This application claims priority from U.S. Provisional App. No. 63/375,096, filed September 9, 2022, which is incorporated herein by reference.

FIELD

[0001] This application is related to the field of massage mattresses, in particular, air massage beds, chairs, etc.

BACKGROUND

[0002] A massage mattress provides both therapeutic benefits, as well as general well-being to users. However, many massage mattresses are restricted by inherent design constraints that limit their flexibility and functionality.

[0003] There is a need for improved design for massage mattresses.

SUMMARY

[0004] An aspect of the application is a system for providing a massage to a subject lying on a mattress, wherein the mattress comprises: a mattress insert, wherein the mattress insert is secured to the mattress, and wherein the secured mattress insert can be unsecured from the mattress; and wherein the mattress insert comprises: one or more airbags, wherein each airbag comprises an upper air chamber and a lower air chamber, and wherein the upper air chamber and the lower air chamber are connected by one or more vent holes, and wherein stabilizing lines are present within the upper air chambers and lower air chambers at the conjunction of the upper air chambers and lower air chambers; and wherein each airbag of the one or more airbags is arranged in an ordered array, wherein the ordered array positions each of the airbags beneath a body section of the subject lying on the mattress; and wherein each airbag of the one or more airbags within the mattress insert is connected to an air channel for each respective airbag, wherein the air channel provides air that can alter air pressure within the airbags, wherein the alteration of air pressure within each of the airbags can cause that particular airbag to inflate or deflate; and wherein an air control box controls the air pressure within each of the airbags, wherein the air control box can control the inflation or deflation of each airbag, and wherein the inflation or deflation of each airbag in relation to each of the other airbags provides a massage to the subject lying on the mattress. In certain embodiments, the air bag positioned in the ordered array so that the airbag will be beneath the lumbar section of the body has a greater width than the other airbags in the ordered array; and further wherein the air bag positioned in the ordered array so that the airbag will be beneath the lumbar section of the body inflates to a greater height than the other airbags in the array when the air control box increases air pressure in the one or more airbags to a maximum. In certain embodiments, the lower air chamber is secured by a stabilization strap and the upper and lower air chambers are connected by elastic straps.

[0005] Another aspect of the application is a method for providing a massage to a subject lying on a mattress, wherein the method comprises the steps of: securing a mattress insert, wherein the mattress insert is secured to the mattress, and wherein the mattress insert comprises one or more airbags, wherein each airbag comprises an upper air chamber and a lower air chamber, and wherein the upper air chamber and the lower air chamber are connected by one or more vent holes, and wherein stabilizing lines are present within the upper air chambers and lower air chambers at the conjunction of the upper air chambers and lower air chambers, and wherein each airbag of the one or more airbags is arranged in an ordered array, wherein the ordered array positions each of the airbags beneath a body section of the subject lying on the mattress; increasing or decreasing air pressure within each of the one or more airbags by flow of air through an air channel that is connected to each respective airbag comprised within the mattress insert; controlling the flow of air through an air channel by an air control box, which is connected to the air channels; raising or lowering the height of each of the one or more airbags in relation to each other by altering the air pressure within the air bags, wherein the raising or lowering of the height of each of the one or more airbags in relation to each other provides a massage to the subject lying on the mattress.

[0006] Another aspect of the application is a mattress insert for providing a massage, wherein the mattress insert comprises: one or more airbags, wherein each airbag comprises an upper air chamber and a lower air chamber, and wherein the upper air chamber and the lower air chamber are connected by one or more vent holes, and wherein stabilizing lines are present within the upper air chambers and lower air chambers at the conjunction of the upper air chambers and lower air chambers; and wherein each airbag of the one or more airbags is arranged in an ordered array, wherein the ordered array positions each of the airbags beneath a body section of the subject lying on the mattress; and wherein the mattress insert has a top side and a bottom side, and wherein a layer of elastic polyurethane fabric covers the one or more airbags on the top side of the mattress insert, and wherein a layer of needle punched cotton is underneath the one or more airbags on the bottom side of the mattress insert, and wherein the mattress insert contain holes on the bottom side of the mattress insert that connect to vent holes on the lower air chamber of each of the one or more airbags. In certain embodiments, the mattress insert further comprises zippers that are positioned on the sides of the mattress insert.

[0007] An aspect of the application is a method of providing a massage to a subject, comprising the steps of: laying the subject on a mattress comprising the system as described herein. In certain embodiments, further comprising the steps of: inflating the air chambers of the airbags, wherein the increase in air pressure within the air chambers causes the airbags to increase in height, wherein the air chambers are folded to lie flat on top of each other prior to inflation. In certain embodiments, further comprising the steps of: positioning an airbag on top of another airbag, wherein both airbags are inflated simultaneously, and wherein the simultaneous inflation of the airbags causes the combined height of the airbags to increase over that height that would be obtained by each individual airbag if that individual airbag had been inflated individually without the airbags being positioned with one airbag on top of the other.

