Abstrict An adjustable bed including a multi-section mattress frame mounted
on a base frame. The mattress frame includes a head section and
a lower section. The lower section may include an intermediate or
seat section and a leg section. A mattress support is joined to
the mattress frame. The mattress support includes a plurality of
wire grids joined to the sections. Each grid includes a plurality
of tandemly arranged, transversely extending, generally rectangular
closed loops. End portions of the loops are axially aligned and
joined to lateral or side portions of the mattress frame. A plurality
of parallel, longitudinally or axially extending support wires are
positioned on the loops. The support wires extend generally parallel
to the lateral portions or sides of the mattress frame. Ends of
the support wires may be downturned and joined to an end wire.
Claims The embodiments of the invention in which an exclusive property
or privilege is claimed are defined as follows:
1. A mattress frame for an adjustable bed, said frame comprising:
a generally U-shaped member including an end section joined to
spaced, generally parallel side sections; and
a rigid wire grid work affixed to said U-shaped member, said grid
work including:
a plurality of transversely extending, spaced closed wire loops,
said loops each having ends joined to said side sections; and
a plurality of longitudinally extending, spaced, parallel support
wires, said support wires being joined to and resting on said spaced
closed wire loops and positioned to contact a mattress placed on
said U-shaped member.
2. A mattress frame as defined by claim 1 wherein said longitudinally
extending support wires have downwardly turned ends.
3. A mattress frame as defined by claim 2 further including an
end wire joined to said downwardly turned ends.
4. A mattress frame as defined by claim 3 wherein said end wire
includes a base and upstanding legs, said downturned ends being
joined to said base and wherein said frame further includes a transverse
end wire joined to said support wires and to said upstanding legs
of said end wire.
5. A mattress frame as defined by claim 4 wherein said wire loops
are each generally rectangular in plan view with parallel end portions,
said end portions of adjacent loops being axially aligned.
6. A mattress frame as defined by claim 5 further including an
end wire loop having transversely extending, spaced parallel wire
portions joined to curved end portions.
7. A mattress frame as defined by claim 1 wherein said wire loops
are each generally rectangular in plan view with parallel end portions,
said end portions of adjacent loops being axially aligned.
8. A mattress frame as defined by claim 7 further including an
end wire loop having transversely extending, spaced parallel wire
portions joined to curved end portions.
9. A mattress frame as defined by claim 1 wherein said grid work
further includes a plurality of longitudinally extending spacer
wires joined to said closed wire loops.
10. A mattress frame as defined by claim 9 wherein said grid work
further includes a plurality of lower, transversely extending, spaced
closed wire loops, said lower closed wire loops engaging said spacer
wires and having end portions joined to said side sections.
11. A mattress frame as defined by claim 10 wherein said lower
closed wire loops are staggered with respect to said plurality of
spaced closed wire loops so as to be positioned between said plurality
of closed wire loops when the grid work is viewed in plan.
12. A mattress frame as defined by claim 11 wherein said lower
closed wire loops are generally rectangular in plan and said end
portions thereof are axially aligned.
13. A mattress frame as defined by claim 12 wherein said longitudinally
extending support wires have downwardly turned ends.
14. A mattress frame as defined by claim 13 further including a
generally U-shaped end wire having a base joined to said downwardly
turned ends and upstanding legs.
15. A mattress frame as defined by claim 14 further including a
transverse end wire joined to said top surface wire and to said
upstanding legs of said end wire.
16. An adjustable bed, comprising:
a base frame;
a mattress frame including ahead section and a lower section operatively
connected to said head section for relative angular movement, said
sections each including spaced, generally parallel lateral portions;
mounting means on the base frame and connected to said mattress
frame for mounting the mattress frame to the base frame and permitting
the head section to be positioned and locked in different angular
positions with respect to the base frame and said lower section;
a head section mattress support wire grid on said mattress frame
head section; and
a lower section mattress support grid on said mattress frame lower
section, each of said grids including:
a plurality of generally rectangular, closed loop members arranged
in tandem, spaced, generally parallel relationship, said loop members
each including end portions joined to said lateral portions of the
respective mattress frame sections; and
a plurality of spaced, parallel support wires positioned on said
loops and extending generally parallel to said lateral portions.
17. An adjustable bed as defined by claim 16 wherein support wires
of said head section grid include lower ends which are bent downwardly
and said lower section grid includes upper and lower ends which
are bent downwardly.
18. An adjustable bed as defined by claim 17 wherein said head
section grid further includes an end wire joined to said downturned
ends.
19. An adjustable bed as defined by claim 18 wherein said head
section grid further includes a transverse end wire joined to said
support wire and to said end wire.
