Adjustable bed assembly

Abstract

An adjustable bed system is disclosed that includes a mattress and an adjustment mechanism. The mattress includes a head portion and a foot portion rearward of the head portion. The head portion defines a downwardly open cavity. The adjustment mechanism includes a lower base, an upper support movably coupled to the lower base, and an actuator operable to move the upper support relative to the lower base. An adjustment mechanism is positioned in the cavity and coupled with the mattress. When the actuator is operated, the adjustment mechanism moves the adjustable bed system between a flat configuration in which the head portion is substantially coplanar with the foot portion and a tilted configuration in which the head portion is tilted relative to the foot portion.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to and the benefit of U.S. Provisional Application No. 63 / 364,302, filed on May 6, 2022, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] The present disclosure relates to beds, and in particular to adjustable bed systems. Background Art

[0004] Adjustable beds can provide comfort to users in both home and healthcare settings. It would be advantageous to provide an adjustable bed system that, among other benefits, can be compressed for ease of storage and transportation. Summary of the invention

[0005] Embodiments of adjustable bed assemblies and related methods are disclosed herein.

[0006] In one embodiment, an adjustable bed system includes a mattress and an adjustment mechanism. The mattress includes a head portion and a foot portion located behind the head portion. The head portion defines a downwardly open cavity. The adjustment mechanism includes a lower base, an upper support member movably connected to the lower base, and an actuator operable to move the upper support member relative to the lower base. The adjustment mechanism is positioned in the cavity and connected to the mattress. When the actuator is operated, the adjustment mechanism moves the adjustable bed system between a flat configuration and an inclined configuration, in which the head portion is substantially coplanar with the foot portion and in which the head portion is inclined relative to the foot portion.

[0007] The head portion may include an upper sub-portion having a downwardly facing surface defining a cavity, and the upper support of the adjustment mechanism may be coupled to the downwardly facing surface. The upper support of the adjustment mechanism may be coupled to the downwardly facing surface using a hook and loop fastener system. The upper support may include one or more support panels forming one side of the hook and loop fastener system, and the downwardly facing surface may include one or more mattress panels forming another side of the hook and loop fastener system and coupled to the one or more support panels.

[0008] The adjustable bed system may further include a connector that connects the lower base of the adjustment mechanism to a connecting portion of the mattress located behind the cavity to prevent the adjustment mechanism from moving forward relative to the foot portion of the mattress. When the adjustment mechanism moves the adjustable bed system between a flat configuration and an inclined configuration, the connecting portion may not move relative to the flat support surface on which the adjustable bed system is positioned. The connector may include one or more flexible panels, each panel having a first end connected to the lower base and a second end connected to the connecting portion. The first end may be connected to the lower base using a zipper. The one or more panels may cooperatively span less than half the width of the cavity. The one or more panels may be releasably connected to the mattress at one or more of the head end of the cavity or the side of the cavity. The one or more panels may encapsulate the adjustment mechanism in the cavity.

[0009] According to one embodiment, an adjustable bed system includes a mattress and an adjustment mechanism. The mattress includes a head portion and a foot portion. The adjustment mechanism raises the head portion from a first configuration, in which a first upper surface of the head portion and a second upper surface of the foot portion are substantially coplanar, and from a second configuration, in which the first upper surface is inclined relative to the second upper surface. In a third configuration, the first upper surface faces the second upper surface, and the head portion of the mattress is compressed less than the foot portion of the mattress from its relaxed state.

[0010] In a third configuration, the head portion of the mattress and the foot portion of the mattress can be compressed by a removable package. The removable package can be a vacuum bag in which the mattress and the adjustment mechanism are enclosed. The head portion of the mattress can define a cavity in which the adjustment mechanism is positioned.

[0011] According to one embodiment, an adjustable bed system includes a mattress having a head portion and a foot portion and an adjustment mechanism. The adjustment mechanism includes a lower base, an upper support pivotally coupled to the lower base, and an actuator operable to move the upper support upward relative to the lower base. The adjustment mechanism is configured to raise the head portion of the mattress when the actuator is operated from a first configuration to a second configuration. The lower base of the adjustment mechanism is coupled to a coupling portion of the mattress to prevent the lower base from moving in a forward direction away from the foot portion of the mattress.

[0012] The lower base may include a frame having a head end member and a foot end member spaced longitudinally apart, and left and right side members spaced laterally apart and extending between and coupled to the head end member and the foot end member. The head end member may be coupled to a coupling portion of the mattress with a connector extending therebetween. The connector may include a flexible panel that wraps around the head end member of the frame of the lower base. The frame of the lower base may include a post that extends upward from the head end member and engages the upper support when the adjustable bed system is in a first configuration. The front end of the connector may wrap around the head end member on different sides of the post. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The present disclosure is best understood from the following detailed description when read in conjunction with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not to scale. Instead, the sizes of the various features are arbitrarily enlarged or reduced for clarity.

[0014] Figure 1 is an upper right front perspective view of a first embodiment of an adjustable bed system with a mattress and adjustment mechanism in a tilted configuration.

[0015] Figure 2 yes Figure 1 Upper right front perspective view of an adjustable bed system of FIG. 1 with the mattress in an inclined configuration and the adjustment mechanism of the adjustable bed system in a flat configuration.

[0016] Figure 3 yes Figure 1 Lower left front perspective view of an adjustable bed system with the mattress in an inclined configuration and the adjustment mechanism in a flat configuration.

[0017] Figure 4 yes Figure 1 Lower left front perspective view of the adjustment mechanism in a flat configuration.

[0018] Figure 5 is a front right perspective view of the upper portion of the adjustment mechanism in a tilted configuration.

