with, the interlock connector 202 opens the safety loop and disables operation of the motor 20 until the barrier is restored and the system reset. In some embodiments, the electrical interlock connector 202 may employ a plug-and-receptacle configuration or other mating connector arrangement to complete the safety circuit.

Intermediate lower base cross members 32 support drive shaft end bearings 36 thereabove. Adjustable feet 40 mounted to the intermediate lower base cross members 32 allow a level of the base frame 12 to be adjusted relative to the underlying surface, allowing the lower base frame 32 to be oriented horizontally, regardless of irregularities in the underlying surface. A drive motor mount 42 is supported across the innermost base cross members 34. The protective barriers 200 described above may partially or fully enclose this region while still allowing access for maintenance when intentionally removed.

Referring also to FIG. 2, a plurality of vertical base members 44 support a pair of upper base side members 46 over the lower base side members 26. A plurality of upper base cross members 50, 52, 54 extend between the upper base cross members 46, collectively defining an upper base frame.

Outermost upper base cross members 50 define a perimeter of the upper base frame together with the upper base side members 46. A pair of swing arms 16 are connected to each of the intermediate upper base cross members 52. Innermost upper base cross members 54 add additional stiffness to the upper base frame.

Referring to FIG. 3, the bed frame 14 includes a pair of bed side members 60 with a plurality of bed cross members 62, 64, 66 extending therebetween. A perimeter of the bed frame 14 is defined by the bed side members 60 and the bed cross members 62, 64, 66. Advantageously, the bed cross members 62, 64, 66 have an inverted-U cross-section. Referring also to FIG. 5, this configuration allows bed frame mounting blocks 70 to extend into the intermediate bed cross members 64 for connecting the bed frame 14 to the swing arms 16. An innermost bed cross member 66 adds additional stiffness to the bed frame 14.

In some embodiments, a crush-avoidance system 210 is mounted along at least a portion of the perimeter of the bed frame 14 as depicted in FIG. 3. The crush-avoidance system 210 may include a soft, compressible upper sensor tube 212 secured along the side members 60 and cross members 62, 64. The upper sensor tube 212 defines an internal optical path extending along its length. A light emitter 214 and a corresponding light sensor 216 are positioned within the upper sensor tube 212 such that the emitter 214 produces a directed light signal, and the light sensor 216 is configured to receive that signal during normal operation. The geometry and material properties of the upper sensor tube 212 maintain the optical path in a substantially unobstructed state when the tube is not deformed.

 During operation of the bed assembly, the controller 208 continuously monitors the signal output from the light sensor 216. The controller 208 may store a reference value or baseline corresponding to an expected received-light intensity level. If a child, pet, or object presses against the upper sensor tube 212, even slightly, the tube deforms, altering its internal shape and attenuating or interrupting the transmitted light. The light sensor 216 detects this change as a drop in received-light intensity, a loss of signal continuity, or a change in signal pattern. In response, the controller 208 interprets the deviation as a potential obstruction and automatically disables the motor 20, thereby halting movement of the bed frame 14. Operation remains disabled until the obstruction is removed, the optical path is restored, and the controller 208 receives a reset command or otherwise reinitializes the safety circuit.

To mitigate potential crush or pinch hazards in the clearance region between the moving bed frame 14 and the stationary lower base frame 32, a crush-detection system 220 may be mounted around the upper perimeter of the lower base frame 32 as shown in FIG. 3. The crush-detection system 220 may include a compressible lower sensor tube 222 that similarly defines an internal optical transmission pathway. A light emitter 224 and a corresponding light sensor 226 are arranged such that the light sensor 226 continuously receives a signal from the light emitter 224 when the lower sensor tube 222 is in an undeformed condition.

 If a hand, foot, limb, or other object enters the clearance region between the upper and lower frames, even slight pressure against the lower sensor tube 222 causes deformation that disrupts or attenuates the transmitted light. The light sensor 226 detects this disruption, and the controller 208 immediately triggers an electrical shut-down of the motor 20. Because the lower sensor tube 222 is mounted in the area most susceptible to pinch forces, the system provides rapid detection of hazardous conditions before significant movement can occur. The controller 208 may prevent reactivation of the motor 20 until the optical signal is fully restored and a reset procedure is performed, ensuring that obstructions are cleared prior to resuming motion.

Referring to FIGS. 6 and 7, respective pairs of the swing arms 16 connect each intermediate upper base cross member 52 to the overlying intermediate bed cross member 64. Each swing arm 16 includes a pair of base members 72 extending downwardly from opposite sides of the respective upper base cross member 52 and a pair of bed members 74 extending downwardly from opposite sides of the respective bed cross member 64.