[0008] One of ordinary skill will understand that the differing embodiments disclosed in this application can all be used either independently or in combination with each other and there is no limitation implied on such combinations by the order or manner in which embodiments are disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] While the present disclosure will now be described in detail, and it is done so in connection with the illustrative embodiments, it is not limited by the particular embodiments illustrated in the figures and the appended numbered paragraphs. Units of dimensions shown in figures are in millimeters; one of ordinary skill will understand the units shown are not limiting and only represent a particular embodiment.

[0010] Fig. 1 shows an exemplary embodiment of an air mattress assembly. Shown: (1) zippers; (2) mattress insert air bag assembly (left, right); (3) mattress cover; (4)(6) air bag connector; (5) air pump control box; (7) remote.

[0011] Fig. 2 shows an exemplary embodiment of a mattress insert air bag assembly.

[0012] Fig. 3 shows a perspective view of an exemplary embodiment of the middle layer of the mattress insert.

[0013] Fig. 4 shows exemplary embodiments of a top view of the mattress insert and a bottom view of the mattress insert.

[0014] Fig. 5 shows an exemplary embodiment of the airbag design, which comprises an upper airbag and lower airbag that are connected. [0015] Fig. 6 shows an exemplary embodiment of a remote control.

[0016] Fig. 7 shows images of an exemplary embodiment of the air mattress.

[0017] Fig. 7 shows images of an exemplary embodiment of the air mattress.

[0018] Fig. 8 shows an exemplary embodiment of a design for the placement of a mattress insert in situ on a conventional mattress frame.

[0019] Fig. 9A-C shows further views of the same exemplary embodiment of a design for the placement of a mattress insert in situ on a conventional mattress frame.

[0020] Fig. 10A-B shows an alternative embodiment of the mattress insert.

[0021] Fig. 11 shows an exemplary embodiment of an air pump operating with the alternative embodiment.

[0022] Fig. 12 shows an exemplary embodiment of a production process.

[0023] Fig. 13 shows an exemplary embodiment of a mattress insert air bag assembly.

[0024] Fig. 14 shows a perspective view of an exemplary embodiment of separable insertion connector.

[0025] Fig. 15 shows exemplary embodiment of a mattress insert air bag assembly.

[0026] Fig. 16 shows an exemplary embodiment of layout of the air bag on the air bag assembly.

[0027] Fig. 17 shows an exemplary embodiment of positioning of the air pipe.

[0028] Fig. 18 shows images of an exemplary embodiment of the double layer air bag.

[0029] Fig. 19 shows images of an exemplary embodiment of the air bag assembly.

[0030] Fig. 20 shows an exemplary embodiment of airbag dimensions and layout.

[0031] Fig. 21 shows an exemplary embodiment of an inflated double chamber airbag with elastic straps connecting top and bottom air chambers and stabilization strap connecting the lower air chamber to the airbag shown. DETAILED DESCRIPTION OF THE INVENTION

[0032] Reference will be made in detail to certain aspects and exemplary embodiments of the application, illustrating examples in the accompanying structures and figures. The aspects of the application will be described in conjunction with the exemplary embodiments, including methods, materials and examples, such description is non-limiting and the scope of the application is intended to encompass all equivalents, alternatives, and modifications, either generally known, or incorporated here. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. One of skill in the art will recognize many techniques and materials similar or equivalent to those described here, which could be used in the practice of the aspects and embodiments of the present application. The described aspects and embodiments of the application are not limited to the methods and materials described.

[0033] As used in this specification and the appended claims, the singular forms "a," "an" and "the" include plural referents unless the content clearly dictates otherwise.

[0034] Ranges may be expressed herein as from "about" one particular value, and/or to "about" another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. It is also understood that there are a number of values disclosed herein, and that each value is also herein disclosed as "about" that particular value in addition to the value itself. For example, if the value "10" is disclosed, then "about 10" is also disclosed. It is also understood that when a value is disclosed that "less than or equal to "the value," greater than or equal to the value" and possible ranges between values are also disclosed, as appropriately understood by the skilled artisan. For example, if the value " 10" is disclosed the "less than or equal to 10" as well as "greater than or equal to 10" is also disclosed.

System

[0035] An aspect of the application is a system for providing a massage to a subject lying on a mattress, wherein the mattress comprises: a mattress insert, wherein the mattress insert is secured to the mattress, and wherein the secured mattress insert can be unsecured from the mattress; and wherein the mattress insert comprises: one or more airbags, wherein each airbag comprises an upper air chamber and a lower air chamber, and wherein the upper air chamber and the lower air chamber are connected by one or more vent holes, and wherein stabilizing lines are present within the upper air chambers and lower air chambers at the conjunction of the upper air chambers and lower air chambers; and wherein each airbag of the one or more airbags is arranged in an ordered array, wherein the ordered array positions each of the airbags beneath a body section of the subject lying on the mattress; and wherein each airbag of the one or more airbags within the mattress insert is connected to an air channel for each respective airbag, wherein the air channel provides air that can alter air pressure within the airbags, wherein the alteration of air pressure within each of the airbags can cause that particular airbag to inflate or deflate; and wherein an air control box controls the air pressure within each of the airbags, wherein the air control box can control the inflation or deflation of each airbag, and wherein the inflation or deflation of each airbag in relation to each of the other airbags provides a massage to the subject lying on the mattress.