[0019] Figure 6 yes Figure 1 An upper right front perspective view of a mattress in a tilted configuration.

[0020] Figure 7 yes Figure 1 A lower left front perspective view of a mattress in a tilted configuration.

[0021] Figure 8 yes Figure 1 A rear view of the mattress of an adjustable bed system in a tilted configuration.

[0022] Fig. 9 yes Figure 1A side view of an adjustable bed system in a flat configuration with the mattress partially cut away to illustrate the adjustment mechanism.

[0023] Fig.10 is a lower left front perspective view of the second embodiment of the bed system in a tilted configuration.

[0024] Fig.11 yes Fig.10 Upper right front perspective view of the adjustable bed system in a reclined configuration.

[0025] Fig.12 is a top view of a third embodiment of an adjustable bed system with hidden features depicted in phantom lines.

[0026] Fig.13 is a side partial cross-sectional view of the fourth embodiment of the adjustable bed system in a flat configuration.

[0027] Fig.14 yes Fig.13 A side partial cross-sectional view of an adjustable bed system with a head portion and a foot portion in a reclined configuration.

[0028] Fig.15 yes Figure 1 A side view of an adjustable bed system in an uncompressed state in a mechanical compression system.

[0029] Fig.16 yes Fig.15 A side view of an adjustable bed system in a compressed state in a mechanical compression system.

[0030] Fig.17 is a side view of the adjustable bed system in a collapsed configuration. DETAILED DESCRIPTION

[0031] refer to Figures 1 to 9 , the adjustable bed system 100 generally includes a mattress 110 and an adjustment mechanism 120 configured to move the mattress 110 between different positions when in use. For example, in use, the adjustable bed system 100 can be in a first or flat configuration (see, e.g., Fig. 9 ) and a second or tilted configuration (see e.g. Figures 1 to 3 ), in a first or flat configuration, in which the upper surfaces of the head portion 112 and the foot portion 114 of the mattress 110 are substantially coplanar with each other (e.g., horizontal), and in a second or inclined configuration, in which the upper surface of the head portion 112 is inclined relative to the upper surface of the foot portion 114 (e.g., remains horizontal) by pivoting about the center portion 116 of the mattress 110. The adjustable bed system 100 is configured to be supported by a flat support surface, such as a slat or platform of a bed frame, a bed foundation, or a floor.

[0032] When not in use, for example, when the adjustable bed system 100 is stored or transported, the adjustable bed system 100 can be arranged into a third or collapsed configuration in which the foot portion 114 of the mattress 110 is folded over the head portion 112 with their upper surfaces positioned against or otherwise facing each other (e.g., with packaging therebetween). In the third configuration, the head portion 112 and the foot portion 114 of the mattress 110 can also be compressed, for example with external packaging, to reduce the spatial volume of the adjustable bed system 100 for storage or transport as compared to when in the use configuration. The first or reclining position can also be referred to as a horizontal or reclining configuration or position. The second or inclined configuration can also be referred to as an elevated or sitting configuration or position.

[0033] Various directional terms are used to describe the various components, features, and functions of the adjustable bed system 100 described herein, and may be used to refer to the orientation of portions of the bed. The term "head" generally refers to the head of the bed, which is the side of the bed where a person would normally place their head. The term "foot" generally refers to the foot of the bed, which is the side of the bed where a person would normally place their feet. Directional variations of "head," such as "head side" and "head end," generally refer to components or features that are closer to the head of the bed than the foot of the bed. The terms "toward the head" and "forward" refer to directions toward the head of the bed. Directional variations of "foot," such as "foot side" and "foot end," generally refer to components or features that are closer to the foot of the bed than the head of the bed. The terms "toward the foot" and "backward" refer to directions toward the foot of the bed. The terms longitudinal and length are directions extending between the head and foot of the bed. The terms "lateral" and "width" are directions extending between the left and right sides of the bed. Height-related terms, such as upward, above, downward, down, and inclined, are usually nominally vertical.

[0034] The mattress 110 is formed of one or more foam materials, such as polyurethane. In one example, the mattress 110 is unitary, wherein the foam material throughout the head portion 112, the foot portion 114, and the center portion 116 has substantially uniform material properties. In another example, the mattress 110 is multi-piece, wherein the foam material within and / or between each of the head portion 112, the foot portion 114, and the center portion 116 has different material properties. In one example, the hardness and / or density of the mattress 110 decreases as it moves upward. In yet another example, the mattress 110 is at least partially formed of a hybrid construction having different elastic and compressible materials, such as memory foam, foam plastic, gel, organic batting, latex, or spring coils. In the case of spring coils, the spring coils can be pocket coils (e.g., encapsulated in a sheath or other flexible covering or shell) embedded in the foam of the mattress 110 (e.g., foam formed around the spring coils). As Figure 2 and Fig. 9 As shown, the mattress 110 has a height M_H extending vertically between the upper and lower surfaces of the mattress 110, a width M_W extending from left to right between the left and right sides of the mattress 110, and a length M_L extending longitudinally between the head end and the foot end of the mattress 110. The mattress 110 can be a standard size (e.g., a single bed, an extra-long single bed, a full-size bed or a double bed, a queen bed, a king bed), and thus the mattress 110 can be a rectangular cube with a substantially uniform height M_H, width M_W, and length M_L.

[0035] The mattress 110 further defines a cavity 118 in the head portion 112 in which the adjustment mechanism 120 is positioned. The cavity 118 is downwardly open so that the adjustment mechanism 120 can protrude from the bottom surface of the mattress 110. The cavity 118 can be formed during molding of the mattress 110 or by removing material.