A first pivot joint 76 connects the base member 72 upper ends to the respective intermediate upper base cross member 52 while a second pivot joint 80 connects the lower ends of the base members 72 and the bed members 74. Each pivot joint 76, 80 preferably includes a respective bearing block 82 with a ball bearing mounted therein. Upper and lower ends of the base members 72 connect to the ball bearings of the first and second pivot joints 76, 80 respectively.

The bearing block 82 of each first pivot joint 76 is mounted to the top of the respective intermediate upper base cross member 52. The bearing block 82 of each second pivot joint 80 is mounted to a bottom plate 90. Lower ends of each pair of bed members 74 are fixed to opposite sides of the respective bottom plate 90.

A common upper plate 92 connects the upper ends of the bed members 74 of each pair of swing arms 16. A pair of the bed frame mounting blocks 70 connect to an upper surface of each upper plate 92, with the bed frame mounting blocks 70 being secured within the respective intermediate bed frame cross member 64.

Referring to FIGS. 4 and 8, near each end, the drive shaft 22 is supported by of the drive shaft end bearings 36 located proximate to a respective pair of the swing arms 16. Each drive shaft end bearing 36 is preferably a plain bearing including a bushing 94 mounted in a bearing support plate 96 connected to the respective intermediate lower base cross member 32. The drive shaft end bearings 36 help prevent any radial misalignment of the drive shaft 22 during operation and eliminate corresponding noticeable perturbations to the motion cycle of the bed frame 14.

Referring to FIGS. 7 and 9, each end of the drive shaft 22 carries a crank 100 fixed to rotate therewith. Each drive shaft 22 end extends through a shaft passage 102 formed through one end of the respective crank 100. Each passage 102 opens onto 104 an adjacent end of the crank 100, allowing the drive shaft 22 to be securely clamped within the shaft passage 102 via an endplate 104. Each end of the drive shaft 22 includes a flat surface 106 that engages the endplate 104, ensuring proper radial alignment of each crank 100 on the drive shaft 22 and inhibiting rotation of the shaft 22 relative to the crank during operation. Preferably, the radial alignment of the crank 100 on each end of the drive shaft 22 is identical.

An opposite end of each crank 100 is connected to a crank end of a respective one of the drive arms 24 via a rotatable crank joint 114. A swing end of each drive arm 24 extends between, and is rotatably connected to, the base members 72 of one of each pair of swing arms 16 via a rotatably swing joint 116. Each of the joints 114, 116 is preferably a ball and socket joint (see also FIG. 3) allowing some rotation of each drive arm 24 about its axis during operation to accommodate some degree of misalignment between its crank and swing ends.

The radial displacement of each crank joint 114 from the drive shaft 22 by the crank 100 allows conversion of the rotation of the drive shaft 22 to a reciprocal motion of the drive arms 24. As used herein, in a “neutral” position of the drive shaft 22, there is no horizontal displacement between the rotational axes of the crank joints 114 and drive shaft 22. FIG. 7 depicts the drive shaft 22 in the neutral position, with the cranks 100 oriented vertically in the “twelve o’clock” direction. It will be appreciated that the drive shaft 22 would also be in the neutral position with each crank oriented vertically in the “six o’clock” direction.

In the neutral position, vertical levels L of the drive shaft 22 and the swing joints 116 of the swing ends of the drive arms 24 are equal. As used herein, the “vertical level” is referenced to a horizontal plane extending below a horizontally leveled base frame 12. This configuration results in the most direct application of force from the drive shaft 22 through the drive arms 24 throughout the entire motion cycle and further helps eliminate noticeable perturbations thereto. Additionally, the vertical level of the swing joints 116 is closer to lower ends of the base members 72 than upper ends thereof.

Opposite ends side-to-side motion of the bed frame 14 are achieved with the cranks 100 oriented in the “three o’clock” (FIG. 10) and “nine o’clock” (FIG. 11) directions. Advantageously, the total horizontal motion between the opposite extremes is between 4 and 5 inches, and more particularly, between 4.5 and 5 inches. Due to the angular motion of the swing arms 16, the bed frame 14 will also rise slightly with respect to, while remaining parallel with, a horizontal reference plane during each transition from a neutral position to either end of the motion cycle.

The present inventors have determined that another source of noticeable perturbations to the motion cycle occurs during the direction change at these opposite ends of the motion cycle. With reference to the drive shaft 22 position, these occur when the cranks 100 transition through the “three o’clock” and “nine o’clock” directions where the drive arms 24 switch from pushing to pulling and vice versa. In particular, under some load conditions on the bed frame 14, a noticeable “lurching” or “falling” sensation can sometimes be experienced.