[0036] In certain embodiments, the mattress insert is secured to the mattress by a zipper. One of ordinary skill will understand that the means by which the mattress insert is secured to the mattress may be varied, e.g., buttons, according to the design goals. One of ordinary skill will understand that the positioning of the zippers can be varied according to the design goals.

[0037] In certain embodiments, the upper air chambers and lower air chambers are oblong in shape. One of ordinary skill will understand that the shape of the airbags may be varied. One of ordinary skill will understand that the number of airbags in the ordered array can vary, such as plurality of airbags where two or more, three or more, four or more, five or more airbags, preferentially six airbags may be used, or a greater number according to the design goals for the massage mattress.

[0038] In certain embodiments, the upper air chambers and lower air chambers have stabilizing lines. In certain embodiments, the upper air chambers and lower air chambers have merging lines. In certain embodiments, the upper air chambers and lower air chambers have ultrasonic crimping lines (which are stabilizing lines). One of ordinary skill will understand that the upper and lower air chambers can be merged together to form an airbag in various ways. In certain embodiments, the airbag may be manufactured as a whole product per se with equivalent structural stabilization lines formed within the airbags through the manufacturing process, e.g., 3D printing. In certain embodiments, there may be a single air chamber for one or more airbags. In certain embodiments, there may be more than two air chambers. In certain embodiments, there may be three air chambers. One of ordinary skill will understand that the number and relative sizes of the air chambers may be varied according to the goals of the design.

[0039] In certain embodiments, the mattress insert is positioned underneath a mattress topper.

[0040] In certain embodiments, an air pressure sensor is part of the system of controlling air pressure withing the air chambers and different airbags. In particular embodiments, precise pressure values are set for each airbag and used to control the flow of air in and out of the airbags while the level of air pressure within the airbag as monitored by the air pressure sensor(s). The particular placement of an air pressure sensor within the system is not limiting.

[0041] In certain embodiments, the mattress insert is a mattress topper.

[0042] In certain embodiments, the ordered array of the airbags follows the sequential order of body sections of one or more selected from the group consisting of neck, back, lumber, hip, thigh and calf. One of ordinary skill will understand that the number of body sections that is focused on by the ordered array can be varied according to the design goals.

[0043] In certain embodiments, the air bag positioned in the ordered array so that the airbag will be beneath the lumbar section of the body has a greater width than the other airbags in the ordered array.

[0044] In certain embodiments, the air bag positioned in the ordered array so that the airbag will be beneath the lumbar section of the body inflates to a greater height than the other airbags in the array when the air control box increases air pressure in the one or more airbags to a maximum.

[0045] Another aspect of the application is a method of providing a massage to a subject, comprising the steps of: laying the subject on a mattress comprising the systems and apparatus described herein.

[0046] In certain embodiments, the control unit is programmed to selectively inflate the air chambers of the airbags via a pump in a repeating pattern to provide the subject lying on the mattress with a massage. One of ordinary skill will understand that the pump may have the capability of changing the air pressure within the airbags so as to produce inflating, deflating or holding in position (e.g. maintaining a particular height) of the airbag.

[0047] The systems described herein can further include one or more sensors. The types of sensors are not intended to be limited and may include pressure sensors, load sensors, force sensors, temperatures sensors, humidity sensors, motion sensors, vibrational piezoelectric sensors and the like. The systems described herein may also further include a control system in operative communication with the sensors and configured to receive signals therefrom, which can be used to adjust pressure and/or air flow to the subject lying on the mattress as well as continually monitor the occupancy, position, and/or sleep state of the individual. As such, the control system can responsively adjust the pressure and/or air flow to the subject lying on the mattress based on the occupancy, position, and/or sleep state.

[0048] In certain embodiments, each one of the airbags further includes a pressure sensor for sensing pressure within each of the airbags, which can then be used by the air control unit to provide a repeatable pressure change in selected airbags via the pump. The repeatable pressure change can be made to occur in selected airbags such as, for example, in response to a weight detected by two or more particular airbags such as from a prone individual lying on the mattress. This will decrease the volume of the air in the airbag, and the pressure will increase as a function of the weight of the individual lying on the mattress. The increase in pressure as a function of weight can be detected by the pressure sensors and a repeating pressure pattern can be then made to those airbags such that the subject lying on the mattress experiences a massage. The repeating pressure pattern generally includes sequentially inflating or deflating different airbags.