[0036] For example, the head portion 112 includes an upper sub-portion 112a and a lower sub-portion 112b (in Figure 1 The upper sub-portion 112a may have a height U_H (see, e.g. Fig.15 ). For example, the upper sub-portion 112a of the head portion 112 forms a downwardly facing surface that defines the upper end of the cavity 118. In a relaxed state, the height U_H of the upper sub-portion 112a above the cavity 118 can be, for example, about 4 inches, more or less. The lower sub-portion 112b of the head portion 112 includes a left lower sub-portion 112b-1, a right lower sub-portion 112b-2, a head-end lower sub-portion 112b-3, and a foot-end lower sub-portion 112b-4, which respectively form right-facing, left-facing, foot-facing, and head-facing surfaces that respectively define the left, right, head-end, and foot-end of the cavity 118. As mentioned above, the mattress 110 can be multi-piece, which can include lower sub-portions 112b-1, 112b-2, 112b-3, and 112b-4 (i.e., these lower sub-portions define the cavity 118) that are harder and / or denser than the inner and / or outer sub-portions (e.g., at a common height) of the foot portion 114. As shown, the various surfaces of the upper sub-portion 112a and the lower sub-portion 112b that define the cavity 118 can be substantially planar and substantially perpendicular to each other, so that the cavity 118 is a rectangular cube.

[0037] As mentioned above, the mattress 110 may also include coil springs (e.g., pocket coil springs, not shown) that may be positioned vertically in the upper subsection 112a of the head portion 112 above the cavity 118. The foot portion 114 may also include coil springs, in which case these coil springs may have different heights (e.g., taller) and / or material properties (e.g., stiffness) than the coil springs in the upper subsection 112a of the head portion 112.

[0038] like Figure 6 As shown, the cavity 118 can be considered to have a cavity height C_H extending from the downwardly facing surface of the upper sub-portion 112a of the head portion of the mattress 110 (i.e., surrounding the cavity), a cavity width C_W extending from left to right between the right-facing surface of the lower left sub-portion 112b-1 and the left-facing surface of the lower right sub-portion 112b-2, and a cavity length C_L extending longitudinally between the foot-facing surface of the head-end lower sub-portion 112b-3 and the head-facing surface of the foot-end lower sub-portion 112b-4. The cavity length C_L can be, for example, between 15% and 45% (e.g., between 25% and 40%) of the mattress length M_L. In other examples, the cavity length C_L can be less than 50% or between 30% and 50% of the mattress length M_L. The cavity width C_W can be, for example, between 80% and 100% (e.g., between 85% and 95%) of the mattress width M_W. In further examples, the cavity width C_W may be greater than 60% or between 60% and 90% of the mattress width M_W.

[0039] The mattress 110 may further include one or more outer covers. For example, the mattress 110 may include an upper cover 110a, such as a covering pad, which is connected to and / or extends on the upper surface of the foam material forming the mattress 110. Alternatively or additionally, the mattress 110 may include a lower cover 110b, such as a woven material, which is connected to (e.g., adhered to) the lower surface of the foam material forming the mattress 110 and / or extends thereon. The lower cover 110b may also be referred to as an edge fabric. The upper cover 110a and / or the lower cover 110b may further extend on the vertical surfaces or portions thereof at the head end, foot end, and left and right sides of the mattress 110. The upper cover 110a and / or the lower cover 110b may be considered to form a portion of the head portion 112 and / or foot portion 114 of the mattress 110. The lower cover 110a (eg, edge fabric) may also line the cavity 118 (eg, be adhered or otherwise coupled to a surface defining the cavity 118).

[0040] refer to Fig.12, a variation 100' of an adjustable bed system is configured as a two-position adjustable bed system to have two head portions that are independently movable from one another. In one example, a mattress 110' can be configured to have a left head portion 112L and a right head portion 112R that are independently movable from one another, and a single foot portion 114 having left and right sides that are not independently movable from one another (e.g., with a continuous foam formed therebetween and / or with another type of connection therebetween). The adjustable bed system 100' includes a first adjustment mechanism 120L (e.g., a left adjustment mechanism) and a second adjustment mechanism 120R (e.g., a right adjustment mechanism) that are positioned in a cavity 118 of the left and right head portions 112L, 112R of the mattress 110'. The cavity 118 and the adjustment mechanisms 120L, 120R can be configured substantially as described elsewhere with respect to the cavity 118 and the adjustment mechanism 120, including a coupler 130 (as further described below). In another example (not shown), the dual-position adjustable bed system may include two adjustable bed systems 100 that form the left and right sides of the dual-position adjustable bed system and include head sections that are independently adjustable from each other (i.e., each adjustable bed system has one mattress 110 and one adjustment mechanism 120). In this case, the left and right mattresses 110 and / or adjustment mechanisms 120 may be coupled to each other to prevent relative longitudinal and / or lateral movement therebetween.

[0041] refer to Fig.13 and Fig.14, another variation of the bed system 100" includes a mattress 110", a first adjustment mechanism 120H (e.g., a head adjustment mechanism) at a head portion 112 of the mattress 110", and a second adjustment mechanism 120F (e.g., a foot adjustment mechanism) at a foot portion 114 of the mattress 110". The mattress 110" and the first adjustment mechanism 120H are configured as described elsewhere with respect to the mattress 110 and the adjustment mechanism 120, for example, wherein the mattress 110" defines a cavity 118, in which the first adjustment mechanism 120H is positioned, the first adjustment mechanism being configured to move the head portion 112 of the mattress 110 between a flat configuration and an inclined configuration. The mattress 110" is further configured to include a second cavity 118F in which the second adjustment mechanism 120 is positioned, wherein the second adjustment mechanism 120F is configured to move a portion of the foot portion 114 of the mattress 114 between a flat configuration and an inclined configuration. More specifically, the second adjustment mechanism 120F supports and is configured to lift (e.g., tilt) a portion of the mattress 110" that generally corresponds to the user's thigh (e.g., the thigh portion 114-1), while a distal portion of the mattress 110" (e.g., the distal foot portion 114-2) is suspended by the second adjustment mechanism 120H and is not otherwise supported by the second adjustment mechanism 120F. The cavity 118F and the second adjustment mechanism 120F can be generally as described with respect to the cavity 118 and the adjustment mechanism 120, but have a shorter longitudinal length and / or distance, whereby the mattress 110" is engaged at the shorter longitudinal length and / or distance. The middle portion 116 of the mattress 116 is positioned longitudinally between the first adjustment mechanism 120H and the second adjustment mechanism 120F and is configured to remain engaged with a support surface (e.g., a base or platform) as each of the first adjustment mechanism 120H and the second adjustment mechanism 120F moves between its flat configuration and inclined configuration.

[0042] Further interactions between the mattress 110 and the adjustment mechanism 120 and related features are discussed in further detail below.

[0043] Additionally, refer to Figure 4 and Figure 5 , the adjustment mechanism 120 generally includes a lower base 122, an upper support 124 movable relative to the lower base 122, and an actuator 126 operable to move the upper support 124 relative to the lower base 122 and thereby move the mattress 110 between the flat and inclined configurations. The adjustment mechanism 120 and the cavity 118 of the mattress 110 are cooperatively configured to position the adjustment mechanism 120 within the cavity 118, e.g., the adjustment mechanism 120 is substantially (e.g., completely) contained within the cavity 118 when in the flat configuration and the collapsed configuration, and the adjustment mechanism 120 is partially contained within the cavity 118 (i.e., partially protrudes from the cavity) when in the inclined configuration.

[0044] The lower base 122 is configured to be supported by a planar support surface (e.g., a floor or bed foundation) on which the adjustable bed system 100 is also positioned, and is configured to stably support the upper support 124 and the head portion 112 of the mattress 110 thereon. For example, the lower base 122 of the adjustment mechanism 120 and the lower surface of the foot portion 114 of the mattress 110 can rest on the same planar support surface. The lower base 122 has a lower base width B_W and a lower base length B_L over which the lower base 122 engages or otherwise transmits force to the planar support surface, for example, the lower base width B_W and the lower base length B_L can be 65% to 95% (e.g., 70% to 90%) of the cavity width C_W and the cavity length C_L, respectively. The lower base 122 that transmits vertical forces to the support surface can be positioned completely in front of the foot portion 114 and / or the middle portion 116 of the mattress 110, or other portion of the mattress that remains supported by (e.g., directly or indirectly engaged with) the support surface. For example, the adjustable bed system 100 may not include any rigid components that extend from the adjustment mechanism 120 rearwardly to the foot portion 114 and / or the middle portion 116 of the mattress 110 (e.g., above the bottom surface of the mattress 110, such as the bottom cover 110b).

[0045] The lower base 122 can be configured as a linear frame. For example, the lower base 122 can generally include a spaced-apart left and right side members 122a, 122b (e.g., forming a lower base width B_W and / or extending parallel to each other in a longitudinal direction) and a spaced-apart head end member 122c and a foot end member 122d, which extend between and are connected to the left and right side members 122a, 122b (e.g., extending parallel to each other in a left-to-right direction). Each of the members 122a, 122b, 122c, 122d can be formed, for example, of steel, other metals, or other rigid materials.

[0046] The lower base 122 may further include a support post 122e. The support post 122e is positioned on the head side of the lower base 122 and projects upward to engage the upper support 124 when in a flat configuration and thus support the upper support 124. For example, the support post 122e may be centrally located within the lower base width B_W and / or project upward from the head end member 122c of the frame of the lower base 122.

[0047] The upper support 124 is configured to support and move the head portion 112 of the mattress 110 between a flat configuration and an inclined configuration relative to the lower base 122 and, therefore, relative to the flat support surface below it. The upper support 124 has an upper support width S_W and an upper support length S_L over which the upper support 124 engages the head portion 112 of the mattress or otherwise transmits forces to the head portion 112 of the mattress, and the upper support width S_W and the upper support length S_L may, for example, be greater than the lower base width B_W and the lower base length B_L, respectively, and may be between 80% and 100% (e.g., between 90% and 100%) of the cavity width C_W and the cavity length C_L, respectively.

[0048] The upper support 124 is movably coupled to the lower base 122 and is movable relative to the lower base in a predetermined path. For example, as shown, the upper support 124 is pivotally coupled to the lower base 122 and is pivotable relative to the lower base 122 about a pivot axis. In the illustrated example, the foot end of the upper support 124 is pivotally coupled to the lower base 122 using a hinge 128 having a pivot axis, which can be positioned generally above the lower base 122 (e.g., the frame of the lower base) and below the upper support (e.g., the frame of the upper support, as discussed in further detail below). For example, the hinge 128 can be coupled to the foot end member 122d of the lower base 122. Alternatively, the upper support 124 can be movably coupled to the lower base 122 in another manner (such as using a four-bar linkage), for example in which the head side of the upper support 124 has a greater range of motion relative to the lower base 122 than the foot side of the upper support 124.

