WO2005032305A2

WO2005032305A2 - Air mattress system

Info

Publication number: WO2005032305A2
Application number: PCT/US2004/032703
Authority: WO
Inventors: John H. Ii Saunders; David J. Smith
Original assignee: Saunders John H Ii; Smith David J
Priority date: 2003-10-02
Filing date: 2004-10-02
Publication date: 2005-04-14
Also published as: WO2005032305A3; WO2005032305A9

Abstract

The present invention provides a new and useful system for reducing air pressure while maintaining air volume flow generally and particularly a method for reversibly inflating and deflating a commercial truck air mattress (60) via the standard air compressor (20) of the truck. One of the unique abilities of the present invention is the down regulation of the air pressure via a regulator (4) to a level useful for inflating the air mattress (60) to a level suitable for sleeping comfortably.

Description

AIR ATRESS SYSTEM FIELD OF THE INVENTION The present invention relates generally to air compression technology and more particularly to a system and method for regulating highly compressed air flow to a form usable in situations and for devices having comparatively miniscule air pressure requirements.

BACKGROUND OF THE INVENTION Commercial trucking is a very demanding profession that requires long hours and intense concentration. Over the years, trucking companies have regulated the number of hours that drivers can log within a certain time span and as a result the need for comfortable accommodations arose. Though many commercial trucks have sleeping accommodations attached, the bed may not be as comfortable as it could be. In order to address this problem, manufacturers proposed providing air mattresses for the beds to increase the level of comfort. Unfortunately, conventional air mattresses are not easily adjustable to suit the varying comfort profiles of different individuals. For example a person that likes a firm mattress may prefer an air mattress at 1 psi while another prefers a softer mattress at 0.3 psi. Moreover, the preference of the user may vary over time; therefore, the mattress needs to be readily adjustable. Additionally, pressure changes occur due to altitude changes while driving (e.g., a mattress set to 1 psi at sea level then travels in the truck to an altitude of 4,000' above sea level - the pressure needs to be regulated due to density changes resulting from the altitude variance. Most commercial trucks operated on US roads have an operational air compressor designed to support functions such as brakes, windows, seats, and door locks, these compressors are rated at either 13.2 or 15.2 cfm with normal operating pressures between 100- 125psi, with α pressure relief at 150psi. This poses a problem if used as a source for the air mattress in that anything above I psi would be impractical for use as a bed and anything above 6 psi would rupture the bladder of the air mattress. Moreover, in instances where the air pressure is reduced to I psi or lower, the airflow is diminished to the point that it is impractical for inflating an air mattress conveniently. Therefore, there remains a need for an air mattress system that can utilize the existing air compression apparatus of conventional commercial trucks while having the ability to down regulate the air supplied to the air mattress preferably below 1 psi. An additional need remains for a compression apparatus that allows for the reduction of air pressure while retaining sufficient airflow for use in a variety of applications. There also remains a need for an apparatus that can allow for manual inflation and deflation of the air mattress bladder in a simple and convenient manner. In particular, as the air density fluctuates due to altitude changes, which would be common during cross-country hauling, there needs to be a way to relieve that pressure on the air mattress to avoid rupturing the air mattress bladder. However, there also remains a need for an automatic compression regulation means such as an electrically powered air pressure and airflow regulator baffle within the compression apparatus in general and the compression valve in particular.

SUMMARY OF EXEMPLARY EMBODIMENTS The present invention provides a new and useful system and method for reversibly inflating and deflating a commercial truck air mattress via the standard air compressor of the truck. One of the unique abilities of the present invention is the down regulation of the air pressure while maintaining airflow at a level useful for inflating the air mattress to a level suitable for sleeping comfortably. It is, therefore, an additional principal objective in accordance with a preferred embodiment of the present invention to provide a regulation valve for reducing the air pressure between the air compressor and the air mattress, which keeps airflow at a suitable working level. It is also a principal objective in accordance with a preferred embodiment of the present invention to provide an air mattress system allowing for the reversible regulation of air pressure from a truck's air compressor to the air mattress in the sleeping compartment of the truck with a hand-held device. Another objective of a preferred embodiment of an air mattress system is to provide a means of inflating an air mattress using the existing air compression apparatus of a commercial truck without having to resort to a separate compressor module. In the furtherance of this and other objectives, the air mattress is preferably operably coupled to the air supply line leading from the truck's compressor, the compressor itself having a valve member designed specifically for down regulating the air pressure that is fed directly to the mattress or other auxiliary functions with requirements below 6 psi. Yet another objective in accordance with an alternative embodiment of present invention is to provide a system that provides a regulator operatively configured between the air mattress and the air compressor to facilitate down regulation of air pressure in cases where the air compressor does not have such capacity. The present invention possesses many advantages and features.

Further objectives, features and advantages of the invention will become more apparent to those persons skilled in this area of technology and others when reading the detailed description of exemplary preferred embodiments of the present invention taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is α conceptual view of a preferred embodiment of the present invention depicting an air mattress system comprising an air compressor, regulator valve and air mattress operatively coupled such that the regulator valve facilitates the diminution in air pressure from about 125 psi to a preferable useful range of about between 0.1 psi - 6 psi and more preferably 0.3 psi - 1 .5psi.

FIG. 2 shows an aerial perspective an exemplary embodiment of a regulator valve in accordance with the present invention. FIG. 3 shows a side perspective view of the regulator valve of

FIG. 1 , showing the pressure release members thereof.

FIG. 4 shows enlarged perspective view of an exemplary embodiment of a regulator valve, in accordance with the present invention, having an electrical source coupling member that allows for the electrical air compression.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Commercial trucks operating on US roads, which have sleeping accommodations, have an operational air compressor designed to support functions such as brakes, windows, seats, and door locks. These compressors are rated at 1 — 20 cfm with the most common either 13.2 or 15.2 cfm and a normal operating pressures between 1 - 200 psi with the most common being 100-125psi, with a pressure relief at 150psi. An exemplary truck mattress air valve in accordance with the present invention can either originate at the on-board air compressor or tap into an existing air-line already located in the cab of the truck. The approximately 125psi air enters the valve through a tube having an outer diameter of preferably between about 0.5" - 2.5". As the air passes the reduction member or regulator of the valve it will be reduced to approximately 0.1 - 2 psi in a tube having an outer diameter of approximately between about 0.375" - 1.5". Operational pressure at the mattress should not exceed 6 psi but is preferably below 1 psi. Once the air pressure is reduced to below 6 psi, it will then be available at all times at the control portion of the valve to operate the air mattress. The key to successfully compressing the air is to sufficiently reduce the air pressure without reducing the air volume flow below useful parameters. To that end, the valve must for example reduce the air pressure to 1 psi or below without reducing the air volume flow below 3 cfm. Since the pressure to air volume flow ratio on standard compressors is roughly 8:1 psi/cfm, in order to make the valve work efficiently the valve must increase the ratio between the entrance and the exit fittings to above 15:1 and preferably above 23:1. As a result, with an average air mattress that fits into a cab being approx 15.5 cubic feet, the mattress needs to be filled at a flow rate of approx 3 cfm, which is well below the standard volume of 13 - 15 cfm of the standard compressor, while also reducing the pressure from 125psi to 1 psi. Moreover, the compression apparatus must account for instances where the intake tube has a smaller diameter than the output fitting or vice versa. In preferred embodiments, the operator will have a toggle switch or button located on a handheld unit to either allow air to enter the mattress or allow air to vent overboard back into the ambient air of the truck cabin. This toggle switch or button is a manual operation design, whereas the operator is physically controlling the position of the valve. An alternate applicator design would not alter the basic concept but would allow the valve to be electrically controlled from a remote. The operator would select "firmer" or "softer" on a hand held remote, and an electrical signal (either direct or IR remote) may control the operation of the valve. From an Original Equipment Manufacturer (OEM) standpoint, there are two preferred options. An air-line would run from the compressor to the air mattress location in the cab. The line would connect to a valve that reduces the pressure and regulates flow either manually or electrically. A tube is then used to supply the appropriate flow of air and pressure to the mattresses. The second option is that air is regulated on the compressor to adapt the air to 2psi and then supply air to a valve at the mattress. The aftermarket would have to tie into the existing system on the truck. The option for the aftermarket is to "T" into an existing line located in the cab such as the air-line under the driver's seat. This line would supply 125psi air to the valve and the remainder of the system would work as previously described. With specific reference being made to FIG. 1 , a preferred embodiment of the present invention provides an air mattress system 10 comprising an air compressor 20, a regulator 40 and an air mattress 60 operatively coupled via conduits 30 and 50. In certain embodiments where the regulator 40 is integrated into either the air compressor 20 or the air mattress 60, the number of conduits 30 and 50 necessary for an operable system 10 is reduced. The principal function of the regulator 40, regardless of its location in the system 10 is to provide a means of reducing the normal air pressure from the air compressor 20 to a usable level below the maximum air pressure threshold of the air mattress 60. In preferred embodiments, the system is configured with an actuation device or remote 70 for controlling the air pressure in the air mattress 60. In particular, the actuation device 70 can either be coupled directly to the air mattress 60, integrated into the control system of the truck or be provided as a stand alone wireless remote device 70 that controllably interfaces with the relief valve 80 on the air mattress 60 to regulate how much air enters and exits the air mattress 60. The relief valve 80 may serve the dual purpose of controlling the air entering and exiting the air mattress 60 or alternatively may serve only one of the those functions with the other function provided by an additional valve 100 operatively coupled with the air mattress 60. The air mattress 60 itself preferably comprises at least one bladder 90 for receiving and retaining the air fed to the air mattress 60 via regulator 40. Multiple bladders 90 may be provided, which allow for differential regulation of air pressure at different zones of the air mattress 60 where each zone is regulated by a bladder 90 or a portion thereof. Referring generally to FIGS 2-4, an alternative embodiment of a valve 120 is provided, where the regulator 140 is incorporated therein. In particular, the valve 120 provides for air to flow inward at fitting 105 and exiting at fitting 1 15. Between fittings 105 and 1 15 the air pressure and^' flow are reduced from the origin psi and cfm to target psi and cfm, respectively. By utilizing gating members or alternatively porous structures in the interior of the valve 120, the standard pressure to flow ratio can be optimized to reduce the amount of pressure at a higher rate than the diminution of air volume flow. This in turn allows for a low pressure at the outward fitting 1 15 while preserving sufficient active air volume flow at the outward fitting 1 15 to perform the work. FIG. 4 in particular shows an electrical coupling member 125 that allows for reversible coupling of the valve 120 to an electrical current that is readily available. It must be kept in mind that a variety of electrical power sources and coupling means may be provided to perform this function, which would be readily apparent to one of ordinary skill in the art, once apprised with the fundamental features disclosed in this application. As shown in FIGS. 2-3, alternative embodiments also provide for at least one pressure release point, opening or valve135 that allows for the release of compressed air at multiple points in the compression system 100. In particular the air can pass through an optional interior port 145 or alternatively through release hoses 155. In either case the preferred means of pressure release would be a single release point 135, though the compression system 100 can be configure to provide for additional release points 135. Any and all such changes, modifications, variations, and other uses and applications which do not depart from the spirit and scope of the present invention are therefore covered by and embraced within the present invention and patent application and the appended claims.

Claims

What is claimed is: 1. A vehicle with an air mattress system, the air mattress system comprising: an air mattress having a maximum air pressure threshold operatively coupled with an air compressor having a normal operating air pressure in excess of the air pressure threshold of the air mattress and a regulator operatively connected with the air compressor in which the normal operating air pressure of the compressor is adjustable below the maximum air pressure threshold of the air mattress.

2. The vehicle of claim 1 , wherein the air mattress further comprises a normal air volume flow such that the air pressure and the air volume flow have a normal ratio, wherein the ratio of air pressure to air volume flow is adjustable by the regulator such that the spread in, the ratio of air pressure to air volume flow is greater than the spread in the normal ratio.

3. The vehicle of claim 2, wherein the air mattress further comprises an air release opening.

4. The vehicle of claim 2, wherein the normal operating air pressure of the compressor is in a range between about 7 - 150 psi.

5. The vehicle of claim 4, wherein the normal operating air pressure of the compressor is in a range between about 100 - 125 psi.

6. The vehicle of claim 1 , wherein the maximum air pressure threshold of the air mattress is in a range between about 4 - 6 psi.

7. The vehicle of claim 4, wherein the normal air volume flow is in a range of between about 1 - 30 cfm.

8. The vehicle of claim 6, wherein the normal air volume flow is in a range of between about 1 - 30 cfm.

9. The vehicle of claim 2, wherein the adjusted air pressure is 1.5 psi or less and the adjusted air volume flow is about 6 cfm or less.

10. The vehicle of claim 2, wherein the normal ration is below between about 1 :1 - 8:1 and the adjusted ratio is above 9:1 .

1 1. The vehicle of claim 10, wherein the adjusted ratio is at least 24:1.

12. The vehicle of claim 1 , wherein the air mattress further comprises an air release valve.

13. The vehicle of claim 12, wherein excess air is releasable from the air mattress via the air release valve.

14. The vehicle of claim 12, wherein the system further comprises a remote control operatively coupled therewith for activating the flow of air to the air mattress and/or release of air from the air mattress via the air release valve.

15. An air compression system for providing depressurized air to an appliance needing air, the air compression system comprising: an air compressor having a normal operating air pressure; an appliance having a maximum air pressure threshold below the normal operating air pressure, the appliance operatively coupled with the air compressor; and α regulator operatively connected with the air compressor in which the normal operating air pressure of the compressor is adjustable, by the regulator, below the maximum air pressure threshold of the air mattress.

16. The air compression system of claim 15, wherein the air compressor further comprises a normal air volume flow such that the air pressure and the air volume flow have a normal ratio, wherein the ratio of air pressure to air volume flow is adjustable by the regulator such that the spread in the ratio of air pressure to air volume flow is greater than the spread in the normal ratio. /

17. The air compression system of claim 15, wherein the regulator is configured between the air compressor and the appliance for adjusting the normal operating air pressure of the compressor.

18. The air compression system of claim 15, wherein the regulator is coupled directly with the air compressor for adjusting the normal operating air pressure of the compressor.

19. The air compression system of claim 15, further comprising a down regulation valve coupled with the appliance to prevent the air pressure of the air entering the air mattress to exceed the maximum air pressure threshold of the air mattress.

20. The air compression system of claim 15, wherein the normal operating air pressure of the compressor is in a range between about 7 - 150 psi.

21. The vehicle of claim 20, wherein the normal operating air pressure of the compressor is in a range between about 100 - 125 psi.

22. The αir compression system of claim 15, wherein the maximum air pressure threshold of the appliance is in a range between about 4 - 6 psi.

23. The air compression system of claim 15, wherein the normal air volume flow is in a range of between about 1 - 30 cfm.

24. The air compression system of claim 20, wherein the normal air volume flow is in a range of between about 1 - 30 cfm.

25. The air compression system of claim 15, wherein the adjusted air pressure is 1.5 psi or less and the adjusted air volume flow is about 6 cfm or less.

26. The air compression system of claim 15, wherein the normal ratio is between about 1 :1 - 8:1 and the adjusted ratio is above about 8:1.