20. An adjustable bed as defined by claim 19 wherein each of said
grids includes a plurality of longitudinally extending spacer wires
joined to said closed loops and extending generally parallel to
said support wires.
21. An adjustable bed as defined by claim 20 wherein each of said
grids further includes a plurality of lower closed loops having
transverse portions engaging said spacer wires and end portions
joined to said lateral portions of one of the mattress frame sections.
22. An adjustable bed as defined by claim 21 wherein said lower
closed loops in plan are positioned between said plurality of generally
rectangular closed loops.
Description BACKGROUND OF THE INVENTION
The present invention relates to beds and more particularly to
mattress supports for adjustable, multi-section beds.
A conventional residential bed includes a frame, a box spring and
a mattress. The mattress is positioned on the box spring. Many different
types of adjustable beds have been proposed principally for use
in the healthcare industry. A typical hospital or nursing home bed
includes a base frame and a multi-section mattress frame. The mattress
frame may include a head section and a lower section. The lower
section may, in turn, be separated into a seat or intermediate section
and a foot section. The sections are pivotally interconnected and
their relative positions may be changed. The occupant may be moved
from a horizontal position to a seated position with the knees bent,
for example. The sections may be adjusted manually or electric motors
may be provided. Generally, healthcare beds are only provided in
a nonstandard or reduced width twin bed size. The twin bed may be
approximately four inches less than the standard residential twin
bed to facilitate movement of the bed through doors and the like.
Healthcare beds have generally included a sheet metal pan or a
wire grid work to support the mattress on the frame. The grid work
includes longitudinally extending and transversely extending wires
supported by a plurality of extension springs. Articulation of the
bed sections results in relative movement between the mattress and
the mattress support and frame structure.
Available healthcare beds have not been generally accepted in the
residential or general consumer market due, in part, to cost and
complexity. The advantages of adjustability have generally not,
therefore, been available to the consumer. The narrower than standard
width of the healthcare bed has also limited appeal. Any attempt
to articulate a standard box spring construction would be cost prohibitive.
The relative motion between the mattress and the support would result
in undesirable friction and fabric wear. The standard wire grid
supports used in the healthcare beds are structurally inadequate
for double or full and queen size bed versions, which would find
appeal in the residential market.
A need exists, therefore, for an adjustable bed including a mattress
support surface which can provide an essentially friction and wear-free
interface with the mattress, which can be adapted to twin, full
and queen size articulating beds and which is relatively inexpensively
manufactured and reliable in use.
SUMMARY OF THE INVENTION
In accordance with the present invention, the aforementioned needs
are fulfilled. Essentially, a wire grid work mattress support is
provided which includes a plurality of closed loop members arranged
in tandem, generally parallel relationship. A plurality of mattress
support wires are joined to the loop members. The loop members are
joined to side portions of a mattress frame. The support wires extend
in spaced, parallel relationship and generally parallel to the side
portions of the mattress frame. The parallel support wires provide
a relatively friction and wear-free interface with a mattress. In
addition, the support wires limit or prevent sideways movement of
the mattress on the frame. The mattress still, however, easily moves
as the bed is adjusted. The closed loop members provide sufficient
structural strength to adapt the mattress support to conventional
bed widths.
In narrower aspects of the invention, the wire loop members are
generally rectangular in plan, having end portions which are axially
aligned. The end portions are welded or otherwise suitably joined
to the mattress frame. An end of the grid work has the support wires
downturned and joined to an end wire. The end wire may be U-shaped
with legs joined to a transverse end wire. The downturning of the
ends prevents snagging with the mattress and increases the strength
or rigidity of the grid work.
In addition, increased structural support may be provided by a
plurality of longitudinally extending space wires joined to the
wire loop members and extending generally parallel to the support
wires. Another set of transversely extending closed loop members
may be secured to the support wires. In the preferred form, this
set of closed loop members is positioned in staggered relationship
to the set positioned under the support wires. The additional spacer
wires and rectangular loop members provide increased strength to
accommodate standard or double and queen size mattress widths.
The mattress support in accordance with the present invention is
relatively easily manufactured from standard steel wire currently
used in healthcare bed products. The support surface provides a
relatively friction and wear-free interface between the support
and mattress. The support is readily adapted to twin, full and queen
size articulating beds. The mattress support permits the advantages
of articulating bed structures to be provided to the consumer, residential
or general retail market.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side, elevational view of an adjustable bed with an
articulated or adjusted position shown in phantom;
FIG. 2 is a perspective view of a mattress frame incorporated in
the present invention;
FIG. 3 is a fragmentary, enlarged perspective view of the mattress
frame, a bed frame or base and a positioner;
FIG. 4 is a perspective view of a mattress support in accordance
with the present invention;
FIG. 5 is a fragmentary, cross-sectional view showing the attachment
of the mattress support to the mattress frame;
FIG. 6 is a fragmentary, perspective view showing a modified mattress
support attached to a bed frame;
FIG. 7 is a perspective view of another mattress support in accordance
with the present invention; and
FIG. 8 is a fragmentary, cross-sectional view showing the attachment
of the embodiment of FIG. 7 to a mattress frame.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An adjustable bed incorporating the mattress support in accordance
with the present invention is illustrated in FIG. 1 and generally
designated by the numeral 10. Bed 10 includes a castored base frame
12 having legs 14 16 supported on castors 18. Base frame 12 defines
lateral side portions 20. A multi-section mattress frame 22 is positioned
on base frame 12.
Mattress frame 22 includes a head section 24 and a lower section
26. For simplicity, only a two section adjustable bed is illustrated.
Commonly owned U.S. Pat. application to Peterson, Ser. No. 07/540282
filed Jun. 18 1990 entitled ADJUSTABLE BED and now U.S. Pat. No.
5105486 discloses a bed wherein the lower section 26 includes
an intermediate or seat section pivoted to a foot section. The three
section bed permits adjustment into a "knee break" position.
Section 26 is pivotally interconnected to section 24 at pivot ends
28 30. As shown in FIGS. 1 and 2 sections 24 26 are formed by
tubular members. Section 24 is generally U-shaped in plan and includes
a base 34 and elongated lateral portions 36 38. Lower section 26
includes a base 40 and elongated lateral portions 42 44. Sections
24 26 are formed by bending circular in cross section tubular members
and deforming the end portions to define pivot ends 28 30. The
tubular sections eliminate or reduce sharp corners or edges which
could possibly cut or injure the user if portions of the occupant
are caught between the bed frame and stationary objects during adjustment.
As shown in FIGS. 1 and 2 mattress support frame 22 includes mounting
tabs 46 48 50 and 52. Tabs 46 48 are pivoted to rigid links 56
which extend from side portions 58 of base frame 12. Links 62 extend
between attachment tabs 50 52 and link brackets 64 join to portions
58 of frame 12. Link 62 permits longitudinal movement of the bed
frame as it is moved from a flat horizontal position illustrated
in solid lines in FIG. 1 to a contoured or seated position, as illustrated
in phantom.
Various mechanisms may be used to hold the mattress frame sections
in angular positions. FIG. 3 illustrates a linear positioner, generally
designated 70 which may be used. As shown in FIGS. 2 and 3 a rigid
link 72 is joined to a transversely extending tubular portion 74
of frame section 24. A second rigid link 76 is joined to a transversely
extending tubular portion 78 of frame portion 26. An elongated rod
82 is pivoted at an end 84 to rigid link 76. Rod 82 extends through
a linear positioner lock mechanism 86. Mechanism 86 is pivoted by
a point 88 to rigid link 72. An adjustable stop 90 is positioned
on end 92 of linear positioner rod 82. Positioned within lock mechanism
86 are a pair of spaced, apertured lock plates (not shown) through
which rod 82 extends. The lock may be released from contact with
rod 82 by a cam mechanism actuated by a cable 96. The linear positioner
and lock mechanism are more fully described and illustrated in the
aforementioned U.S. Pat. application Ser. No. 07/540282. A gas
spring 102 extends between link 72 at pivot pin 88. Gas spring 102
is pivoted at an end 104 to base frame portion 20. An opposite end
106 is pivoted to strut 72. The sections 24 26 may be manually
moved to an angular position or placed in the horizontal position
and locked in position through the linear positioner 70. Other lock
mechanisms may, of course, be used in an adjustable bed.
A mattress 120 is placed on mattress frame 22. A wire grid work,
generally designated 130 in FIG. 4 provides a mattress support
structure. The grid work includes a plurality of longitudinally
extending, parallel, equally spaced support wires 132. A plurality
of closed loop wire members 134 136 138 and 140 are joined to
an under surface of support wires 132. Grid work 130 defines two
areas designated 142 and 144. Grid work 130 is joined to upper frame
section 24 as explained below, and area 144 is adjacent the seat
or lower back area of the bed.
When in position, closed loop member 134 is adjacent the head end
of the bed. Member 134 includes spaced, parallel transversely extending
portions 146 148. Portions 146 148 are joined to semicircular
end portions 150. Curved portions 150 approximate the curvature
of the corners or bent portions where the base 34 and legs 36 38
of frame section 24 join.
Each of the transversely extending wire loop members 136 138 and
140 includes spaced, parallel transversely extending portions 152
154 joined to end portions 156. End portions 156 of the tandemly
arranged, spaced loop members are in axial alignment. Loop members
136 138 and 140 are generally rectangular in plan view. The axial
dimension of end portions 156 in loops 138 140 is less than the
axial dimension of end portion 156 of loop 136. The configuration
of the loops within the seat area 144 increases the density of transverse
wire portions. This increases the strength, rigidity and load carrying
capacity of the grid work at the seat area.
End portions 162 of wires 132 are downturned at a 90.degree. angle
with respect to the longitudinally extending portions of the wire.
In the embodiment shown in FIG. 4 these downturned ends are joined
to a base 164 of a generally U-shaped end wire 166. Upstanding legs
168 of end wire 166 are joined to a transversely extending end wire
170. End wire 166 in conjunction with the downturned ends 162 forms
a truss-like structure at the end of the grid work 130 which increases
the strength and rigidity. Downturning of the ends also ensures
that the grid work will not snag or catch on the mattress which
moves along support wires 132 during bed adjustment.
As shown in FIG. 6 another grid work 180 is provided for lower
section 26 of the mattress frame. Grid work 180 which is of the
same general construction as grid work 130 includes a plurality
of longitudinally extending wires 132 which are joined and supported
on generally rectangular closed loop wire members 182. As an alternative
to end wire 166 wires 132 at their downturned ends 162 may be joined
to a transverse, end wire 184. Transverse wire portion 154 of the
lower most closed loop member 182 performs the function as the transverse
wire 170 illustrated in FIG. 4. The end of grid work 180 adjacent
the pivot between the frame sections is also downturned in the same
fashion as illustrated in either FIG. 4 or 6. If a three section
mattress frame is provided, the intermediate section is provided
with an identical grid work with both ends downturned, as illustrated.
Grid works 130 180 are joined to mattress frame sections 24 26
as illustrated in FIGS. 5 and 6. The straight or linearly extending
end portions 156 of the loops are joined by a weld 198 to lateral
tubular portions 36 38 or 42 44 of the respective mattress frames.
As shown, mattress 120 sits on the longitudinally extending support
wires 132. The support wires, due to their positioning and sizing,
provide a relatively friction-free interface between mattress 120
and the mattress support grid work. In addition, mattress 120 will
deform into the space between adjacent wires 132. The grid work
limits or prevents sideways movement between the lateral portions
of the mattress frame.
The mattress support grid work of FIGS. 4 5 and 6 is primarily
adapted for a conventional twin bed width. For larger or wider full,
double or queen size mattress frames, a grid work generally designated
220 and illustrated in FIGS. 7 and 8 is presently preferred. Grid
work 220 includes a plurality of longitudinally extending mattress
support wires 222. Mattress support wires 222 are positioned on
a first layer of transversely extending closed loop members 224
and 226. Members 226 adjacent the seating area of the grid work
provide an increased density of transverse wire portions 228. The
closed loop, generally rectangular members 226 include axially aligned
end portions 230.
Increased strength is provided in embodiment 220 by another layer
of rectangular closed loop members 236. A plurality of spacer wires
238 are joined to closed loop members 226. Spacer wires 238 extend
parallel to and are staggered between wires 222. Members 236 are
joined to wires 238. Wires 238 space loop members 236 from loop
members 226. As shown in FIG. 7 members 236 are joined to spacer
wires 238 in a staggered position, in plan view, with respect to
loop members 226. Loop members 236 similarly include axially aligned
end portions 230.
As shown in FIG. 8 end portions 230 of loop members 226 236 are
joined to the lateral portions of the mattress support frame by
suitable welds 242. The staggering of the rectangular loop members
permit access to and alternate welding of both layers of the loop
members to the longitudinally extending wires. Grid work 220 creates
a truss-like arrangement of wire structure. The truss-like arrangement
reliably supports the heaviest expected bed occupants over the entire
width of full and queen size beds. End portions of grid work 220
are downturned in the same fashion of the embodiment of FIGS. 4
and/or 6 to prevent snagging or tearing of the mattress.
The grid works of the present invention provide sufficient strength
to support a mattress and the occupants in an adjustable bed. The
grid works are easily and relatively inexpensively manufactured
using wire and conventional techniques. Increased strength and rigidity
is provided at the seat areas of the bed by increasing the density
of the transverse wire portions of the loop members. A relatively
friction and wear-free interface is created between the mattress
and the mattress support. Sideways movement of the mattress on the
support is restricted or prevented.
In view of the above description, those of ordinary skill in the
art may envision various modifications which would not depart from
the inventive concepts disclosed herein. The above description should,
therefore, be considered as only that of the preferred embodiments.
The true spirit and scope of the present invention may be determined
by reference to the appended claims. |