[0049] The upper support 124 can be configured as a linear frame. For example, the upper support 124 can generally include a left side member 124a and a right side member 124b spaced apart (e.g., forming an upper support width S_W and / or extending parallel to each other in a longitudinal direction) and a head end member 124c and a foot end member 124d spaced apart, the head end member 124c and the foot end member 124d extending between and connected to the left side member 124a and the right side member 124b (e.g., extending parallel to each other in a left-to-right direction). The upper support member 124 may further include one or more intermediate members, for example, a transverse member 124e extending from left to right between the left side member 124a and the right side member 124b and connected to the left side member 124a and the right side member 124b and / or a longitudinal intermediate member 124d extending longitudinally between the head end member 124c and the foot end member 124d and connected to the head end member 124c and the foot end member 124d.

[0050] As mentioned above, the foot end of the upper support 124 is pivotably coupled to the lower base 122 using a hinge 128. For example, the hinge 128 can be coupled to the foot end member 124d, wherein the pivot axis of the hinge is positioned below the foot end member (e.g., below each of the members 124a, 124b, 124c, 124d). Each of the members 124a, 124b, 124c, 124d, 124e, and 124f can be formed, for example, from steel, other metals, or other rigid materials.

[0051] The actuator 126 is configured to selectively move the upper support 124 relative to the lower base 122. For example, as shown, the actuator 126 can be a linear actuator having a first end pivotally coupled to the head side of the upper support 124 and a second end pivotally coupled to the foot side of the lower base 122. As the actuator 126 is selectively extended and retracted, the upper support 124 moves relative to the lower base 122, thereby moving the head portion 112 of the mattress 110 toward an inclined configuration and a flat configuration, respectively. The actuator 126 can be or include, for example, a lead screw actuator, a ball screw actuator, a linear motor, or other types of linear actuators. In other examples, the actuator 126 can alternatively include a motor and gears, pulleys, belts, and / or chains through which force is transmitted from the motor to raise the upper support 124 relative to the base 122. The actuator 126 may be controlled in any suitable manner, such as by a controller that interfaces with a control device (eg, a remote control, a smart phone, etc.) or a simple switch that supplies power thereto.

[0052] As mentioned above, the first end of the actuator 126 is pivotally coupled to the head side of the upper support 124. For example, as shown, the first end of the actuator 126 can be pivotally coupled to the longitudinal middle member 124f of the upper support 124 near the head end member 124c via the hinge 126a, or can alternatively be pivotally coupled to the head end member 124c with the hinge 126a. The pivot axis of the hinge 126a can be positioned above the pivot axis of the hinge 128 and / or below the upper support 124 (e.g., the frame of the upper support).

[0053] As also mentioned above, the second end of the actuator 126 is pivotally coupled to the foot side of the lower base 122. For example, as shown, the second end of the actuator 126 can be pivotally coupled to the foot end member 122d via a hinge 126b. The pivot axis of the hinge 126b can be positioned below and / or in front of the pivot axis of the hinge 128 and / or in the same plane as the lower base 122 (e.g., the frame of the lower base).

[0054] The adjustment mechanism 120 can be coupled to the mattress 110 to prevent relative movement therebetween. The adjustment mechanism 120 is operable to pivot the head portion 112 of the mattress 100 upward from a flat configuration to an inclined configuration by generally pressing upward against the head portion 112 of the mattress and downward against a support surface (e.g., a bed frame or base) supporting the adjustable bed system 100. However, as the upper support 124 tilts from the flat configuration to the inclined configuration, the force from the head portion 112 acting on the upper support 124 changes from a vertical direction (e.g., straight down in the absence of a horizontal force component) to acting in a forward direction. The direction of the changed force can tend to cause the head portion 112 of the mattress to slide downward along the upper support 124 toward its rear end and / or tend to push the adjustment mechanism 120 away from the mattress 110 in a forward direction.

[0055] The upper support 124 of the adjustment mechanism 120 engages and / or may be coupled to the head portion 112 of the mattress to prevent movement therebetween, such as to prevent longitudinal or lateral sliding of the head portion 112 relative to the upper support 124. For example, the engagement or coupling of the upper support 124 to the head portion 112 prevents the head portion 113 from sliding downwardly along the upper support 124, such as when the adjustable bed system 100 is in, moving to, or moving from an inclined configuration.

[0056] In one example, the upper support 124 may include one or more support panels 124g that substantially span the upper support width S_W. For example, the one or more support panels 124g may be coupled to and extend between the left and right members 124a, 124b. The one or more support panels 124g may be configured to distribute forces from the upper support 124 to the mattress 110 (e.g., the upper sub-portion 112a of the head portion 112 thereof), for example, over a larger surface area than the frame of the upper support 124.

[0057] One or more support panels 124g can alternatively or additionally be configured to be securely coupled to the mattress 110 (e.g., to the upper subsection 112a of the head portion 112 thereof) to prevent or limit relative movement therebetween. For example, one or more support panels 124g can include a first connection feature on an upper surface thereof, such as one side of a hook-and-loop fastener (e.g., a loop side or other material configured to couple to a hook side).

[0058] The mattress 110 may include one or more mattress panels 119 that are coupled to the downwardly facing surface (i.e., surrounding the cavity) of the upper sub-portion 112a of the head portion 112 of the mattress 110, such as coupled to the lower cover 110b. The mattress panel 119 includes a second connection feature on its downwardly facing surface that is configured to engage the first connection feature of the upper support 124, such as the other side (e.g., the hook side) of the hook and loop fastener. Additionally or alternatively, the mattress panel 119 may, for example, be adhered to the downwardly facing surface of the upper sub-portion 112a of the mattress 110. Furthermore, in some examples, the mattress 110 or portions thereof may be molded to one or more support panels 124g. When the adjustment mechanism 120 is positioned in the cavity 118 of the mattress 110, the mattress panel 119 is arranged to be engaged by the support panel 124g. When the adjustment mechanism 120 is positioned in the cavity and the upper support member 124 is pressed against the downward-facing surface of the head portion 112 of the mattress 110, the support panel 124g is pressed against the mattress panel 119 to connect thereto and prevent relative movement (e.g., shear movement or sliding movement) therebetween, and thereby prevent relative movement between the upper support member 124 of the adjustment mechanism 120 and the head portion 112 of the mattress 110.

[0059] In yet another example, the mattress 110 can be configured to be coupled to the upper support 124 using straps coupled to the upper sub-portion 112a (e.g., coupled to the lower cover 110b lining the cavity 118) and / or a plurality of recesses in the upper sub-portion 112a that receive the straps therein (e.g., further recessed relative to the cavity 118) or otherwise coupled to the upper support 124 of the adjustment mechanism 120 (e.g., a member of the frame of the upper support). In yet another example, clips, snaps, magnets, or other fasteners can couple the head portion 112 of the mattress 110 (e.g., the upper sub-portion 112a) to the upper support 124 of the adjustment mechanism 120. In yet another example, the upper support 124 of the adjustment mechanism 120 can be embedded in the foam forming the mattress 110, for example, where the foam is cured around the frame member and / or support panel 124g (e.g., formed of a mesh material).

[0060] The lower base 122 of the adjustment mechanism 120 can be coupled to the mattress 110 to prevent the adjustment mechanism 120 from moving relative to the mattress 110 in a forward direction, for example, when the adjustable bed system 100 is in, moves to, or moves from the tilted configuration. More specifically, the coupler 130 couples the lower base 122 of the adjustment mechanism 120 to another portion of the mattress 110 to prevent the lower base 122 from moving away from the other portion of the mattress 110 (e.g., the foot portion 114 of the mattress) in the forward direction. For example, the coupler 130 couples to the lower base 122 at a front end 130a and couples to a coupling portion 110c of the mattress 110 at a rear end 130b that is located behind the cavity 118 and / or does not change or substantially change position relative to a support surface (e.g., a bed frame or base) or the foot portion 114 of the mattress 110 when the adjustable bed system 100 moves between the flat configuration and the tilted configuration. The coupling portion 110c may be or otherwise include, for example, the foot portion 114 of the mattress 110 (eg, a lower surface or portion of the foot portion or lower cover 110b ), or may alternatively or additionally include the intermediate portion 116 .

[0061] Reference again Fig.13 and Fig.14 In the case of an adjustable bed mechanism 100" that includes a first adjustment mechanism 120H and a second adjustment mechanism 120F that correspond to the head portion 112 and the foot portion 114 of the mattress 110", respectively, one or more coupling portions 110c may include or be formed by the middle portion 116 of the mattress 110". For example, the first connector 130H of the first adjustment mechanism 130 may be coupled to the middle portion 116 of the mattress 110", and the second connector 130H of the second adjustment mechanism 130 may be coupled to the middle portion 116 of the mattress 110" at the same or different coupling positions 110c. In addition, a single connector 130 may extend between and couple the first adjustment mechanism 120H and the second adjustment mechanism 120F (e.g., with a common panel extending therebetween).

[0062] The coupler 130 may be or include one or more flexible panels. Each of the panels forms a front end 130a and a rear end 130b of the coupler 130 (i.e., disposed toward the head end and the foot end of the adjustable bed system 100, respectively). Figures 1 to 3 and Figure 7 As shown, the connector 130 is configured as a panel that spans the cavity width C_W of the cavity 118. Figure 10 to Figure 11As shown, the coupler 130 is configured to span a panel that is less than half of the cavity width C_W of the cavity 118. In another configuration (not shown), the coupler 130 may include two or more flexible panels (e.g., strips) that are spaced apart and cooperatively form a width that is less than half of the cavity width C_W of the cavity. The panels are made of a substantially inextensible material (such as woven nylon or other woven fabric) to prevent the lower base 122 from moving forward relative to the foot portion 114 of the mattress 110.

[0063] The rear end 130b of the coupler can be coupled to the mattress 110 in any suitable manner. For example, the panel of the coupler 130 can be formed continuously with the lower cover 110b (e.g., the rear end 130b is continuous with the lower cover 110b) or can be coupled to the lower cover (e.g., stitching, adhesive, or fasteners, such as a zipper). In addition, the mattress 110 can include a reinforcement at the coupling location 110c, for example, including a material other than the lower cover 110b and / or a material that is stronger than the lower cover 110b, such as nylon or a ripstop material, which is coupled to the mattress 110 (e.g., adhered and / or sewn to the lower cover 110b) and the rear end 130b of the coupler 130 is coupled to the reinforcement.

[0064] The front end 130a of the panel is coupled to the lower base 122. For example, the front end 130a is configured to wrap around the head end member 122c (as shown) or the foot end member and is coupled to itself with a suitable fastener (e.g., a zipper, as shown), and thus the front end 130a of the panel is coupled to the lower base 122. Alternatively, the front end 130a of the panel may include one or more additional attachment panels that extend from the panel (e.g., sewn or otherwise attached thereto) and are configured to wrap around the head end member 122c or the foot end member and be coupled to the panel with a suitable fastener (e.g., a zipper). For example, where the frame of the lower base 122 includes a centrally positioned support post 122e, the panel (or attachment panel) may wrap around the head end member 122c on each side of the support post 122e. When in the first, second, and third configurations, the panel of the coupler 130 can extend below the foot end member 122d and can further extend below the head end member 122c of the lower base.

[0065] The front end 130a (e.g., a panel) of the coupler 130 can also be configured to releasably couple to the mattress 110 forward of the cavity 118, which can retain and / or partially or completely enclose the adjustment mechanism 120 within the cavity 118 when the mattress is in the third configuration. When the front end 130a of the coupler 130 is released from the mattress 110, the adjustment mechanism 120 can be operated to move the adjustable bed system 100 toward the tilted configuration (e.g., such that the lower base 122 of the adjustment mechanism is at least partially outside and / or below the cavity 118). For example, the front end 130a can be releasably coupled to the mattress 110 (e.g., the lower cover 110b at the head end of the mattress) using a zipper or other suitable releasable coupling device (e.g., snaps, buttons, hook and loop fasteners). Where the coupler 130 is a panel that spans the cavity width C_W of the cavity 118, the left and right sides of the panel may be coupled to the mattress 110 laterally outward of the cavity 118 (e.g., using a zipper extending around the left, right, and front sides of the cavity 118, such as Figures 1 to 3 and Figure 7 ).

[0066] refer to Figures 15 to 17 As mentioned above, the adjustable bed system 100 can be disposed in a third configuration, such as for transport or storage. In the third configuration, the adjustment mechanism 120 is in a flat configuration (e.g., a collapsed configuration) and positioned in the cavity 118 of the head portion 112 of the mattress 110, and the foot portion 114 is folded over the head portion 112 so that their upper surfaces face each other.

[0067] Additionally, each of the head portion 112 and the foot portion 114 can be compressed (e.g., in a vertical direction) to reduce the volume of the head portion 112 and the foot portion 114 relative to their relaxed state. The head portion 112 and the foot portion 114 can be compressed by different amounts relative to their dimensions in the relaxed state, for example, the head portion 112 is compressed less than the foot portion 114 in absolute measure and relative to the total mattress height M_H. For example, in the case where the mattress 110 has a substantially constant mattress height M_H over a mattress width M_W and a mattress length M_L and the adjustment mechanism 120 is substantially incompressible in the vertical direction, the foam forming the head portion 112 (e.g., the upper sub-portion 112a of the head portion) of the mattress 110 is thinner than the foam forming the foot portion 114, so that an equally applied force (e.g., pressure) will cause the head portion 112 to compress a less amount than the foot portion 114. For example, the foam forming each of the upper sub-portion 112a of the head portion 112 and the foot portion 114 may be compressed to a maximum allowable compression factor, such as approximately 50% of its thickness.

[0068] The head portion 112 and foot portion 114 of the mattress 110 may be maintained in a compressed state using a removable packaging 150, for example, vacuum sealed in the packaging 150 (eg, a vacuum bag). The adjustment mechanism 120 is contained in the packaging 150 (eg, under vacuum).

[0069] The adjustable bed system 100 can be placed in a third configuration (e.g., packaged) in different ways. In any of the examples described below, the adjustment mechanism 120 is inserted into the cavity 118 of the mattress, and the connector 130 is connected to the lower base of the adjustment mechanism (e.g., by wrapping the connection panel 130c around the head end member 122c and connecting to itself with a zipper, and the connection panel 130c can be further releasably connected to the mattress 110 in front of the cavity 118 and / or the mattress 110 on the side of the cavity 118, such as with a zipper). The adjustable bed system 100 is then compressed and maintained in a compressed state.

[0070] In a first example, a vacuum is used to compress and maintain the adjustable bed system 100. The adjustable bed system 100 is placed in a packaging 150 (ie, a vacuum bag), a vacuum is drawn in the packaging 150 to compress the mattress 110, and the packaging 150 is sealed to maintain the vacuum.

[0071] In a second example, the adjustable bed system 100 is mechanically compressed and maintained in a compressed state using a vacuum. The adjustable bed system 100 is placed in a packaging 150 (i.e., a vacuum bag), the head portion 112 and the foot portion 114 of the mattress 110 are mechanically compressed by different distances, a vacuum is drawn in the packaging 150 simultaneously with or after the mechanical compression, and the packaging 150 is sealed to maintain the vacuum and maintain the mattress 110 in a compressed state.

[0072] To mechanically compress the adjustable bed system 100, a plate compression system 1260 may be used. In one example, the plate compression system 1260 includes a press 1262 that presses a single planar plate (not shown) downwardly against the upper surfaces of the head portion 112 and the foot portion 114 of the mattress 110 to compress the head portion 112 and the foot portion 114 a common distance. The press 1262 of the plate compression system 1260 may be operated, for example, hydraulically, pneumatically, or using weight and gravity. In a second example, the press 1262 presses a step plate 1264 (e.g., at a common pressure) or a plurality of plates (e.g., at a common or different pressures) downwardly against the upper surfaces of the head portion 112 and the foot portion 114 of the mattress 110. The step plate 1264 includes a head plate 1264a at a first height, a foot plate 1264b at a second height lower than the first height, and a transition portion 1264c extending between the head plate 1264a and the foot plate 1264b. The press 1262 presses the step plate 1264 against the mattress 110 over a stroke distance greater than the compression distance of the foot portion 114 and the difference P_H between the first height of the head plate 1264a and the second height of the foot plate 1264b. Due to the different heights of the head plate 1264a compressing the head portion 112 of the mattress 110 and the foot plate 1264b compressing the foot portion 114 of the mattress 110, the plate compression system 1260 compresses the head portion 112 by a different amount than the foot portion 114 (i.e., the head portion 112 is compressed by a less distance than the foot portion 114). Furthermore, the step plate 1264 may be configured such that a compressed height M_Hc of the foot portion 114 of the mattress 110 and a compressed height U_Hc of the upper sub-portion 112a of the head portion 112 of the mattress 110 are substantially equal.