[0049] For example, the repeating pattern can include a wave pattern by selectively sequentially inflating and deflating the airbags in order followed by repetition of the wave pattern. However, it should be noted that any repeating pressure pattern can be programmed. It should also be noted that the repeating pattern can include simultaneously increasing the pressure of two or more airbags followed by release of the excess pressure and increasing the pressure of one or more of the other airbags in a repetitive pattern. [0050] Exemplary air supplies and pneumatic pumps are disclosed in U.S. Pat. Nos. 8,181,290; 8,191,187; 8,065,763; 7,996,936; and 7,877,827; and US Pat. Pub. Nos. 2012/0227182; 2012/0131748; 2011/0296611; 2011/0258778; 2011/0119826; 2010/0011502; and 2008/0148481; incorporated by reference in their entireties.

[0051] The control system can include a processor, a memory, and a transceiver and may communicate with the one or more sensors wirelessly or via wired connections. In certain embodiments, the control system is configured to collect the information received from the one or more sensors in the memory.

[0052] In exemplary embodiments, the processor may be a digital signal processing (DSP) circuit, a field-programmable gate array (FPGA), an application specific integrated circuit (ASIC) or the like. The processor can be any custom made or commercially available processor, a central processing unit (CPU), an auxiliary processor among several processors, a semiconductor based microprocessor (in the form of a microchip or chip set), a macroprocessor, or generally any device for executing instructions.

[0053] In certain embodiments, the control system includes a Bluetooth or Wi-Fi transceiver that can be used to communicate with a wireless device or wireless network. In certain embodiments, the control system is configured to connect to a web-service over a WiFi connection and a subject lying on the mattress can use the web-service to modify one or more settings of the control system and to view data collected by the control system that is stored in the memory. In certain embodiments, data collected by the control system may be stored locally, on a wireless device or a web-based Cloud service.

Method

[0054] Another aspect of the application is a method for providing a massage to a subject lying on a mattress, wherein the method comprises the steps of: securing a mattress insert, wherein the mattress insert is secured to the mattress, and wherein the mattress insert comprises one or more airbags, wherein each airbag comprises an upper air chamber and a lower air chamber, and wherein the upper air chamber and the lower air chamber are connected by one or more vent holes, and wherein stabilizing lines are present within the upper air chambers and lower air chambers at the conjunction of the upper air chambers and lower air chambers, and wherein each airbag of the one or more airbags is arranged in an ordered array, wherein the ordered array positions each of the airbags beneath a body section of the subject lying on the mattress; increasing or decreasing air pressure within each of the one or more airbags by flow of air through an air channel that is connected to each respective airbag comprised within the mattress insert; controlling the flow of air through an air channel by an air control box, which is connected to the air channels; raising or lowering the height of each of the one or more airbags in relation to each other by altering the air pressure within the air bags, wherein the raising or lowering of the height of each of the one or more airbags in relation to each other provides a massage to the subject lying on the mattress.

[0055] In certain embodiments, the method further comprising the steps of: unsecuring a first secured mattress insert so as to replace the first secured mattress insert with a second mattress insert; securing the second mattress insert to the mattress. In certain embodiments, the method further comprising the steps of: controlling temperature of the air flowing in the air channels, wherein raising the temperature of the air in the air channels provides a hot massage to the subject lying on the mattress. In certain embodiments, the method further comprising the steps of: inserting the mattress insert underneath a mattress topper. In certain embodiments, the method further comprising the steps of: placing a layer of foam above the one or more airbags within the mattress insert; and positioning the mattress insert to be the mattress topper.

Mattress Insert [0056] Another aspect of the application is a mattress insert for providing a massage, wherein the mattress insert comprises: one or more airbags, wherein each airbag comprises an upper air chamber and a lower air chamber, and wherein the upper air chamber and the lower air chamber are connected by one or more vent holes, and wherein stabilizing lines are present within the upper air chambers and lower air chambers at the conjunction of the upper air chambers and lower air chambers; and wherein each airbag of the one or more airbags is arranged in an ordered array, wherein the ordered array positions each of the airbags beneath a body section of the subject lying on the mattress; and wherein the mattress insert has a top side and a bottom side, and wherein a layer of elastic polyurethane fabric covers the one or more airbags on the top side of the mattress insert, and wherein a layer of needle punched cotton is underneath the one or more airbags on the bottom side of the mattress insert, and wherein the mattress insert contain holes on the bottom side of the mattress insert that connect to vent holes on the lower air chamber of each of the one or more airbags. One of ordinary skill will understand that the use of elastic polyurethane fabric or needle punched cotton may be varied with use of equivalent materials if need be, in accordance with particular design goals.

[0057] In certain embodiments, the mattress insert further comprises zippers that are positioned on the sides of the mattress insert.