Advantageously, referring to FIG. 4 a shaft brake 120 is used to provide a constant preload on the drive shaft 22 during rotation and can effectively eliminate noticeable perturbations associated with these transitions in the motion cycle. Referring to FIGS. 12-14, the shaft brake 120 includes a stationary disc 122 through which the drive shaft 22 passes and which is engaged on opposite surfaces thereof by rotating friction pads 124, 126 carried by the drive shaft 22. In the depicted embodiment, the stationary disc 122 is held in place by a brake housing 130 mounted to a side of a transmission 132.

The friction pads 124, 126 are carried by a hub 134, with the friction pad 124 being located within the housing 130 and the friction pad 126 being located externally. The hub 134 is internally keyed to the drive shaft 22 to ensure rotation therewith. Externally, splines 136 are formed on the hub 134, the splines 136 having an increased diameter at an inner end of the hub 134 within the housing 130. Outer sections of the splines 136 are threaded.

The friction pads 124, 126 are internally splined so as to be rotationally coupled to the hub 134 and drive shaft 22 while being able to move axially relative thereto. The expanded diameter inner end of the splines 136 prevents the inner pad 124 from sliding off the hub 124 within the housing, while a nut 140 threads onto the splines 136 externally, retaining the outer pad 126.

A spring 142 is arranged between the nut 140 and the outer pad 126, allowing the braking force of the shaft brake 120 to be adjusted by tightening and loosening the nut 140. The spring 142 is internally splined like the pads 124, 126 and is preferably a toothed spring washer. The braking force can be advantageously adjusted if desired based on the anticipated bed loading.

Referring again to FIG. 4, the drive motor 20 preferably engages the drive shaft 22 through the transmission 132. With the rotational axis of the drive motor 20 being perpendicular to that of the drive shaft 22, the transmission 132 function both to change the direction of the rotational output of the drive motor 20 as well as to decrease the rotational speed (while increasing torque).

Referring to FIG. 15, for ensuring proper alignment during assembly and transport, alignment pins 144 are inserted through aligned holes in the base members 72 and bed members 74 of each swing arm 16. Connecting the bed frame 14 to the upper plates 92 connecting pairs of swing arms 16 allows the base frame 12 and swing arms 14 to remain fully assembled and aligned while still allowing the bed frame 14 to be readily detached and re-attached.

While it would be appreciated that a moving bed assembly according to the present invention could be made in any desired size, the above-described embodiment is dimensioned to accommodate a twin extra-long (XL) mattress on the bed frame 14. Besides simply changing the overall size to accommodate different mattress sizes, a modular approach can be used to make larger beds using the moving bed assembly 10 as a base unit with additional units added to achieve the desired size. In FIG. 16, a king-sized moving bed assembly 10A is formed by connecting the base frame 12 to an additional base frame 12A side-by-side such that respective ones of upper and lower pairs of additional base side members 26A, 46A abut respective ones of the upper and lower pairs of base side members 26, 46 and the additional base cross members extend in parallel with the base cross members. Likewise, the bed frame 14 is connected to an additional bed frame 14A such that one of the additional bed frame side members 60A abuts one of the bed frame side members 60 and the additional bed cross members extend in parallel with the bed cross members. The additional bed frame 14A is supported over the additional base frame 12A by additional swing arms 16A substantially identical to the swing arms 16.

With the exception of the absence of the motor 20, drive shaft 22 and other drive components, in the depicted king embodiment, the base frames 12, 12A and bed frames 14, 14A are substantially identical. However, to ensure proper centering of the adjoined bed frames 14, 14A over the adjoined base frames 12, 12A, attachment points of the bed frame mounting blocks to the intermediate bed cross members can be adjusted relative to the twin XL configuration. Preferably, the base frames 12A is connected to the side of the base frame 12 on which the drive arms 24 are connected to respective swing arms 16, making the contact points between the drive arms 24 and swing arms 16 closer to the center of the combined bed.

For other sizes of modular moving bed assemblies, it will be appreciated that additional base frames and additional bed frames having different widths than the initial base frame 12 and bed frame 14 could be used. For instance, to achieve a queen bed, the additional base and bed frames would be smaller than initial base and bed frames 12, 14.

Referring to FIG. 17, in addition to supporting standard mattresses, a moving bed assembly 10B can support a bed frame 14B having an articulated mattress arrangement 150B located thereon. The bed frame 12B, swing arms 16B, motor 20B and associated drive components remain substantially identical to those discussed above in connection with the moving bed assembly 10. To reduce the overall height of the assembly 10B, as well as to more readily accommodate use of commercially-available articulated mattress arrangements, the bed frame 14B can mount directly to the upper plates 92B connecting the pairs of swing arms 16B, rather than mount via bed frame mounting blocks.

Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims.