Abstrict An adjustable bed includes a universal, or interchangeable, bed
end that can be used at either end of the bed and can be connected
with an existing motor drive assembly. The bed end may include a
gear box having first and second input shafts that are selectively
covered by a movable cover. The bed end may include a frame having
drain openings for draining water from the bed end when the bed
end is washed. The bed end may also include an end cap that is fastened
to the frame in a unique manner, and that helps to maintain a panel
of the bed end cover in a curved or bowed configuration.
Claims Having described the invention, we claim:
1. A gear box for a bed end, comprising: a housing; first and second
input shafts in said housing for receipt of rotational force for
operating said gear box; and a cover associated with said housing
and having a first closed position covering said first input shaft
and enabling access to said second input shaft, and a second closed
position covering said second input shaft and enabling access to
said first input shaft.
2. A gear box as set forth in claim 1 wherein said cover pivots
on said housing between the first closed position and the second
closed position about a pivot axis.
3. A gear box as set forth in claim 1 wherein said cover includes
first and second ears that are resiliently movable relative to each
other to enable movement of said cover into and out of said first
and second closed positions.
4. A gear box as set forth in claim 3 wherein said ears are movable
closer to each other to enable movement of said cover into and out
of said first and second closed positions and are movable away from
each other to enable latching of said cover in one of said first
and second closed positions.
5. A gear box as set forth in claim 1 including a first latch that
releasably holds said cover in the first closed position and a second
latch that releasably holds said cover in the second closed position,
said first latch including a first latching portion of said housing
that is engageable with a latching section of said cover, and said
second latch including a second latching portion of said housing
that is engageable with said latching section of said cover.
6. A gear box as set forth in claim 5 wherein said latching section
of said cover includes first and second ears that are resiliently
movable relative to each other to enable movement of said cover
into and out of said first and second closed positions.
7. A gear box as set forth in claim 6 wherein said cover has an
open position intermediate said first and second closed positions,
each one of said latching portions of said housing including at
least one camming surface for moving said ears toward each other
upon movement of said latching section of said cover from the open
position into one of the first and second closed positions.
8. A gear box as set forth in claim 1 wherein: said cover is supported
on said housing for pivotal movement about a pivot axis relative
to said housing between the first closed position and the second
closed position; and said cover includes first and second ears that
are resiliently movable relative to each other to enable movement
of said cover into and out of said first and second closed positions.
9. A gear box as set forth in claim 8 including a first latch that
releasably holds said cover in the first closed position and a second
latch that releasably holds said cover in the second closed position;
said first latch including a first latching portion of said housing
that is engageable with a latching section of said cover, and said
second latch including a second latching portion of said housing
that is engageable with said latching section of said cover; said
latching section of said cover including first and second ears that
are resiliently movable relative to each other to enable movement
of said cover into and out of said first and second closed positions;
and said cover having an open position intermediate said first and
second closed positions, each one of said latching portions of said
housing including at least one camming surface for moving said ears
toward each other upon movement of said latching section of said
cover from the open position into one of the first and second closed
positions.
10. A gear box as set forth in claim 1 wherein the cover is associated
with a primary opening on the gearbox housing, and the gearbox housing
also has a secondary opening for enabling access to one of the first
and second input shafts by a manual crank.
11. A gear box as set forth in claim 10 further including a manual
crank engageable through the secondary opening with the first input
shaft and being removable from the first input shaft and thereby
from the gear box of the bed end.
12. A gear box as set forth in claim 10 wherein the cover enables
access to a first end portion of the first input shaft, and the
secondary opening enables access to an opposite second end portion
of the first input shaft.
13. A gear box as set forth in claim 12 further including a second
cover supported on the gearbox housing and selectively movable to
cover or open the secondary opening.
14. A gear box as set forth in claim 1 further including a manual
hi-lo crank that includes a securing mechanism for releasably securing
the manual crank to the gear box.
15. A gear box as set forth in claim 14 wherein the securing mechanism
comprises a detent member engageable with the first input shaft
to resist removal of the manual crank from the height adjustment
mechanism without application of a strong pulling force.
16. A gear box as set forth in claim 14 wherein the securing mechanism
comprises a detent member having a resilient portion that resiliently
engages a portion of the first input shaft.
17. A gear box as set forth in claim 16 wherein the securing mechanism
comprises a wire spring member.
18. A gear box as set forth in claim 1 having a main body portion
that encloses the first and second input shafts and having an output
portion that projects from the main body portion and that is adapted
to be secured to the frame of a bed end.
19. A gear box as set forth in claim 18 wherein the output portion
has a chamber adapted to receive an output shaft that is rotatable
with a lead screw of the bed end, the lead screw and the frame and
the gearbox being movable vertically upon raising and lowering movement
of the bed.
20. A gear box as set forth in claim 19 wherein the housing has
first and second shaft chambers for receiving the first and second
output shafts, respectively.
21. A gear box as set forth in claim 18 wherein the primary opening
in the gear box housing opens into an input shaft chamber that extends
transversely to and communicated with the output chamber.
22. A gear box as set forth in claim 1 wherein the gear box is
adapted to be secured to a frame of a bed end for vertical movement
with the bed end frame.
23. An assembly including at least first and second gear boxes,
each gear box including a housing, first and second input shafts
in the housing for receipt of rotational force for operating the
gear box, and a cover associated with the housing and having a first
closed position covering the first input shaft and enabling access
to the second input shaft and a second closed position covering
the second input shaft and enabling access to the first input shaft.
Description TECHNICAL FIELD
The present invention relates to an adjustable bed. In particular,
the present invention relates to a bed having a bed spring or other
portion that is vertically adjustable, for example, for use in home
health care.
BACKGROUND OF THE INVENTION
Adjustable beds are often used in home health care. Such beds typically
include a height adjustment mechanism that is operable to raise
or lower the bed spring. The height adjustment mechanism may be
manual or electric. A manual mechanism uses a hand crank to operate
a gearbox to raise and lower the bed spring. An electric mechanism
uses an electric motor that rotates a drive shaft or drive tube.
The drive shaft is connected with gearboxes that face inward on
the respective bed ends, that is, toward the opposite end. When
the motor is actuated, rotational force is transmitted to the bed
ends to synchronously raise and lower movable portions of the bed
ends that support the bed spring. One such type of adjustable bed
end is shown in U.S. Pat. No. 5134731 the entire disclosure of
which is incorporated herein by reference.
Since the rotational force acts in the same direction of rotation
at both ends of the bed, identical head and foot bed ends are not
used because their gearboxes would cause one bed end to raise and
the other bed end to lower. As a result, separate head ends and
foot ends are typically provided for an adjustable bed. This results
in the need to manufacture and store two different kinds of bed
ends, and can cause mistakes when delivering and setting up a bed
in a patient's home.
SUMMARY OF THE INVENTION
The present invention relates to an adjustable bed and to various
features of the bed. In various embodiments, the bed includes a
universal, or interchangeable, bed end that can be used at either
end of the bed and can be connected with an existing motor drive
assembly. The bed end may include a gear box having first and second
input shafts that are selectively covered by a movable cover. The
bed end may include a frame having drain openings for draining water
from the bed end when the bed end is washed. The bed end may also
include an end cap that is fastened to the frame in a unique manner,
and that helps to maintain a panel of the bed end cover in a curved
or bowed configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other features of the present invention will
become apparent to one skilled in the art to which the present invention
relates upon consideration the following description of the invention
with reference to the accompanying drawings, in which:
FIG. 1 is a schematic elevational view of one embodiment of an
adjustable bed in accordance with the present invention;
FIG. 2 is a schematic elevational view of one embodiment of a bed
end that forms part of the bed of FIG. 1;
FIG. 3 is a sectional view of one embodiment of a slip nut assembly
that forms part of the bed end of FIG. 2;
FIG. 4 is a perspective view of one embodiment of a slip nut that
forms part of the slip nut assembly of FIG. 3;
FIG. 5 is a sectional view of one embodiment of a gearbox that
forms part of the bed end of FIG. 2;
FIG. 6 is an elevational view of the gearbox of FIG. 5;
FIG. 7 is a schematic perspective view of the bed of FIG. 1;
FIG. 8 is a view of a prior art bed end;
FIG. 9 is an elevational view of one embodiment of a crank that
is usable with the bed end of FIG. 2;
FIG. 10 is a view similar to FIG. 5 showing the crank of FIG. 9
attached to a gearbox;
FIG. 11 is a sectional view of an alternative gearbox embodiment
that can be part of the bed end of FIG. 2;
FIG. 12 is a sectional view of a portion of the gearbox of FIG.
11;
FIG. 13 is a sectional view of another alternative gearbox embodiment
that can be part of the bed end of FIG. 2;
FIGS. 14-17 are views of alternative corner plates one embodiment
of that can be used with the bed end of FIG. 2;
FIG. 18 is an elevational view of one embodiment of a plastic bed
end cover in accordance with the present invention;
FIG. 19 is a cutaway sectional view of the bed end cover of FIG.
18;
FIG. 20 is an exploded view of an alternative plastic bed end cover
embodiment in accordance with the present invention;
FIG. 21 is an exploded view of another alternative plastic bed
end cover embodiment in accordance with the present invention;
FIG. 22 is a front elevational view of a gearbox including a movable
cover in accordance with a feature of the invention, the cover being
shown in one closed position;
FIG. 23 is a view similar to FIG. 22 showing the cover in a second
closed position;
FIG. 24 is a schematic side elevational view of a portion of the
gearbox including the cover;
FIG. 25 is a top plan view of a portion of the gearbox and cover;
FIG. 26 is an enlarged front elevational view of a portion of the
gearbox and cover;
FIG. 27 is a schematic elevational view of a frame that forms part
of the bed end and including two drain openings in the frame;
FIG. 28 is a schematic perspective view of a portion of the frame
of FIG. 27 showing one of the drain openings;
FIG. 29 is a top plan view of a portion of the frame of FIG. 27;
FIG. 30 is a perspective view of a bed end including a removable
cover in accordance with the invention;
FIG. 31 is a sectional view through portions of the cover including
an end cap;
FIG. 32 is another sectional view of the end cap of FIG. 31;
FIG. 33 is an enlarged partial sectional view illustrating one
manner of attachment of the end cap to the frame;
FIG. 34 is a view similar to FIG. 33 illustrating another manner
of attachment of the end cap to the frame;
FIG. 35 is a sectional view illustrating engagement of the end
cap with a center panel of the cover; and
FIG. 36 is a fragmentary sectional view illustrating attachment
of the end cap to the frame.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to adjustable beds. In particular,
the present invention relates to a bed having a bed spring or other
portion that is vertically adjustable, for example, for use in home
health care. As representative of the present invention, FIG. 1
illustrates one embodiment of a bed 10. The bed 10 is illustrated
as being placed on a floor 12.
The bed 10 includes a bed end 14 that is located at the head end
of the bed. The bed 10 also includes a bed end 14a that is located
at the foot end of the bed. The bed end 14 is referred to herein
as the "head end" of the bed 10. The bed end 14a is referred
to herein as the "foot end" of the bed 10. The head end
14 of the bed 10 is identical to, and interchangeable with, the
foot end 14a of the bed, as is discussed in more detail below.
The head end 14 of the bed 10 (FIG. 2) includes a fixed portion
20 and a movable portion 22. The fixed portion 20 of the head end
14 is that portion of the head end 14 that stays in position on
the floor 12 when the height of the bed 10 is adjusted. The movable
portion 22 of the head end 14 is that portion of the head end that
moves vertically relative to the floor 12 and relative to the fixed
portion 20 of the head end, when the height of the bed 10 is adjusted.
This movement effects vertical movement of the portions of the bed
on which the patient is located, as discussed below.
The fixed portion 20 of the head end 14 (FIG. 2) includes first
and second inner legs 24 and 26 that are interconnected by a cross-beam
28. The inner legs 24 and 26 are identical to each other in construction
and so their constituent parts are numbered identically.
Each one of the inner legs 24 and 26 has a square, tubular cross-sectional
configuration with an inner side wall 30 that faces the opposite
side of the bed end 14. Each one of the inner legs 24 and 26 has
an upper end portion 32 and an opposite lower end portion 34. The
inner legs 24 and 26 extend generally perpendicular to the floor
12 when the bed 10 is assembled as shown in the drawings.
The cross-beam 28 has a tubular, rectangular cross-sectional configuration
that extends perpendicular to the inner legs 24 and 26 and parallel
to the floor 12. The cross-beam 28 has opposite upper and lower
side walls 48 and 50 and opposite inner and outer side walls. The
cross-beam 28 also has first and second end walls 48 and 50 that
close the ends of the cross-beam and provide a mounting structure
for supporting the cross-beam.
The cross-beam 28 is connected between the upper end portions 32
of the inner legs 24 and 26 respectively. Specifically, the first
end wall 48 of the cross-beam 28 is fixedly secured to the upper
end portion 32 of the first leg 24 specifically, the inner side
wall 30 by fastener structure that, in the illustrated embodiment,
includes a plurality of bolts 52. In a similar manner, the second
end wall 50 of the cross-beam 28 is fixedly secured to the upper
end portion 32 of the second leg 26 specifically, the inner side
wall 30 by fastener structure that, in the illustrated embodiment,
includes a plurality of bolts 54. As a result, the cross-beam 28
and the first and second inner legs 24 and 26 are fixed to each
other as one unit that rests on the floor 12 and that does not move
vertically when the height of the bed 10 is adjusted as described
below. These three pieces together form the fixed portion 20 of
the head end 14. It should be understood that the cross-beam 28
could be configured differently, so long as it comprises structure
that rigidly joins the inner legs 24 and 26 for transmitting force
between the movable portions 22 of the bed end 14 and the fixed
portion 20 of the bed end.
The movable portion 22 of the head end 14 of the bed 10 includes
structural and operational parts, as well as decorative/covering
parts. The decorative/covering parts are not shown in FIGS. 1-6
so that the structural and operational parts can be viewed. The
decorative/covering parts are described below.
The movable portion 22 of the head end 14 includes a frame structure,
or frame 60. The frame 60 includes an upper cross bar 62 a lower
cross bar 64 and first and second outer legs 66 and 68. The upper
cross bar 62 has a tubular cross-sectional configuration that extends
perpendicular to the outer legs 66 and 68 and parallel to the floor
12. The upper cross bar 62 has first and second end portions 70
and 72. The lower cross bar 64 has a tubular cross-sectional configuration
that extends perpendicular to the outer legs 66 and 68 and parallel
to the floor 12. The lower cross bar 64 has first and second end
portions 74 and 76.
The first and second outer legs 66 and 68 of the frame 60 are identical
to each other and so their constituent parts are numbered identically.
Each one of the outer legs 66 and 68 has a square, tubular cross-sectional
configuration with an inner major side wall 78 that faces the opposite
side (left to right as viewed in FIG. 2) of the bed end 14. Each
one of the outer legs 66 and 68 has an upper end portion 80 and
an opposite lower end portion 82. The outer legs 66 and 68 extend
perpendicular to the floor 12 when the bed 10 is assembled as shown
in the drawings.
The first and second end portions 70 and 72 of the upper cross
bar 62 are fixed to the upper end portions 80 of the first and second
outer legs 66 and 68 respectively, by welding, for example. The
first and second end portions 74 and 76 of the lower cross bar 64
are fixed to the first and second outer legs 66 and 68 respectively,
by welding, for example. As a result, the upper and lower cross
bars 62 and 64 and the first and second outer legs 66 and 68 are
fixed to each other as one unit that is movable vertically when
the height of the bed 10 is adjusted as described below.
The first and second inner legs 24 and 26 of the head end 14 of
the bed 10 are telescopically received in the first and second outer
legs 66 and 68 of the head end, respectively. The inner legs 24
and 26 are smaller in cross-sectional configuration than the outer
legs 66 and 68 and are slidable within the outer legs. When the
inner legs 24 and 26 are thus assembled with the outer legs 66 and
68 the lower end portions 34 of the inner legs project from the
outer legs. Casters or other floor-engaging structure 86 (FIG. 1)
may be fixed to the lower end portions 34 of the inner legs 24 and
26.
The inner side wall 78 of the first outer leg 66 is cut away or
relieved in a known manner to allow travel clearance for the bolts
52 when the first inner leg 24 moves vertically relative to the
first outer leg. In a similar manner, the inner side wall 78 of
the second outer leg 68 is cut away or relieved in a known manner
to allow travel clearance for the bolts 54 when the second inner
leg 26 moves vertically relative to the second outer leg. As a result,
the entire movable portion 22 of the head end 14 including the
upper and lower cross bars 62 and 64 and the first and second outer
legs 66 and 68 is movable vertically as one unit, relative to the
fixed portion 20 of the head end, when the height of the bed 10
is adjusted as described below.
The movable portion of the head end 14 of the bed 10 includes a
drive assembly 90 for receiving rotational force and, in response,
moving the movable portion 22 of the head end vertically relative
to the fixed portion 20 of the head end. The drive assembly 90 includes
a gearbox 140 described below in detail, that is fixed in position
on the lower cross bar 64 of the frame 60.
The drive assembly 90 also includes an externally threaded acme
screw or lead screw 92. The lead screw 92 is mounted generally vertically
in the frame 60. An upper end portion 94 of the lead screw 92 is
supported on the upper cross bar 62 for rotational movement relative
to the frame 60 about a drive axis 96. An upper screw pin 98 (FIG.
3) projects radially outward from the lead screw 92 near the upper
end portion 94 of the lead screw. The upper end portion 94 of the
lead screw 92 is not movable axially relative to the upper cross
bar 62.
A lower end portion 100 of the lead screw 92 (FIG. 5) is supported
on the gearbox 140 in a manner described below for rotation relative
to the frame 60. The lower end portion 100 of the lead screw 92
includes an axially projecting tenon 102 that forms the lower terminal
end of the lead screw. The lower end portion 100 of the lead screw
92 is not movable axially relative to the lower cross bar 64. As
a result, the lead screw 92 is fixed for movement vertically with
the frame 60 and with the other parts of the movable portion 22
of the head end 14.
The drive assembly 90 of the head end 10 also includes a slip nut
assembly 104 (FIGS. 3 and 4) for transmitting force between the
lead screw 92 and the cross-beam 28. The slip nut assembly 104 includes
a slip nut housing 106. The nut housing 106 is fixed by bolts 108
to the upper side wall 40 of the cross-beam 28 at a location inside
the cross-beam. As a result, the slip nut housing 104 is rigidly
coupled by the cross-beam 28 to the inner legs 24 and 26.
The slip nut assembly 104 also includes a slip nut. The slip nut
may be of the one-piece type shown in U.S. Pat. No. 5134731 entitled
Adjustable Bed Having Adjustable Height Legs With Synchronization
Feature, the entire subject matter of which is hereby incorporated
by reference.
Alternatively, and as preferred, the slip nut assembly 104 includes
a slip nut 110 as shown and described herein. The slip nut 110 is
formed as two separate pieces 112 and 114 as seen in FIGS. 3 and
4. The first and second slip nut halves 112 and 114 are formed by
casting or molding. The first and second slip nut halves 112 and
114 are identical to each other.
An upper slip nut pin 116 is formed as one piece with the first
slip nut half 112. A lower slip nut pin 118 is formed as one piece
with the second slip nut half 114. The upper and lower slip nut
pins 116 and 118 project axially from opposite upper and lower end
surfaces of the slip nut 110. The two slip nut halves 112 and 114
when placed together as shown in FIG. 3 define an internal thread
convolution 120 into which the lead screw 92 is threaded. A plurality
of circumferential grooves 122 are formed on the outer surface of
the slip nut 110. The grooves 122 do not extend helically but rather
extend perpendicular to the drive axis 96.
The slip nut assembly 104 further includes a pair of pressure plates
124 mounted in the slip nut housing 106. The pressure plates 124
have internal grooves 126 that mesh with the external grooves 122
on the slip nut 110 to provide for relative rotation, without relative
axial movement, between the slip nut and the pressure plates. The
pressure plates 124 are movable laterally in the slip nut housing
106 (left to right as viewed in FIG. 3) but are blocked from rotation
within the housing about the axis 96.
A pair of springs 128 are associated with the pressure plates 124.
Each spring 128 is biased against its associated pressure plate
124 by a respective set screw 130 that is screwed into the slip
nut housing 106. The springs 128 urge the pressure plates radially
inward against the slip nut halves 112 and 114 which are, thereby,
urged radially inward against the lead screw 92.
The gearbox 140 (FIGS. 2 5 and 6) is fixed to the frame 60 and
is operable to receive rotational force from outside the head end
14 of the bed 10 and, in response, effect rotation of the lead screw
92 about the drive axis 96. The gearbox 140 includes a housing 142.
The gearbox housing 142 has a main body portion 144 and an output
portion 146 that projects upward from the main body portion. The
gearbox 140 is oriented relative to the frame 60 so that the drive
axis 96 extends vertically into the output portion 146 of the housing
142. The gearbox 140 is fixed by one or more bolts 148 (FIG. 2),
or other means, to the lower cross bar 64 of the frame 60 of the
head end 14 of the bed 10.
Two bushings 150 and 152 (FIG. 5) in the main body portion 144
of the housing 142 support a lower input shaft 160 for rotation
relative to the housing. The bushing 152 is supported on a vertically
extending internal wall 154 of the housing 142. The wall 154 is,
for clarity, not shown in FIG. 6.
The lower input shaft 160 is rotatable about an axis 162 that is
perpendicular to the drive axis 96. A lower gear assembly 164 is
fixed on the lower input shaft 160 for rotation with the lower input
shaft, at a location between the two bushings 150 and 152. The lower
gear assembly 164 includes a spur gear 168 and a bevel gear 166.
The lower input shaft 160 has first and second opposite end portions
170 and 172. A pair of lower drive pins 174 project radially from
the lower input shaft 160 at diametrically opposite locations on
the first end portion 170. The lower drive pins 174 are fixed for
rotation with the lower input shaft 160. A pair of second drive
pins 176 project radially from the second end portion 172 of the
lower input shaft 160. The second drive pins 176 are fixed for rotation
with the lower input shaft 160.
Two bushings 180 and 182 in the main body portion 144 of the housing
142 support an upper input shaft 190 for rotation relative to the
housing. The bushing 180 which is located above the bushing 152
of the lower input shaft 160 is supported on the internal wall
154. The upper input shaft 190 is rotatable about an axis 192 that
is perpendicular to the drive axis 96 at a location above and parallel
to the lower input shaft 160 and its axis 162. As a result, the
upper input shaft 190 is located between the lower input shaft 160
and the output portion 146 of the gearbox housing 142.
An upper gear assembly 194 is fixed on the upper input shaft 190
for rotation with the upper input shaft, at a location between the
two bushings 180 and 182. The upper gear assembly 194 includes a
spur gear 196 and a bevel gear 198. The upper input shaft 190 has
first and second opposite end portions 200 and 202. A pair of upper
drive pins 204 project radially from the upper input shaft 190 at
diametrically opposite locations on the first end portion 200. The
upper drive pins 204 are fixed for rotation with the upper input
shaft 190.
The upper gear assembly 194 on the upper input shaft 190 is in
meshing engagement with the lower gear assembly 164 on the lower
input shaft 160. Specifically, the spur gear 196 on the upper gear
assembly 194 is in meshing engagement with the spur gear 168 of
the lower gear assembly 164. As a result, rotation of the lower
input shaft 160 in either direction about its axis 162 results in
rotation of the upper input shaft 190 in the opposite direction
of rotation about its own axis 192. Similarly, rotation of the upper
input shaft 190 in either direction about its axis 192 results in
rotation of the lower input shaft 160 in the opposite direction
of rotation about its own axis 162.
The output portion 146 of the housing 142 supports an output gear
assembly 208. The output gear assembly 208 includes an output bevel
gear 210 that is in meshing engagement with the bevel gear 198 on
the upper input shaft 190. The output bevel gear 210 is supported
in the output portion 146 of the housing 142 by one or more bushings
212 for rotation about the drive axis 96. An upwardly opening mortise
214 is formed in the output bevel gear 210. The tenon 102 on the
lower end portion 100 of the lead screw 92 extends into the mortise
214 in the output bevel gear 210. As a result, the output bevel
gear 210 is fixed for rotation with the lead screw 92 about the
drive axis 96. Therefore, rotation of either the lower input shaft
160 or the upper input shaft 190 results in rotation of the lead
screw 92 about the drive axis 96.
The gearbox housing 142 has several access ports for the input
shafts 160 and 190. The main body portion 144 of the gearbox housing
142 has a main access opening 220 adjacent the first end portions
200 and 170 of the upper and lower input shafts 190 and 160 respectively.
The main access opening 220 faces the foot end 14a of the bed 10
when the bed is assembled, as shown in FIG. 1. A movable door or
drive shaft cover 222 is pivotally connected to the gearbox housing
142. The cover 222 is movable between a first position as shown
in solid lines in FIG. 5 and a second position as shown partially
in dash-dot lines in FIG. 5. In the first position, the cover 222
covers the lower input shaft 160 and makes the upper input shaft
190 accessible from the exterior of the gearbox 140. In the second
position, the cover 222 covers the upper input shaft 190 and makes
the lower input shaft 160 accessible from the exterior of the gearbox
140.
The main body portion 144 of the gearbox housing 142 has a secondary
access opening 224 adjacent the second end portion 172 of the lower
input shaft 160. The secondary access opening 224 faces away from
the foot end 14a of the bed 10 when the bed is assembled. A movable
cover or cover 226 is pivotally connected to the gearbox housing
142. The cover 226 is movable between a first or closed position
as shown in solid lines in FIG. 5 in which the cover covers the
second end portion 172 of the lower input shaft 160 and a second
or open position (not shown) in which the cover is opened and the
lower input shaft 160 is accessible from the exterior of the gearbox
140.
The foot end 14a of the bed 10 (FIG. 1) is identical in construction
to the head end 14. Corresponding parts of the foot end 14a are
identified herein with reference numerals identical to those of
the corresponding parts of the head end 14 but having the suffix
"a" attached.
The foot end 14a of the bed 10 is interchangeable with the head
end 14. When the bed 10 is assembled as in FIG. 1 the main access
opening 220a of the gearbox 140a of the foot end 14a of the bed
faces toward the main access opening 220 of the gearbox 140 of the
head end 14 of the bed.
Because the head end 14 and the foot end 14a are identical, the
main access opening 220a of the foot end gearbox 140a is at the
same height off the floor 12 as the main access opening 220 of the
head end gearbox 140. The lower input shaft 160a of the foot end
gearbox 140a is at the same height off the floor 12 as the lower
input shaft 160 of the head end gearbox 140. The upper input shaft
190a of the foot end gearbox 140a is at the same height off the
floor 12 as the upper input shaft 190 of the head end gearbox 140.
The bed 10 includes a spring assembly 230 for supporting a mattress
(not shown) on which the patient lies. The spring assembly shown
includes a head spring 232 a foot spring 234 and a knee unit 236;
other spring assemblies can be used. The several parts of the spring
assembly 230 may be pivotable relative to each other and relative
to the head end 14 and the foot end 14a, in a known manner. The
spring assembly 230 is supported by brackets on the movable portions
22 and 22a of the head end 14 and the foot end 14a, respectively,
in a known manner, for vertical movement with the movable portions
of the head end and the foot end.
The foot spring 234 supports an electric motor shown schematically
at 240 (FIG. 1). The electric motor 240 is actuatable in a known
manner by one or more controls, such as a pendant (not shown), to
raise or lower the spring assembly 230 in a manner described below.
The bed 10 includes a drive tube assembly 250 for transmitting
rotary force from the electric motor 240 to the head end 14 of the
bed, and from the electric motor 240 to the foot end 14a of the
bed. The drive tube assembly 250 includes a first drive tube section
252. The first drive tube section 252 extends between and interconnects
the motor 240 and the head end 14 of the bed 10. The drive tube
assembly 250 also includes a second drive tube section 254. The
second drive tube section 254 extends between and interconnects
the motor 240 and the foot end 14a of the bed 10.
The first drive tube section 252 is connected with the motor 240
in a known manner so that the first drive tube section is rotatable
in a first direction of rotation, relative to both the head end
14 of the bed and the foot end 14a of the bed, upon "raising"
actuation of the motor. The first drive tube section 252 is rotatable
in a second direction of rotation opposite the first direction,
upon "lowering" actuation of the motor 240.
The second drive tube section 254 is connected with the motor 240
in a known manner so that the second drive tube section is rotatable
in the same first direction of rotation upon "raising"
actuation of the motor, and rotatable in the same second direction
of rotation opposite the first direction, upon "lowering"
actuation of the motor. Thus, the first drive tube section 252 and
the second drive tube section 254 are coupled for rotation with
each other in the same direction of rotation, relative to the head
end 14 and the foot end 14a of the bed 10 upon actuation of the
electric motor 240.
A typical position for the parts of the bed 10 is shown schematically
in FIG. 1. The first drive tube section 252 extends from the electric
motor 240 to the upper input shaft 190 of the gearbox 140 on the
head end 14 of the bed 10 as shown in dash-dot lines in FIG. 5.
The drive pins 204 on the upper input shaft 190 of the gearbox 140
of the head end 14 couple the upper input shaft for rotation with
the first drive tube section 252.
The second drive tube section 254 extends from the electric motor
240 to the lower input shaft 160a (not shown) of the gearbox 140a
on the foot end 14a of the bed 10. The drive pins 174a (not shown)
on the upper input shaft 160a of the gearbox 140a of the foot end
14a couple the lower input shaft 160a for rotation with the second
drive tube section 254.
As a result, the connection between the drive tube assembly 250
and the head end 14 of the bed 10 is at a different vertical height
off the floor 12 than the connection between the drive tube assembly
and the foot end 14a of the bed, even though the two gearboxes 140
and 140a are each, as a whole, at the same vertical height off the
floor.
Upon actuation of the motor 240 in a direction of rotation so as
to raise the bed 10 the drive tube assembly 250 rotates in a first
direction of rotation relative to the head end 14 and the foot end
14a of the bed. The first drive tube section 252 and the second
drive tube section 254 both rotate in the first direction of rotation.
The first direction of rotation is generally perpendicular to the
axes of rotation 96 and 96a of the lead screws 92 and 92a, respectively.
The first drive tube section 252 which is coupled for rotation
with the upper input shaft 190 of the gearbox 140 of the head end
14 causes the upper input shaft to rotate in the first direction
of rotation, for example, clockwise as viewed in FIG. 6 as indicated
by the arrow 253. The rotation of the upper input shaft 190 is transmitted
through the upper bevel gear 198 (FIG. 5) into the output shaft
208 and thence into the lead screw 92 of the head end 14 of the
bed 10.
The lead screw 92 rotates about the drive axis 96. The rotation
of the lead screw 92 constitutes rotation relative to the slip nut
110. Because the lead screw 92 and the slip nut 110 are threadedly
engaged, this relative rotation produces relative axial movement
between the lead screw and the slip nut.
The relative axial movement between the lead screw 92 and the slip
nut 110 is produced because the slip nut does not rotate on the
lead screw. The slip nut 110 does not rotate because of the pressure
plates 124 of the nut assembly 104. Specifically, the pressure plates
124 are mounted non-rotatably about the axis 96 in the nut housing
106. The radially inwardly directed force exerted by the pressure
plate springs 128 urging the pressure plates 124 against the slip
nut halves 112 and 114 is normally strong enough so that the abutting
engagement of the pressure plates and the slip nut halves couples
the slip nut to the pressure plates and thus prevents the slip nut
from rotating on the lead screw 92. When the lead screw 92 is driven
to rotate about its axis 96 therefore, the rotational force transmitted
from the lead screw to the slip nut is not great enough to overcome
this holding force exerted by the pressure plates 124 on the slip
nut, and the slip nut does not rotate with the lead screw. Instead,
the slip nut 110 translates along the screw 92 (or vice versa),
producing relative axial movement between the nut housing 106 and
the screw.
The relative axial movement that results is movement of the lead
screw 92 and not the nut 110 for the following reasons. The slip
nut 110 is mounted in the nut housing 106 which is fixed to the
cross-beam 28 of the fixed portion 20 of the head end 14 of the
bed 10. The fixed portion 20 of the bed 10 rests on the floor 12
supporting the movable portion 22 of the head end 14 off the floor.
As a result, force tending to produce relative axial movement between
the slip nut housing 104 and the lead screw 92 tends to cause the
movable portion 22 of the head end 14 including the lead screw
92 to move axially in space relative to the floor 12 as it rotates
about the drive axis.
Because the lead screw 92 is fixed in position vertically on the
frame 60 the vertical movement of the lead screw 92 drives the
entire movable portion 22 of the head end 14 vertically upward,
relative to the fixed portion 20 of the head end. The frame 60 of
the head end 14 and the gearbox 140 move vertically with the lead
screw 96 relative to the floor 12.
The structure of the fixed portion 20 of the head end 14 is advantageous
as follows. Axially directed force from the slip nut housing 106
is transmitted directly into the rigid cross-beam 28 to which the
slip nut housing is fixed. This force is transmitted directly into
the inner legs 24 and 26 to which the cross-beam 28 is rigidly
fixed. As a result, no cables or pulleys, such as those shown in
the aforementioned U.S. Pat. No. 5134731 are needed in the head
end 14 of the bed 10.
The slip nut assembly 104 is operative to limit upward and downward
travel of the movable portion 22 of the head end 14 of the bed 10
in a manner similar to that described in U.S. Pat. No. 5134731
discussed above. Specifically, when the lead screw 92 reaches its
end of downward travel relative to the slip nut 110 the radially
extending pin 98 (FIG. 3) on the rotating screw contacts the axially
projecting pin 116 on the slip nut 110. This engagement couples
the slip nut 110 for rotation with the lead screw 92 overcoming
the holding force of pressure plates 124. As the slip nut 110 rotates
thereafter, it rotates within the pressure plates 124 and thus within
the slip nut housing 104. Because the slip nut 110 is rotating with
the lead screw 92 it is no longer translating along the lead screw,
and the slip nut no longer transmits axial force from the lead screw
to the nut housing 106. This eliminates further relative vertical
movement between the lead screw 92 and the slip nut 110 and the
movable portion 22 of the head end 14 ceases vertical movement relative
to the fixed portion 20 of the head end.
The above-described construction of the slip nut 100 is advantageous
as follows. Because the slip nut 100 can be cast or molded, no costly
machining process is needed. In addition, the axially projecting
pins 116 and 118 can be formed as one piece with the remainder of
the slip nut 110 simplifying the manufacturing process. Because
the two slip nut halves 112 and 114 are identical, only one mold
is needed. Also, when the slip nut 110 rotates at its end of travel
as described above, the parting line between the two slip nut halves
112 and 114 makes an audible clicking noise that can signal the
user of the bed of the end of travel condition.
At the same time that the first drive tube section 252 is driving
the lead screw 92 of the head end 14 to move the head end upward,
the second drive tube section 254 is driving the lead screw 92a
of the foot end 14a of the bed 10 to move the foot end upward. FIG.
7 is a schematic perspective view of parts of the bed 10 that illustrates
the directions of movement of the parts. The second drive tube section
254 is coupled (not shown) to the lower input shaft 160a of the
gearbox 140a of the foot end 14a. Upon actuation of the motor 240
to raise the head end 14 of the bed 10 as described above, the second
drive tube section 254 rotates in the same first direction of rotation
in space relative to the head end 14 and the foot end 14a of the
bed.
The rotation of the second drive tube section 254 causes the lower
input shaft 160a of the foot end 14 to rotate in the first direction
of rotation, which is counter-clockwise if looking at the great
box 140a as viewed in FIG. 6 because the foot end 14a faces the
opposite direction from the head end 14. This rotation of the lower
input shaft 160a is transmitted through the bevel gears 164a and
194a into the upper input shaft 190a, causing the upper input shaft
190a to rotate in the opposite direction, that is, a clockwise direction
as viewed in FIG. 6. This rotation of the upper input shaft 190a
is transmitted into the output shaft 208a and thence into the lead
screw 92a of the foot end 14a of the bed 10.
The lead screw 92a of the foot end 14a of the bed 10 rotates about
its drive axis 96a within the foot end of the bed. This screw rotation
within the foot end 14a is in the same direction in space as the
direction of rotation of the lead screw 92 within the head end 14
of the bed 10. As a result, the rotation of the lead screw 92a of
the foot end 14a causes the movable portion 22a of the foot end
of the bed 10 to move vertically relative to the floor 12 in the
same direction as the head end 14 is moving.
Thus, both ends 14 and 14a of the bed 10 move vertically in the
same direction--upward or downward as viewed in FIGS. 6 and 7--because
the drive tube assembly 250 is connected with different input points
in the two gearboxes 140 and 140a. This simultaneous movement occurs
even though the first drive tube section 252 and the second drive
tube section 254 are rotating in the same direction relative to
the other parts of the assembled bed 10. This result is achieved
in the bed 10 by coupling the second drive tube section 254 with
the lower input shaft 160a of the gearbox 140a of the foot end 14a
whenever the first drive tube section 252 is coupled with the upper
input shaft 190 of the gearbox 140 of the head end 14 of the bed
10 (or vice versa).
When the movable portion 22 of the head end 14 of the bed 10 and
the movable portion 22a of the foot end 14a of the bed move vertically,
the bed spring assembly 230 moves vertically also, relative to the
floor 12 as desired. This has the effect of raising or lowering
a patient who is lying on the bed spring assembly 230.
It can thus be seen that, in the bed 10 illustrated in FIGS. 1-7
the bed end 14 is interchangeable with the bed end 14a, thus making
the bed ends "universal". As a result, when parts of a
bed 10 are selected from a warehouse for delivery to a home customer,
any two bed ends 14 can be selected; there is no need to pick a
"head end" and a distinct "foot end". This can
eliminate trips back to the warehouse if an incorrect selection
is made and discovered at the time of setting up the bed 10 in the
home. In addition, this "universal" quality of the bed
end 14 can make it unnecessary to manufacture two different bed
ends for use in the bed 10.
The bed end 10 described above incorporates an elevating mechanism
including the cross-beam 28 that is rigidly tied between the inner
legs 24 and 26. The cross-beam 28 receives force from the lead screw
92 via the slip nut 110 and the slip nut housing 104 and transmits
that force to the inner legs 24 and 26. It should be understood
that other types of elevating mechanisms could be used. For example,
FIG. 8 illustrates a prior art bed end shown in U.S. Pat. No. 5134731.
The bed end shown in FIG. 8 includes an elevating mechanism that
uses pulleys and cables to transmit force between the slip nut housing
and the inner legs of the bed end. This is one type of alternative
elevating mechanism that is usable in a universal bed end 14 as
described above.
FIGS. 9 and 10 illustrate a gearbox hi/lo crank 260 for use in
the head end 14 of the bed 10. Prior art home articulating bed designs
that are semi electric beds (manual hi/lo) have a die cast primary
crank with a folding handle. The crank is permanently fixed to the
gearbox. Because the crank has to be located at the foot end of
the bed (projecting out into the room from the outer major side
surface of the foot end), then by default the bed end that has the
crank must be used as the foot end; the head end and the foot end
are not interchangeable.
Some beds also include an emergency crank that is a simple wire-form
crank for emergency use only. This has one end adapted to engage
the articulation motors and the other end adapted to engage the
hi/lo gearbox. By virtue of its light weight construction this crank
is not suitable for extended use.
The crank 260 (FIGS. 9 and 10) of the present invention includes
a two-part handle 262 that is hinged at 264 to reduce its size when
installed. A slotted tube 266 projects from the handle 262. The
tube 266 has a cylindrical configuration adapted to fit over the
second end portion 172 of the lower input shaft 160 of the gearbox
140 when the cover is pivoted upward, as shown in FIG. 10. A pair
of diametrically opposed slots 268 in the tube 266 fit over the
drive pins 176 on the second end portion 172 of the lower input
shaft 160. The tube 266 is made from steel and is strong enough
together with the other parts of the crank 260 to raise or lower
the bed 10 repeatedly over the lifetime of the bed end 14 without
deformation.
The crank 260 also includes a detent member 270. In the illustrated
embodiment, the detent member 270 is a U-shaped wire spring having
a base portion 272 crimped onto the tube 266. Two resilient leg
portions 274 of the wire spring 270 project from the base portion
272. Each one of the leg portions 274 has a bent end portion 276
adapted to engage (fit behind) one of the drive pins 176 on the
lower input shaft 160.
To assemble the crank 260 to the gearbox 140 the user places the
tube 266 of the crank over the second end portion 172 of the lower
input shaft 160. The slots 268 in the tube 266 are fitted over the
drive pins 176. As the tube 266 is slid axially over the input shaft
160 the bent end portions 276 of the legs 274 of the wire spring
270 engage the drive pins 176 and are cammed away from the drive
pins to allow the tube to slide fully onto the input shaft.
When the drive pins 176 reach the ends of the slots 268 the wire
spring legs 274 resiliently move back into their starting position.
In this position, the drive pins 176 engage the bent end portions
276 of the wire spring legs 274. This engagement resists removal
of the tube 266 from the input shaft 160 without a strong pull.
Thus, the crank 260 is fixedly but not permanently attached to the
gearbox 140 and may be used with the gearbox for so long as the
bed 10 is assembled in that location. When the bed 10 is to be disassembled,
the crank 260 can be removed by the dealer.
The crank 260 is strong enough to be used as an everyday crank
for hi/lo purposes, or for emergency (power failure) operations.
Nevertheless, the crank 260 is removable from the input shaft 160
by the dealer so that it can be placed on either bed end 14 or 14a
during assembly of the bed 10. Because the crank 260 is removable
from the bed end 14 and usable on another bed end 14 this helps
to make the bed ends 14 and 14a universal--that is, interchangeable
at either end of the bed 10 in comparison to a bed end having a
permanently affixed crank.
FIGS. 11 and 12 illustrate an alternative gearbox 140a for use
in the head end 14 or foot end 14a of the bed 10. The gearbox 140a
is similar to the gearbox 140 (FIGS. 1-6), and parts that are the
same or similar are given the same reference numerals with the suffix
"a" added.
The gearbox 140a includes a housing 142a. The housing 142a has
a main body portion 144a and an outlet portion 146a that projects
upward from the main body portion. The gearbox 140a is mounted on
the frame, in a manner not shown, so that the drive axis 96a extends
vertically into the outlet portion 146a of the housing 142a.
Two bushings 150a and 152a in the main body portion 144a of the
housing 142a support a single input shaft 280 for rotation relative
to the housing. The input shaft 280 is rotatable about an axis 282
that is perpendicular to the drive axis 96a.
The input shaft 280 has first and second opposite end portions
284 and 286. A first gear assembly 288 is fixed on the input shaft
280 for rotation with the input shaft, adjacent the first end portion
284 of the input shaft. A second gear assembly 290 is fixed on the
input shaft 280 for rotation with the input shaft, adjacent the
second end portion 286 of the input shaft. The second gear assembly
290 is spaced apart from the first gear assembly 288.
A pair of drive pins 292 project radially from the input shaft
280 at diametrically opposite locations on the first end portion
284. The drive pins 292 are fixed for rotation with the input shaft
280. The gearbox housing 142a has a single access opening 294 adjacent
the first end portion 284 of the input shaft 280. The access opening
294 is not covered by a cover.
The output portion 144a of the housing 140a supports an output
bevel gear 210a that is located between the first and second gear
assemblies 288 and 290 on the input shaft 280. The output bevel
gear 210a is supported in the output portion 144a of the housing
140a, by one or more bushings 212a, for rotation about the drive
axis 96a. The output bevel gear 210a has a mortise and tenon connection
296 to the lead screw 92a, as described above with reference to
FIG. 5. As a result, the lead screw 92a is fixed for rotation with
the output bevel gear 210a about the drive axis 96a.
The input shaft 280 is supported by the bushings 150a and 152a,
for sliding movement relative to the housing 142a in a direction
parallel to the axis of rotation 282 of the drive shaft. The input
shaft 280 includes a locator pin 300 (FIGS. 11 and 12) that projects
radially from a location between the first and second gear assemblies
288 and 290. The locator pin 300 is received in a U-shaped slot
302 in the housing. The slot 302 has first and second end portions
304 and 306 and a central portion 308.
When the locator pin 300 is in the first end portion 304 of the
slot 302 as shown in FIGS. 11 and 12 the first gear assembly 288
on the input shaft 280 is in meshing engagement with the output
bevel gear 210a. As a result, rotation of the input shaft 280 in
a first direction about the axis 282 results in rotation of the
output bevel gear 210a, and the lead screw 92a, in a first direction
of rotation about the drive axis 96a.
When the locator pin 300 is in the second end portion 306 of the
slot 302 the input shaft 280 is moved axially from the position
shown in FIG. 11 and the second gear assembly 290 on the input
shaft is in meshing engagement with the output bevel gear 210a.
Therefore, rotation of the input shaft 280 in the first direction
about the axis 282 results in rotation of the output bevel gear
210a, and the lead screw 92a, in a second or opposite direction
of rotation about the drive axis 96a.
As a result, the bed end 14 to which the gearbox 140a is attached
can be used at either end of the bed 10 and still provides simultaneous
upward or downward movement of both bed ends, simply by moving the
input shaft 280 from one position to the other. Therefore, a bed
10 having two identical bed ends 14 with gearboxes 140a of the
type shown in FIGS. 11 and 12 can use the two bed ends interchangeably
simply by adjusting the gearbox as described above.
FIG. 13 illustrates another alternative gearbox 140b for use in
the head end or foot end of the bed 10. The gearbox 140b is similar
in construction and operation to the gearbox 140a (FIGS. 11 and
12). Parts of the gearbox 140b that are the same as or similar to
corresponding parts of the gearbox 140a are given the same reference
numerals with the suffix "b" attached.
The gearbox 140b (FIG. 13) includes an input shaft 280b that is
supported for sliding movement relative to the housing 142b in a
direction parallel to the axis of rotation of the input shaft. Disposed
between the two gear assemblies 288b and 290b on the input shaft
280b is a control portion 310 of the input shaft. The control portion
310 includes two circumferential grooves 312 and 314 spaced axially
from each other. The gearbox 310 also includes a locator pin 316.
The locator pin 316 is supported on the housing 142b for in-and-out
(radial) sliding movement relative to the housing and to the input
shaft 280b.
When the locator pin 316 is in the first groove 312 on the input
shaft 280b, as shown in FIG. 13 the first gear assembly 288b on
the input shaft 280b is in meshing engagement with the output bevel
gear 210b. As a result, rotation of the input shaft 280b in a first
direction about the axis 282b results in rotation of the output
bevel gear 210b, and the lead screw 92b, in a first direction of
rotation about the drive axis 96b.
The locator pin 316 can be pulled out of the first groove 312 against
the bias of a spring 318 to enable the input shaft 280b to be moved
axially until the second groove 314 is located radially inward of
the locator pin. The locator pin 316 can then be released and the
spring 318 will hold it in the second groove 314. In this position,
the second gear assembly 290b on the input shaft 280b is in meshing
engagement with the output bevel gear 210b. Therefore, rotation
of the input shaft 280b in the first direction about the axis 282b
results in rotation of the output bevel gear 210b, and the lead
screw 92b, in a second or opposite direction of rotation about the
drive axis 96b.
As a result, the bed end 14 to which the gearbox 140b is attached
can be used at either end of the bed 10 and still provide simultaneous
upward or downward movement at both bed ends 14 and 14a, simply
by moving the input shaft 280b axially from one position to the
other. Therefore, a bed 10 having two identical bed ends with gearboxes
140b of the type shown in FIG. 13 can use the two bed ends interchangeably
simply by adjusting the gearbox as described above.
FIGS. 14-17 illustrate some alternative corner plate (bracket)
designs for use in the head end 14 or foot end 14a of the bed 10.
The corner plates shown in FIGS. 14-17 can be used with other bed
ends, and, specifically, with other bed ends that do not have one
of the gearbox designs 140 140a or 140b, or the elevating mechanism
described above. The corner plates are designed to enable a bed
end to which the corner plates are attached, to be reversed front
to back and still function to support a spring assembly of the bed.
This feature makes the bed ends more easily used at either end of
the bed 10.
The corner plates are shown with bed ends 14b, 14c, and 14d that
are similar in construction and operation to the bed end 14. The
bed end 14b (FIG. 14) includes first and second corner plates 320
and 322 that are mirror images of each other and that extend from
first and second opposite major side surfaces 324 and 326 of the
bed end 14b.
When the bed end 14b is assembled in a bed 10 so that the first
corner plate 320 is to be used (for example with a frame rail or
a spring assembly shown partially at 328), the first corner plate
320 is uncovered. A wall protector 330 is placed over the unused
second corner plate 322. As a result, the first corner plate 320
is available for use, and the second corner plate 322 is protected
and covered to prevent contact with the wall if the bed end 14b
is placed with the second corner plate facing the wall.
When the bed end 14b is assembled in a bed 10 so that the second
corner plate 322 is to be used, the second corner plate is uncovered
(not shown). The wall protector 330 is placed over the unused first
corner plate 320. As a result, the second corner plate 322 is available
for use, and the first corner plate 320 is protected from contact
with the wall.
In this manner, the bed end 14b can be assembled in a bed 10 so
that either the first major side surface 324 or the second major
side surface 326 of the bed end faces the other parts of the assembled
bed 10 and a corner plate 320 and 322 will be available to support
the spring assembly or frame rails 328 of the bed.
The bed end 14c (FIG. 15) includes a corner plate assembly 332
including first and second corner plates 334 and 336 that are mirror
images of each other and that are extendible from first and second
opposite major side surfaces 338 and 340 of the bed end. The corner
plate assembly 332 includes a central portion 342 that is fixed
by rivets 356 or in another manner, to a side surface 348 of the
bed end 14c.
The first corner plate 334 is hinged to the central portion 342.
The first corner plate 334 is pivotally movable between a first
position in which it projects from the first major side surface
38 of the bed end 14c as shown in FIG. 15 and a second position
(not shown) in which the first corner plate lies flat against the
first major side surface.
The second corner plate 336 is also hinged to the central portion
342. The second corner plate 336 is pivotally movable between a
first position in which it projects from the second major side surface
340 of the bed end 14c as shown in FIG. 15 and a second position
(not shown) in which the second corner plate lies flat against the
second major side surface.
When the bed end 14c is to be assembled in a bed 10 with the first
major side surface 338 facing the opposite end of the bed, the first
corner plate 334 is swung into the operative position shown in FIG.
15. The frame rail or spring assembly shown partially at 328 is
attached to the first corner plate 334. When this is done, the second
corner plate 336 can be laid flat against the second major side
surface 340 of the bed end 14c, out of the way.
When the bed end 14c is to be assembled in a bed 10 with the second
major side surface 340 facing the opposite end of the bed, the second
corner plate 336 is swung into the operative position shown in FIG.
15. A frame rail or spring assembly such as shown partially at 328
is attached to the second corner plate 336. When this is done, the
first corner plate 334 can be laid flat against the first major
side surface 338 of the bed end 14c, out of the way.
In this manner, the bed end 14c can be assembled in a bed 10 so
that either the first major side surface 338 or the second major
side surface 340 of the bed end faces the other parts of the assembled
bed, and a corner plate 334 or 336 will be available to support
the spring assembly or frame rails 328 of the bed.
The bed end 14d (FIG. 16) includes a single corner plate 350 that
is movable between first and second opposite major side surfaces
352 and 354 of the bed end 14d. The bed end has two support pins
356 for supporting the corner plate 350. The support pins 356 project
from the side 358 of the bed end 14d.
The bed end 14d also has a lock member indicated schematically
at 360. The lock member 360 may be a pin, for example, that is movable
vertically on the bed end 14d along a slot 362. The corner plate
350 has two notches 364 for receiving the support pins 356 on the
bed end 14d.
When the bed end 14d is assembled in a bed 10 so that the corner
plate 350 is to be used projecting from the first major side surface
352 of the bed end (for example with a frame rail or a spring assembly
shown partially at 328), the corner plate 350 is assembled as shown
attached in FIG. 16 with the pins 356 received in the notches 364.
The lock member 360 is moved into a locking position against the
corner plate 350 to hold the corner plate in position on the bed
end 14d.
When the bed end 14d is assembled in a bed 10 so that the corner
plate 350 is to be used projecting from the second major side surface
354 of the bed end, the corner plate is removed and switched to
the other side of the bed end, as shown to the left in FIG. 16.
The corner plate 350 is hooked onto the support pins 356 and the
locking mechanism 360 is used to hold the corner plate in that position
on the bed end 14d.
In this manner, the bed end 14d can be assembled in a bed 10 so
that either the first major side surface 352 or the second major
side surface 354 of the bed end faces the other parts of the assembled
bed, and a corner plate 350 will be available to support the spring
assembly or frame rails 328 of the bed.
FIG. 17 illustrates the use of the bed end 14d with a spring assembly
or frame rail 370 that has notches for receiving the support pins
356 on the bed end. In this case, a separate corner plate, such
as the corner plate 350 is not needed. The support pins 356 function
as the reversible corner plate. The spring assembly or frame rail
370 is supportable from either major side surface 352 or 354 of
the bed end 14d.
The parts of the bed end 14 shown in FIGS. 1-6 are structural and
operational parts for controlling at least one operational aspect
of the bed, specifically, elevation of the bed. A bed end 14 in
accordance with the present invention also includes a bed end cover
for enclosing and covering the operational and structural parts.
Several alternative covers are shown, in FIGS. 18-22.
The preferred material for these bed end covers is an engineered
plastic. The selected material should be washable without being
affected by water or solvents and without absorbing moisture. The
selected material should also be scratch resistant, impact resistant,
and ultraviolet resistant. Also, the material should be able to
be molded or extruded with a single color throughout. Suitable materials
include but are not limited to HDPE, ABS, and PVC.
The materials typically used for prior art decorative/covering
panels in home care adjustable beds are paper or fiberboard covered
in vinyl laminate. This material can scratch completely through
the laminate, absorbs moisture when washed, does not have high impact
resistance, and is not ultraviolet resistant. In addition, such
a cover is manufactured by dropping the various panels of the cover
into a fixture, then screwing or gluing them together. This is a
time and labor-intensive operation.
An engineered plastic bed end cover is easier to handle, because
it is impact and scratch resistant. It is also quicker to assemble
in the plant. It is also washable when returned from home use to
the dealer, for use by another patient, as is required. It is cost
effective to manufacture, more durable, and stronger. In addition,
the use of molded plastic for the bed end cover allows for color
variations and therefore more artistic quality to the bed end, as
well as different physical profiles or configurations for the bed
end.
The cover 400 (FIGS. 18 and 19) is one example of a plastic bed
end cover that is constructed in accordance with the present invention.
The cover 400 is a hollow cover for enclosing and covering the operational
and structural assembly shown in FIG. 2. This cover 400 is extremely
easy to assemble to the structural and operational parts of the
bed end 14 as shown in FIG. 2 for example. It is also easy to manufacture
and handle.
The cover 400 is a one-piece plastic cover having an interior major
side panel 402 that faces inward toward the opposite end of the
bed 10 when assembled, and an opposite exterior major side panel
404. The cover 400 is preferably made by blow molding. A preferred
material is HDPE (high density polyethylene).
The cover 400 also has an upper edge portion 406 interconnecting
the interior and exterior major side panel, panels 402 and 404.
First and second opposite side edge portions 408 and 410 of the
cover 400 interconnect the interior and exterior major side panels
402 and 404 adjacent the first and second legs (shown in phantom
in FIG. 18) of the bed end. The cover 400 further has a lower edge
portion 412 extending between the first and second opposite side
edge portions 408 and 410. The cover 400 has an open bottom edge
414 for enabling sliding movement of the hollow cover over the operational
and structural assembly in a direction between the upper edge portion
406 and the lower edge portion 412 of the cover (as indicated by
the arrow 416).
The cover 400 illustrated in FIGS. 18 and 19 has two optional openings
418 extending through the bed end cover between the interior major
side panel 402 and the exterior major side panel 404. The two openings
418 are disposed adjacent the upper edge portion 406 of the cover
400. Each one of the two openings 418 has a lower edge 420 that
extends parallel to the lower edge portion 412 of the cover 400.
As a result, a supporting assembly, such as a trapeze (not shown),
can be clamped onto the bed end 14 between the lower edge 420 of
one of the openings 418 and the lower edge portion 412 of the cover
400.
The cover 430 (FIG. 20) is another example of a plastic bed end
cover that is constructed in accordance with the present invention.
The cover 430 is a hollow cover for enclosing and covering the operational
and structural assembly or parts of a bed end. The cover 430 has
a three-piece plastic construction including a central panel 432
and two identical end caps 433 (only one of which is shown).
The central panel 432 is a one-piece extrusion preferably made
from PVC. The central panel 432 includes an interior major side
panel 434 that faces the opposite end of the bed 10 when assembled,
and an opposite exterior major side panel 436. The panels 434 and
436 are joined by an upper edge panel 438 in an upside-down U-shaped
configuration to form the central panel 432.
The interior major side panel 434 has a planar configuration with
a rectangular rib 440 forming a bottom end portion of the panel.
Similarly, the exterior major side panel 436 has a planar configuration
with a rectangular rib 442 forming a bottom end portion of the panel.
The upper edge panel 438 forms a similar rectangular configuration
with the top edge portions 444 and 446 of the interior and exterior
major side panels 434 and 436 respectively.
The end caps 433 may be made from ABS. The end cap 433 has a generally
planar configuration. The end cap 433 has three flanges 450 452
and 454 that matingly engage three edges, 456 of the central panel
432 to secure the end cap to the central panel. The end cap 433
has a more rigid construction than the central panel 432 and, as
a result, can help to rigidify the assembled cover 430.
The cover 430 has an open bottom edge 462 for enabling sliding
movement of the hollow cover over the operational and structural
assembly in a direction between the upper edge panel 438 and the
bottom edge of the cover, as indicated by the arrow 464.
This cover 430 is therefore easy to assemble to the structural
and operational parts of the bed end 14 as shown in FIG. 2 for
example. It is also easy to manufacture and handle, and has the
other advantages discussed above with reference to the embodiment
of FIGS. 18 and 19.
The cover 470 (FIG. 20) is a third example of a plastic bed end
cover that is constructed in accordance with the present invention.
The cover 470 is a hollow cover for enclosing and covering the operational
and structural assembly.
The cover 470 is similar to the cover 430 (FIG. 20) with the exception
that the central panel 472 in the cover 430 is made from three pieces,
not one. Specifically, the central panel 470 is formed as an interior
major side panel 474 an exterior major side panel 476 and an upper
edge panel 478. The three panels 474-478 when joined together to
form the central panel 472 have an upside-down U-shaped configuration.
The cover 470 otherwise has the all advantages and feature described
above with respect to the cover 430 (FIG. 20).
As noted above, the movable door or drive shaft cover 222 (shown
generally in FIGS. 5 and 6) is pivotally movable relative to the
main access opening 220 and thus relative to the upper and lower
input shafts 190 and 160 respectively. When the gearbox is actuated,
both input shafts 190 and 160 rotate about their respective axes,
even though only one of them is active. It is desirable to cover
the unused input shaft to prevent contact with the rotating parts,
for example by a hand or a finger. In its first position as shown
in solid lines in FIGS. 5 and 6 the cover 222 covers the lower
input shaft 160 and makes the upper input shaft 190 accessible from
the exterior of the gearbox 140. Covering the lower input shaft
160 prevents contact by a user with the rotating lower input shaft
when it is not being used. In its second position, the cover 222
covers the upper input shaft 190 and makes the lower input shaft
160 accessible from the exterior of the gearbox 140. Covering the
upper input shaft 190 prevents contact by a user with the rotating
upper input shaft when it is not being used.
The drive shaft cover 222 its attachment to the gearbox housing
142 and its operation, are shown in more detail in FIGS. 22-26.
The cover 222 has a generally semicircular or semi-oval configuration.
The cover has a main body portion 500 with a wider end 502 that
is formed with two pivot pins 504 that are retained in the gearbox
housing 142. The pivot pins 504 define a pivot axis 506 and support
the cover 222 for pivotal movement relative to the gearbox housing
142 between the first and second positions, which are closed positions
of the cover. The cover 222 can also assume any one of a plurality
of open positions intermediate the first and second closed positions,
as shown in FIG. 24 for example.
At its narrower end 508 the main body portion 500 of the cover
222 is cut out with slots to form a latching section 510 of the
cover. The latching section 510 includes two gripping ears 512 that
project from the main body portion 500. The ears 512 are resiliently
movable relative to the main body portion 500 of the cover 222 and
relative to each other.
The ears 512 have a first position, in their free state, when no
force is applied to them. In this position, the ears 512 are resiliently
biased away from each other, as shown in solid lines in FIG. 25.
The ears 512 have a second position, when force is applied to move
them toward each other, for example by pinching or compressing them
together, as shown in solid lines in FIG. 26. The ears 512 can also
assume any position intermediate the first and second positions,
depending on the amount of force applied to them and whether they
are restrained from movement.
The gearbox housing 142 has a first latching portion 516 for holding
the cover 222 in the first position. The first latching portion
516 includes a notch 518 that is formed between two camming surfaces
520 on the housing 142. The notch 518 opens into a retaining slot
522 that is located behind the notch 518 and that is not separately
visible. Similarly, the gearbox housing 142 has a second latching
portion 526 (FIGS. 22 and 25) for holding the cover 222 in the second
position. The second latching portion 526 includes a notch 528 that
is formed between two camming surfaces 530 on the housing 142. The
notch 528 opens into a retaining slot 532 that is located behind
the notch.
The cover 222 can be releasably latched in either the first position
or the second position relative to the gearbox housing 142. The
cover 222 is normally left in either the first position or the second
position by the user. If the cover 222 is disposed in the second
position, as shown in FIGS. 23-26 the ears 512 are disposed in
the retaining slot 532 in the latching portion 526. When it is desired
to move the cover out of the first position, the ears 512 are pinched
together (moved toward each other), against the inherent bias of
the material of the cover 222.
As the two ears 512 are brought toward each other, their combined
width decreases so that they are able to fit through the notch 528.
The cover 222 is pulled so that the ears 512 come out of the retaining
slot 532 through the notch 528. The cover 222 is then in an open
position, for example, as shown in FIG. 24. In this open position,
when the ears 512 are released, they spring back outwardly, away
from each other, to their free state, in which their combined width
is greater than the width of the notch 528.
When it is desired to move the cover 222 back into the second position,
the cover is pushed against the second latching portion 526 of the
housing 142. The ears 512 engage the camming surfaces 530. The ears
512 are cammed inwardly so that their combined width decreases to
the width of the notch 528. The ears 512 move through the notch
528 into the receiving slot 532. The ears 512 then spring back outward
into engagement with the slot 532. The resilience of the ears 512
holds them in the slot 532 thus latching the cover 222 in the first
position. The latching section 510 of the cover and the second latching
portion 526 of the housing 142 together constitute a first latch
that holds the cover 222 in the first closed position.
The above description with regard to moving the cover 222 into
and out of the second position applies in a similar fashion to moving
the cover into and out of the first position. The latching section
510 of the cover 222 and the second latching portion 516 of the
housing 142 together constitute a second latch that holds the cover
in the second closed position.
As noted above, the movable portion 22 of the head end 14 includes
a frame structure, or frame 60. The bed 14 end may be used with
a multi-piece cover for the frame 60 for example, the cover 430
shown in FIG. 20. Such a cover 430 has seams between the pieces
432 and 434 of the cover. In this case, it is possible that when
the bed end 14 is washed, water can enter the bed end through the
seams between the main panel 432 and the end caps 434. It is desirable
that this water not accumulate in the bed end 14.
In accordance with a feature of the invention, therefore, the bed
end 14 may be provided with one or more drain openings for draining
water or other liquids out of the bed end. FIGS. 27-29 illustrate
portions of a bed frame 540 that is constructed in accordance with
this feature of the invention.
The bed end 540 includes a lower cross bar 542 which has a tubular
cross-sectional configuration that extends perpendicular to side
rails or legs 544 and 546 and parallel to the floor. The tubular
configuration is U-shaped including a base (bottom) wall 548 and
two upstanding side walls 548 that define between them a channel
in the cross bar 542. At least one drain opening is formed in the
base wall 548 of the lower cross bar 542. In the illustrated embodiment,
two drain openings 554 and 556 are formed, spaced apart at either
end of the cross bar 542. The openings 554 and 556 are semi-circular
or half moon in shape, and abut the side rails 544 and 546 respectively,
of the frame.
Because the drain openings 554 and 556 are in the base wall 548
of the cross bar 542 any water that may accumulate in the bed end
540 as a result of washing the bed end, for example, can easily
drain out. If the bed end 540 is tipped to one side or the other,
the water will drain to one end or the other of the cross bar 542
and drain out of the drain opening 554 or 546. Of course, other
shapes and placements of drain openings in accordance with the invention
are possible.
In accordance with one feature of the invention, end caps for a
bed end of the present invention are secured to the side rail of
the bed frame in a manner as described below. This feature is applicable
to a multi-piece bed end cover, for example, the bed end cover 560
(FIG. 20) that is a plastic bed end cover constructed in accordance
with the present invention. The cover 560 is a hollow cover for
enclosing and covering the operational and structural assembly or
parts of a bed end. The cover 560 has a three-piece plastic construction
including a central panel 562 and two identical end caps 564 (only
one of which is shown). The cover 560 is adapted to fit onto a frame
60 (FIG. 2) having outer legs or side rails 66 and 68. Each of the
side rails 66 and 68 has a square cross-sectional configuration
as can be seen in FIG. 35. The side rails 66 and 68 are similar
in construction and so only the one side rail 68 and the attachment
of its associated end cap, is described.
The side rail 68 has a tongue 570 that is located near the lower
end of the side rail, adjacent the cross bar 64. The tongue 570
has an L-shaped configuration including a base leg 572 that projects
outward from the side rail 68 and a main leg 574 that projects upward
from the end of the base leg. The main leg 574 of the tongue 570
thus extends in a direction parallel to the length of the side rail
68.
The end cap 564 has a generally U-shaped cross-sectional configuration
including a base wall 580 and two side walls 582 and 584. The side
walls extend generally parallel to each other from opposite ends
of the base wall 584. The three walls together define a cavity or
chamber 586 in the end cap 564.
The end cap 564 has an inner wall portion 588 that is formed as
one piece with the remainder of the end cap. The inner wall portion
588 is located at the bottom of the end cap, inside the cavity 586
of the end cap 564. The inner wall portion 588 is spaced inward
from the base wall 580 of the end cap 564 and defines a small opening
or space 590 between the base wall and the inner wall portion.
When the end cap 564 is mounted on the side rail 68 the inner
wall portion 588 of the end cap 564 extends over the tongue 570
of the side rail. The tongue 570 of the side rail 68 fits closely
into the small opening 590 between the inner wall portion 588 of
the end cap 564 and the base wall 580 of the end cap. The engagement
of the tongue 570 with the inner wall portion 588 helps to support
the end cap 564 on the side rail 68. The dimensions of the tongue
570 are selected so that the tongue supports the lower end of the
end cap 564 in a solid and stable manner on the side rail 68.
The opposite upper end of the end cap 564 is also secured to the
side rail 68. Preferably, this takes place with a single (one and
only one) fastener. The single fastener may be a screw 590 as shown
in FIG. 34. The screw 590 extends through a single fastener opening
592 in the end cap 564 and into a threaded opening 594 in the side
rail 68. The combination of the single fastener 590 plus the engagement
of the end cap 564 with the tongue 570 is sufficient to secure
the end cap to the side rail 68. The end cap 564 can be easily removed
from the side rail 68 by unscrewing the screw 590 and lifting the
end cap off the tongue 570.
The single fastener may be other than a screw. For example, FIG.
33 shows a push-type fastener 596 of the kind often used for fastening
panels and boards and the like. The fastener 596 has a head 598
that engages the base wall 580 of the end cap 564. A resiliently
deformable portion 600 of the fastener 596 extends through an opening
602 in the side rail 68. The engagement of the fastener 596 with
the side rail 68 holds the upper end of the end cap 564 firmly in
place on the side rail 68. The fastener 596 may also be of the type
that can be pre-assembled with the end cap 564 in a manner so that
the head 598 is hidden inside the end cap and the end cap thus presents
a clean, fastener-free appearance from the outside.
As noted above, the central panel 562 is a one-piece plastic extrusion.
The central panel 562 includes an interior major side panel 610
that faces the opposite end of the bed 10 when assembled, and an
opposite exterior major side panel 612. The side panels 610 and
612 are joined by an upper edge panel in an upside-down U-shaped
configuration to form the central panel 562. When the cover 560
including the central panel 562 and the end caps 564 is assembled
on the frame of the bed end, the major side panels 610 and 612 each
have a curved configuration rather than a planar configuration.
The major side panels 610 and 612 are, preferably, formed during
extrusion with this curved configuration. A preferred material for
the panel 562 is PVC that is extruded into the form required then
frozen into shape over a mold as it cools. Alternatively, the panel
could be roll formed out of steel and painted to match. Plastic
is preferred for economic and durability reasons; it does not dent
like steel and the color match material can hide scratches.
To help the panels 610 and 612 maintain this curved configuration
during use of the bed, rather than possibly being flattened out,
the panels are engaged with the bed end caps 564 in a manner as
follows. The side walls 582 and 584 of the end cap 564 have a non-planar,
or curved, configuration, as can be seen in FIG. 31 for example.
The side wall 582 which is exemplary, is planar in an upper section
620 then is bowed out for a central section 620 that extends for
most of the vertical extent of the side wall. The bowed section
622 terminates in an outwardly projecting cylindrical boss 624.
Below the boss 624 is a lower planar section 626 at the bottom
end of the side wall 582. All along this length, the side wall 582
has an inner surface 628 that has the same curved configuration.
The end cap 564 has portions that hold the inner major side panel
610 of the central panel 562 of the cover 560 against the curved
inner surface 628 of the side wall 582 forcing the major side panel
610 to assume this same curved configuration. Specifically, the
end cap 564 has a plurality of fingers 630 adjacent the first side
wall 582. The fingers 630 are molded as one piece with the end cap
564. The fingers 630 are portions of the end cap 564 that project
from the side wall 582 in a direction parallel to but spaced apart
from the side wall. In the illustrated embodiment, there are three
fingers 630 adjacent to the first side wall 582. There are also
three fingers 632 adjacent to the second side wall 584 on the opposite
side of the end cap 564.
The end cap 564 thus has a channel 634 that is defined between
the fingers 630 and the inner surface 628 of the side wall 582.
The fingers 630 have outer surfaces 636 that are arranged in the
same bowed configuration as the inner surface of the central section
622 of the side wall. As a result, the channel 634 has the same
curved or bowed configuration that is presented by the side wall
582 itself.
Each one of the major side panels 610 and 612 of the central panel
562 of the cover 560 has an edge portion that is located adjacent
to the side rail 68 when the central panel is installed or assembled
on the frame. The inner major side panel 610 has an edge portion
640 and the outer major side panel 612 has an edge portion 642.
The edge portion 640 extends into the channel 634 between the fingers
630 and the first side wall 582. The edge portion 640 of the inner
major side panel 610 is captured between the fingers 630 of the
end cap 564 and the first side wall 582. As a result, the edge portion
640 assumes the same curved configuration as the channel 634 and
as the side wall 582 of the end cap 564.
On the opposite end of the central panel 562 (to the left as viewed
in FIG. 30), the other end cap 564 in a similar manner, imparts
the same curved configuration to the opposite end of the inner major
side panel 610 of the central panel. Because of the material characteristics
of the central panel 562 this curved configuration is constant
and extends all the way across the width of the central panel, between
the end caps 564. The fingers 630 help to support the panel 610
against deflection.
In a similar manner, the second side wall 584 of the end cap 564
cooperates with the second plurality of fingers 632 to define a
channel between them with a curved configuration that matches the
curved configuration of the second side wall. The edge portion 642
of the outer major side panel 612 is captured between the fingers
632 of the end cap and the second side wall 584. The edge portion
642 extends into the channel that is defined between the fingers
632 and the second side wall 584. As a result, the edge portion
640 assumes the same curved configuration as the second side wall
582 of the end cap 564. In addition, the fingers 632 help to support
the panel 612 against deflection.
In this manner, the two major side panels 610 and 612 have identical
curved configurations. This can enable placement of the bed end
14 at either the foot end of the bed 10 or the head end of the
bed, while preserving the same appearance.
In the illustrated embodiment, the edge portions 640 and 642 of
the central panel 562 overlie the side rails 66 and 68 of the frame,
as can be seen in FIG. 35. This arrangement may not be necessary.
For example, the edge portions 640 and 642 could be held back away
inward from the side rail 68 (to the left as viewed in FIG. 35);
it would then be necessary for the fingers and the side walls of
the end cap to extend inward farther past the side rail 68 so as
to capture the edge portions of the central panel. In either case,
the panel edge portions are considered to be adjacent the side rail,
that is, they are close enough to be captured and curved by the
end cap 564.
In the illustrated embodiment, the fingers are located directly
between the side rail 68 and the edge portions 640 and 642 of the
main panel 562. If the edge portions 640 and 642 were located inward
from the side rail 68 (to the left as viewed in FIG. 35), as described
above, the fingers would be between the edge portion and an imaginary
inward projection of the side rail. In either case, the fingers
are considered to be between the side rail 68 and the edge portions
640 and 642 of the main panel 562.
In the illustrated embodiment, the end cap 564 has a generally
U-shaped cross-sectional configuration, for example, as seen in
FIG. 35. In other embodiments, the end cap 564 could have a different
configuration. For example, the end cap 564 could have a generally
C-shaped configuration, with the base wall 580 being curved rather
than planar. The C-shaped configuration would still include a base
wall and side walls that capture the edge portions of the central
panel to provide them with the desired curved configuration.
From the above description of the invention, those skilled in the
art will perceive improvements, changes, and modifications in the
invention. Such improvements, changes, and modifications within
the skill of the art are intended to be included within the scope
of the appended claims. |