[0058] In certain embodiments, the ordered array of the airbags follows the sequential order of body sections of one or more selected from the group consisting of neck, back, lumbar, hip, thigh and calf. The number of body sections may be one or more, two or more, three or more, four or more, five or more, preferably six, or a greater number, in accordance with the design goals. [0059] In certain embodiments, the air bag positioned in the ordered array so that the airbag will be beneath the lumbar section of the body has a greater width than the other airbags in the ordered array.

[0060] In certain embodiments, the air bag positioned in the ordered array so that the airbag will be beneath the lumbar section of the body inflates to a greater height than the other airbags in the array when the air control box increases air pressure in the one or more airbags to a maximum.

[0061] Suitable foams for use in connection with the mattress insert herein, include but are not limited to, polyurethane foams, latex foams including natural, blended and synthetic latex foams; polystyrene foams, polyethylene foams, polypropylene foam, polyether-polyurethane foams, and the like. Likewise, the foam can be selected to be viscoelastic or non-viscoelastic foams. Some viscoelastic materials are also temperature sensitive, thereby also enabling a foam layer to change hardness/firmness based in part upon the temperature of the supported part. Unless otherwise noted, any of these foams may be open celled or closed cell or a hybrid structure of open cell and closed cell. Likewise, the foams can be reticulated, partially reticulated or non-reticulated foams. The term reticulation generally refers to removal of cell membranes to create an open cell structure that is open to air and moisture flow. Still further, the foams may be gel infused, include conductive materials, include phase change materials, or other additive in some embodiments. The different layers can be formed of the same material configured with different properties or different materials.

[0062] The various foams suitable for use in the designs described herein may be produced according to methods known to persons ordinarily skilled in the art. For example, polyurethane foams are typically prepared by reacting a polyol with a polyisocyanate in the presence of a catalyst, a blowing agent, one or more foam stabilizers or surfactants and other foaming aids. The gas generated during polymerization causes foaming of the reaction mixture to form a cellular or foam structure. Latex foams are typically manufactured by the well-known Dunlap or Talalay processes. Manufacturing of the different foams are well within the skill of those in the art.

[0063] The different properties for foams to be used in connection with the designs herein may include, but are not limited to, density, hardness, thickness, support factor, flex fatigue, air flow, glass transition temperature, various combinations thereof, and the like. Density is a measurement of the mass per unit volume and is commonly expressed in pounds per cubic foot. By way of example, the density of foam layers can vary. In some embodiments, the density decreases. In other embodiments, the density increases. In still other embodiments, one or more of the foam layer can have a convoluted surface. The convolution may be formed of one or more individual layers with the foam layer, wherein the density is varied from one layer to the next. The hardness properties of foam are also referred to as the indention load deflection (ILD) or indention force deflection (TFD), and is measured in accordance with ASTM D-3574. Like the density property, the hardness properties can be varied in a similar manner. Moreover, combinations of properties may be varied for each individual layer. The individual layers can also be of the same thickness or may have different thicknesses as may be desired to provide different tactile responses.

[0064] The present application is further illustrated by the following examples that should not be construed as limiting. The contents of all references, patents, and published patent applications cited throughout this application, as well as the Figures and Tables, are incorporated herein by reference

EXAMPLES

Air Mattress Assembly [0065] Fig. 1 shows an exemplary embodiment of an air mattress assembly. The air mattress is shown in position on a conventional mattress; zippers (1) are used to secure the air mattress to the underlying conventional mattress. The zipper are positioned at the sides of the air mattress so as to secure the stability and location of the air mattress while not interfering with the operation of the airbags (represented by the two sets of six rectangles within Fig. 1). The inset picture further shows the location of the zippers (1). The use of zippers enables the air mattress to be unzipped and removed from the conventional mattress on which it has been secured; a new air mattress may then be zipped onto the conventional mattress as a replacement. The ability to replace the air mattress is an inventive aspect of the design and a significant improvement over the art.

[0066] Fig. 1 further shows the mattress insert air bag assembly (2). The mattress insert is the apparatus that is zippered onto the conventional mattress. The mattress insert comprises within it six rectangular airbags that are arrayed in parallel, such that the longer sides to the rectangular air bags are side-to-side. The positioning of the airbags is based on the typical position of a human subject who is lying on top of the air mattress. The position of the airbags within the insert is selected so that each airbag will be located underneath a different body section from head to calves of the subject.

[0067] Fig. 1 also shows the mattress cover (3). The mattress cover on a conventional mattress will typically enclose the mattress insert. The mattress insert will lie underneath the mattress cover and will not be visible to the eye directly unless the mattress cover is removed, e.g., for replacement of the mattress insert with a new one.

[0068] Fig. 1 additionally shows the air bag connectors (4) and (6). The air bar connectors (4) each provide an air channel that runs to each air bag; there are six individual connectors because there are six individual airbags shown in the exemplary embodiment. The air bag connector (6) shows a closer perspective of the connectors, which enter into the air mattress and then connect to the respective airbags. Fig. 5 moreover shows the air pump control box (5), which controls the volume, direction and speed of air flowing through the air channels of the air bag connectors into the air bags inside the mattress insert. Furthermore, Fig. 5 shows a remote control for the operation of the air control box, and by extension, the mattress insert and the massage performed by the air bags.