27. The air compression system of claim 15, wherein the adjusted ratio is at least about 24:1.

28. An air compression system comprising an air mattress having a maximum air pressure threshold operatively coupled with an air compressor having a normal operating air pressure in excess of the air pressure threshold of the air mattress and a regulator operatively connected with the air compressor in which the normal operating air pressure of the compressor is adjustable below the maximum air pressure threshold of the air mattress, the air compressor further comprises a normal air volume flow such that the air pressure and the air volume flow have a normal ratio of between about 6:1 - 9:1 , wherein the ratio of air pressure to air volume flow is adjustable, by the regulator, to above about 20: 1.

29. The αir compression system of claim 15, wherein the appliance further comprises an air release opening.

30. The air compression system of claim 15, wherein excess air is releasable from the appliance via the air release opening.

31. The air compression system of claim 15, wherein the system further comprises a remote control operatively coupled therewith for activating the flow of air to the appliance and/or release of air from the appliance via the air release opening.

32. The air compression system of claim 15, wherein the regulator is configured between the air compressor and appliance for adjusting the normal operating air pressure of the compressor.

33. The air compression system of claim 28, wherein the regulator is coupled directly with the air compressor for adjusting the normal operating air pressure of the compressor.

34. The air compression system of claim 28, wherein the regulator is coupled with the air mattress to regulate the level of air pressure from the compressor as the air reaches the air mattress.

35. A method of regulating the airflow to a vehicle air mattress from the on-board air compressor of said vehicle, comprising the steps of: providing a vehicle having a system comprising an air mattress having a maximum air pressure threshold operatively coupled with an air compressor having a normal operating air pressure in excess of the air pressure threshold of the air mattress and a regulator operatively connected with the air compressor in which the normal operating air pressure of the compressor is adjustable below the maximum air pressure threshold of the air mattress; adjusting the air pressure of the air to the mattress below the maximum air pressure threshold; and releasing the adjusted air from the air compressor to the air mattress.

36. The method of claim 35, wherein the air mattress further comprises an air release valve.

37. The method of claim 36, further comprising the step of releasing air from the air mattress via the air release valve.

38. The method of claim 36, wherein the system further comprises a remote control operatively coupled therewith for activating the flow of air to the air mattress and/or release of air from the air mattress via the air release valve.

39. The method of claim 35, wherein the normal operating air pressure of the compressor is adjusted between the air compressor and the air mattress.

40. The method of claim 35, wherein the normal operating air pressure of the compressor is adjusted at the air compressor.

41. The method of claim 35, wherein the normal operating air pressure of the compressor is adjusted at the air mattress.

42. The method of claim 36, wherein the normal operating air pressure of the compressor is in a range between about 7 - 150 psi.

43. The method of claim 42, wherein the normal operating air pressure of the compressor is in a range between 100 - 125 psi.

44. The method of claim 36, wherein the maximum air pressure threshold of the air mattress is in a range between about 4 - 6 psi.

45. A method of regulating the airflow through a compression system to an appliance, comprising the steps of: providing an air compressor having a normal operating air pressure, the air compressor further comprising a normal air volume flow such that the air pressure and the air volume flow have a normal ratio of between about 6:1 - 9:1 ; providing an appliance having a maximum air pressure threshold below the normal operating air pressure, the appliance operatively coupled with the air compressor; and providing a regulator operatively connected with the air compressor in which the normal operating air pressure of the compressor is adjustable, by the regulator, below the maximum air pressure threshold of the appliance; adjusting the air pressure to air volume flow ratio to above about 20:1.

46. The method of claim 45, further comprising the step of releasing the adjusted air from the air compressor to the appliance.

47. A regulation valve capable of adjusting air pressure between an air mattress having a maximum air pressure threshold and an air compressor having a normal operating air pressure in excess of the air pressure threshold of the air mattress such that the normal operating air pressure of the air leaving the air compressor is adjustable below the maximum air pressure threshold of the air mattress prior to entering the air mattress.