[0073] Whether the mattress 110 is compressed using a vacuum or mechanically, with the packaging 150 sealed to maintain the vacuum and the mattress 110 in a compressed state, the mattress 110 can then be folded over the head portion 112 about the central portion 116 and held in the folded state using additional packaging, such as a bag (e.g., with or without further vacuum) or straps into which the packaging 150 is inserted. In the event that the adjustable bed system 100 includes two adjustment mechanisms 120 at the head portion 112, the adjustable bed system 100 can additionally be folded about the longitudinal axis of the mattress 110 (i.e., between the two adjustment mechanisms 120 and the left and right sides of the mattress 100).

[0074] To subsequently use the adjustable bed system 100, the packaging 150 is removed and the front end 130a of the panel is separated from the mattress 110 to allow the adjustment mechanism 120 to raise the head portion 112 of the mattress 110 relative to the lower base 122 and the flat support surface thereunder.

[0075] While the present disclosure has been described in conjunction with certain embodiments, it should be understood that the present disclosure is not limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims, which scope is consistent with the broadest interpretation so as to encompass all such modifications and equivalent structures permitted by law.

Claims

1. An adjustable bed system, comprising: a mattress having a head portion and a foot portion located rearward of the head portion, wherein the head portion defines a downwardly open cavity; as well as an adjustment mechanism having a lower base, an upper support movably coupled to the lower base, and an actuator operable to move the upper support relative to the lower base; wherein the adjustment mechanism is positioned in the cavity and coupled to the mattress, and when the actuator is operated, the adjustment mechanism moves the adjustable bed system between a flat configuration in which the head portion is substantially coplanar with the foot portion and an inclined configuration in which the head portion is inclined relative to the foot portion.

2. The adjustable bed system of claim 1, wherein the head portion includes an upper sub-portion having a downwardly facing surface defining the cavity, and wherein the upper support of the adjustment mechanism is coupled to the downwardly facing surface.

3. The adjustable bed system of claim 2, wherein the upper support of the adjustment mechanism is coupled to the downwardly facing surface using a hook and loop fastener system.

4. An adjustable bed system according to claim 3, wherein the upper support member includes one or more support panels forming one side of the hook and loop fastener system, and the downwardly facing surface includes one or more mattress panels, which form the other side of the hook and loop fastener system and are connected to the one or more support panels.

5. The adjustable bed system according to claim 2 further includes a connector, which connects the lower base of the adjustment mechanism to the connecting portion of the mattress located behind the cavity to prevent the adjustment mechanism from moving forward relative to the foot portion of the mattress.

6. The adjustable bed system according to claim 1 further includes a connector, which connects the lower base of the adjustment mechanism to a connecting portion of the mattress located behind the cavity to prevent the adjustment mechanism from moving forward relative to the foot portion of the mattress.

7. The adjustable bed system of claim 6, wherein the connecting portion does not move relative to the flat support surface on which the adjustable bed system is positioned when the adjustment mechanism moves the adjustable bed system between the flat configuration and the inclined configuration.

8. The adjustable bed system of claim 7, wherein the connector comprises one or more flexible panels, each of the panels having a first end coupled to the lower base and a second end coupled to the coupling portion.

9. The adjustable bed system of claim 8, wherein the first end is coupled to the lower base using a zipper.

10. The adjustable bed system of claim 9, wherein the one or more panels cooperatively span less than half the width of the cavity.

11. The adjustable bed system of claim 9, wherein the one or more panels are releasably connectable to the mattress at one or more of a head end of the cavity or a side of the cavity.

12. The adjustable bed system of claim 11, wherein the one or more panels enclose the adjustment mechanism within the cavity.

13. An adjustable bed system, comprising: a mattress having a head portion and a foot portion; as well as an adjustment mechanism that raises the head portion from a first configuration in which a first upper surface of the head portion and a second upper surface of the foot portion are substantially coplanar and a second configuration in which the first upper surface is inclined relative to the second upper surface; Wherein in a third configuration, the first upper surface faces the second upper surface, and the distance the head portion of the mattress is compressed from its relaxed state is less than the distance the foot portion of the mattress is compressed from its relaxed state.

14. The adjustable bed system of claim 13, wherein in the third configuration, the head portion of the mattress and the foot portion of the mattress are compressed by a removable packaging.

15. The adjustable bed system of claim 14, wherein the removable packaging is a vacuum bag, the mattress and the adjustment mechanism being enclosed in the vacuum bag.

16. The adjustable bed system of claim 13, wherein the head portion of the mattress defines a cavity, the adjustment mechanism being positioned in the cavity.

17. An adjustable bed system comprising: a mattress having a head portion and a foot portion; as well as an adjustment mechanism having a lower base, an upper support pivotally coupled to the lower base, and an actuator operable to move the upper support upward relative to the lower base; wherein the adjustment mechanism is configured to raise the head portion of the mattress when the actuator is operated from a first configuration to a second configuration; and Wherein the lower base of the adjustment mechanism is coupled to a coupling portion of the mattress to prevent the lower base from moving in a forward direction away from the foot portion of the mattress.

18. The adjustable bed system of claim 17, wherein the lower base comprises a frame having a head-end member and a foot-end member spaced longitudinally apart, and left and right side members spaced laterally apart and extending between and coupled to the head-end member and the foot-end member; Wherein the head end member is coupled to the coupling portion of the mattress with a coupler extending therebetween.

19. The adjustable bed system of claim 18 wherein the coupler comprises a flexible panel that wraps around the head end member of the frame of the lower base.

20. The adjustable bed system of claim 19, wherein the frame of the lower base includes struts extending upward from the head end member and engaging the upper support member when the adjustable bed system is in the first configuration, and wherein the front ends of the connectors are wrapped around the head end member on different sides of the struts.

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