[0069] The air connectors may be soft rubberized air hoses, which can be capped and plugged in on one side. Air pressure is monitored and controlled so that the airbags may be inflated to pre-set levels or under manual control. There are at least two sets of air in/outlets: one to inflate and deflate, and also one to hold the air pressure. The airbags cover body positions from at least head to glutes, and may be used in conjunction with different cycles, levels of inflation, hold, relaxing mode, stretch mode, deep tissue pushing movement to relieve tension, and an automated preprogrammed cycle.

Mattress Insert Air Bag Assembly

[0070] Fig. 2 shows an exemplary embodiment of a mattress insert air bag assembly.

The mattress insert contains three layers. As shown in Fig. 2, the top layer is the airbag top cover (8), which may be made of lycra fabric (or any other equivalent material). The middle layer comprises both the air bags (9) and the air bag base (10). The air bag base is made of needle punched cotton; needle punched cotton is used as the airbag base because it can hold each airbag in the right position, while not compromising the softness and ease of the mattress to the subject lying on it. The third layer of the mattress insert is the air bag bottom (11), upon which the zippers (1) are placed that can then be used to zip the mattress insert into the conventional mattress. The zippers are set on the surrounding sides of the mattress insert, so as to help hold the airbags in the right position without falling down, and so that the zippers do not interfere with the feeling of air massage or stretch imparted to the subject lying on the bed. [0071] Fig. 3 shows a perspective view of an exemplary embodiment of the middle layer of the mattress insert. There are six air bags shown on the top side of the middle layer of the mattress insert: neck airbag (12), back airbag (13), lumbar airbag (14), hip airbag (15), thigh airbag (16), and calf airbag (17). The name designations for each airbag are based on the corresponding typical body sections of a subject lying on top of the air mattress underneath which each airbag will be positioned. The airbags may very in size and air capacity. In this exemplary embodiment, the lumbar airbag (14) is wider than the other airbags and will inflate to a greater height; this provides greater support to the lumbar section of the subject lying on the bed. In the embodiments shown in Fig. 3, the remaining airbags are the same size and air capacity. In a particular embodiment, the lumbar airbag (14) is 63 cm x 21 cam in dimensions, and fully inflates to 25 cm height, while the remaining airbags are 63 cm x 14 cam in dimensions and inflate to 18 cam in height. The air pressure control box has a sensor which enables air pressure detection for better control of the relative inflation or deflation of the air bags.

[0072] Fig. 4 shows exemplary embodiments of a top view of the mattress insert and a bottom view of the mattress insert. The top view at the far left of Fig. 4 shows the arrayed order of the airbags within the mattress insert. As can be seen, the lumber airbag, which is third from top in the arrayed order of airbags, is wider than the other airbags. Also the calf airbag, which is the sixth airbag in the arrayed order of airbags, is spaced from the fifth airbag by a greater distance than separates the other airbags. The figure shows the spacing of the airbags in cm. One of ordinary skill will understand that the spacing of the airbags is based on the typical expected positions of body sections of the subject, but may be altered and customized as may be required. The bottom view at the center of Fig. 4 shows the connections between the air channels that flow through the air connectors to the underside of the airbags. As can be seen, each air channel branches out to connect to a specific airbag associated with that air channel. As can be further seen, each air channel divides into two sub-channels which then supply air to the individual airbag to which that particular air channel has been connected. At the far right of Fig. 4, the top image shows the air channels connecting to the underside of the airbags through the bottom side. Also at the far right of Fig. 4, the bottom image shows a close up of the air channels carried by tubes that are fixed onto the underside; in this image, one air channel can be seen branching off to connect with its specific airbag.

Air Bag Design

[0073] Fig. 5 shows an exemplary embodiment of the airbag design, which comprises an upper airbag and lower airbag that are connected. As can be seen, the airbags have an oblong design in which there are two airbags connected to each other. Fig. 5 shows that the top layer, which is the layer closest to the subject lying on the mattress, provides a massage surface that will press upwards with inflation or lower downwards with deflation of the airbag. The top layer is the top surface of the upper airbag. The upper airbag is connected to the lower airbag through vent holes that are aligned in the bottom side of the upper airbag and the top side of the lower airbag. The bottom side of the upper airbag and the top side of the lower airbag are joined so as to form a middle layer of the airbag as a whole. Air can flow through from the lower airbag into the upper airbag. The joining of the upper airbag and lower airbag is created by two ultrasonic crimping lines; in addition to forming the whole airbag structure by joining the upper and lower airbags these ultrasonic crimping lines increase the stability of the airbag design, so that the airbag will not be tilted or overturned arbitrarily when inflated. The bottom side of the lower airbag has two vent holes to which the air channels are attached and air is supplied to the whole air bag. The bottom layer of the airbag is then stitched or fixed in the underlying mattress insert layer. [0074] The airbags are made with a TPU composite (or an equivalent material). The airbags are heat-sealed around the edge. In certain embodiments, the airbags are pre-stitched to a layer of foam, covered by a sleeve, and inserted into a mattress. In certain embodiments, the airbags are located underneath the mattress topper, in which instance a layer of foam is only used on the bottom of the mattress insert as a top layer of foam will be provided by the mattress topper. In certain embodiments, the airbags are the mattress topper, in which instance the airbags are underneath a layer of foam.

Control System

[0075] The operation of the air mattress for massage is controlled by a remote control that a wireless connection to the air control box. As can be seen in Fig. 6, which shows an exemplary embodiment of a remote control, the control can take the form of a hand-held controller with a range of control options offered to a subject lying on the bed. Massage options include full body, upper body, lower body, back, legs, glutes, and vigorous. Individual types of massage options include stretch, relax, wave, and spot massage. Spot massage includes options for neck, back, hips, glutes, thighs, and calves. Individual sections can also be controlled for massage including neck, back, hips, glutes, thighs, and calves. For an individual section, such as the neck shown in Fig. 6, the intensity of massage and the timing of the massage can be adjusted. Other features may include settings for screen brightness, language and a timer.

[0076] The wireless remote may comprise a control dial with directional controls (left and right hand orientation switch), a hold button, a microprocessor inside to control home position, a three-way switch: forward/b ackward and press and hold for returning the bed (or a chair) to home position. In a particular embodiment where the mattress insert is used in connection with a chair, the chair has two actuators: one press for footrest control only, and after thirty seconds, a reset to original programming, so the dial controls the chair; if the user presses and holds, then everything resets to upright sitting position.

Air Mattress

[0077] Fig. 7 shows images of an exemplary embodiment of the air mattress. At top in Fig. 7, the conventional mattress is shown; the mattress insert cannot be seen beneath the mattress cover, although the remote control for the air mattress is visible. At bottom in Fig. 7, the mattress cover has been removed, and the mattress insert can be seen; the mattress insert has been zippered into the conventional mattress frame (a hand is shown lifting an unzippered section of the mattress insert). At center in Fig. 7, the mattress insert with the airbags inflated within the insert can be seen; the greater height and width of the lumbar airbag can clearly be discerned relative to the other inflated airbags.

[0078] Fig. 8 shows an exemplary embodiment of a design for the placement of a mattress insert in situ on a conventional mattress frame. The conventional mattress comprises a foam base that the mattress insert is zippered on top of, and another layer of foam covers the mattress insert. The mattress insert can then be activated to perform massage through the raising and lowering of the airbags positioned in arrayed order within the mattress insert to lie underneath different sections of the body from head to glutes. Figs. 9-10 show further views of the same exemplary embodiment.

[0079] Fig. 10A-B shows an alternative exemplary embodiment of the mattress insert. In this embodiment, the airbags may be adjusted within the mattress insert. In Fig. 10A, the mattress insert is shown opened from the side; a layer of foam is above and below the airbags, in the near frame airbags that have been placed one on top of the other can be seen. In Fig. 10B, a zipper can be seen at top right, while an inflated airbag has been placed within the mattress insert. In certain embodiments, airbags may be placed and moved around within the mattress insert according to need; in other embodiments, the mattress insert comes with the airbags in fixed positions.

[0080] Fig. 11 shows an exemplary embodiment of an air pump used in connection with the alternative embodiment. As can be seen the air pump is not part of the mattress insert and can be removed from the mattress insert to allow ease of storage. The depicted embodiment has a controller linked by wire to the air pump, but a wireless controller can also be used. The different tubes running from the air pump run to different airbags allowing highly individuated control of inflation/deflation within the mattress insert.

Airbag Assembly

[0081] An exemplary embodiment of the production process is shown in Fig. 12. The massage airbag assembly is inserted between a top sponge and bottom sponge to form a massage mattress. These are then machine compressed and the compressed massage mattress is folded and can be rolled up for ease of packing.

[0082] Through the structural design choices and layout described herein, the airbag assembly can solve the problem that each component may be damaged in the compression, winding, packing and other processes during vacuum packing and compression after assembly of the massage mattress.

[0083] In one embodiment, the air bag assembly consists of three components: a control box, extension airpipe and massage air bag pad. These three parts are connected to each other through separable connectors. The massage bag pad is installed in combination with the sponge as the compressible parts, which can experience vacuum compression and rolling up (see Fig. 13).

[0084] The separable insertion connector is set outside the mattress, but close to the mattress. The design height of the connector is 16mm, less than the thickness of the mattress after compression (the overall thickness of the mattress after complete compression is about 30mm) (see Fig. 14).

[0085] The air bag assembly adopts a unilateral air outlet design, that is, an air bag has only one air inlet. This reduces or avoids the folding and rolling of the internal air pipe, and the air inlet and air pipe are arranged on the outside of the mattress. The air pipe is fixed on the bottom fabric of the air bag assembly with soft materials. This design ensures that when the mattress is folded and rolled damage of the air bag assembly and air pipe is avoided (see Fig. 15).

[0086] In addition to the layout of the air bag on the air bag assembly with reference to the body parts, the position of the No. 21 air bag is also set in the middle position away from the mattress. This design can effectively avoid large deformation of the air bag when the mattress is folded in half (see Fig. 16).

[0087] Due to the excellent flexibility of silicone air pipe, when the compressed mattress is opened and used, the air pipe can be immediately restored to its original shape without damage. Therefore, the rolling up of the air pipe will not affect the filling and discharging of air in the mattress (see Fig. 17).

[0088] Through the selection of dimension and the design of the shape and structure of the air bag, the air bag with the largest volume in the air bag assembly can drain the air in the air bag in a short time (such as 5 minutes) after the air valve is closed or stopped in the specific air path system. The mattress can then enter sleep mode without residual air leaving and deflating the mattress undesirably.

[0089] In one embodiment, the design dimensions of the No. 20 waist air bag are Length^600, Width 170mm. As shown in Fig. 18, the No. 20 waist air bag has a double layer design; the double layer air bag on both sides of the design has 2~3 elastic connection strap (or belts) with specific length dimensions (material can be selected such as elastic or other materials with the same tensile tension) which interconnect the top chamber and bottom chamber of the airbag. The purpose of this design is to use the elastic connection belt tensile tension to pull the upper air bag downwards when the lower auxiliary air chamber undergoes fast exhaust to deflate (see Fig. 18). This design solves a problem that when two chambers both inflate (in typical embodiments each airbag may be eight to nine inches tall) this creates a high likelihood of an uneven and asymmetrical collapse of the top chamber when air exhausts quickly (as is required for a massage mattress). The uneven and asymmetrical collapse of the top chamber will negatively impact user experience and the effectiveness of the massage. Thus, the elastic straps are used to ensure that the evenness of the surface is maintained as the top chamber deflates. The elastic straps are stitched, or otherwise fixed, to the top chamber and the bottom chamber, so that they will stretch elastically as inflation occurs. The elastic straps will then be held in tension by the air pressure within the top and bottom chambers of the airbag when the airbag has been inflated. Upon entering a deflationary phase, as air is rapidly exhausted, the top chamber will be pulled evenly downwards as the tension of the elastic straps is relaxed as the air pressure within the airbag eases. One of ordinary skill will understand that the nature of the elastic material, or number of straps, or means of fixing the straps to the airbag is not limiting on the invention, and may be varied according to design preference.

[0090] Better user experience can be achieved through the special structural shape design of airbag. The uneven external force in the process of charging and releasing the air bag will lead to abnormal extrusion or folding of the air bag. In order to keep the positioning of the air bag and maintain normal shape, the designs described herein are adopted to solve the problem of the deformation of the air bag and the unrecoverable overturn of the air bag. [0091] (1) The air bag assembly is connected with the mattress through mechanical connection, including but not limited to other ways such as sewing, zipper pulling, locking and so on.

[0092] (2) The bottom of each air bag is also connected with the base of the air bag assembly through mechanical connection, fixed in a certain position. The mechanical connection includes but is not limited to sewing, zipper pulling, locking, high frequency crimping, etc.

[0093] (3) An air bag is designed as a double layer air bag. A fixed stabilization strap with length greater than half length of the air bag is designed on both sides of the double layer air bag to maintain the stability of the bottom air bag.

[0094] (4) Ultrasonic pressure wiring is designed in the middle of the two-layer air bag to increase the stability of the double-layer design air bag, so that the air bag will not tilt or tip over arbitrarily when inflating (see Fig. 19).

[0095] An exemplary embodiment of airbag dimensions and layout is shown in Fig. 20. An exemplary embodiment of a double layer airbag with top and bottom air chambers inflated can be seen in Fig. 21; the elastic straps connecting to top and bottom air chambers and the stabilization strap connecting the lower air chamber to the mattress are shown in the inflated position.

[0096] While various embodiments have been described above, it should be understood that such disclosures have been presented by way of example only and are not limiting. Thus, the breadth and scope of the subject compositions and methods should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.

[0097] The description herein is for the purpose of teaching the person of ordinary skill in the art how to practice the embodiments of the present application, and it is not intended to detail all those obvious modifications and variations of it which will become apparent to the skilled worker upon reading the description. It is intended, however, that all such obvious modifications and variations be included within the scope of the embodiments of the present application, which is defined by the following claims. The claims are intended to cover the components and steps in any sequence which is effective to meet the objectives there intended, unless the context specifically indicates the contrary.