Note: Descriptions are shown in the official language in which they were submitted.
~ WO 92/07~41 2 0 9 5 7 3 6 PCr/US90/06446
S
I
FLUID FILLED FLOTATION ~IATTRESS
Field o~ the Invenlion
The present invention pertains to the field of fluid-filled mattresses, and moreparticularly to a quiet, seif-regulating fluid mattress which will fit a variety of different,
cu~ .. ,iul,~l bed frames and which shows virtually no fluid loss.
B~.k~.~ ' of fhe In-ention
Pressure adjustable fluid-filied mattresses are well known primarily to prevent bed
sores for long-term hospital patients. Hospital beds equipped ~ith mattresses of tbis type,
sometimes referred to as therapeutic beds, typically have a series of transverse bags across
the width of the bed filled witb pressurized air. The bags are typicall~ arranged into zones
so that the air pressure in each zone can be adjusted i~ J ,d~ ly to suit the weight of
different parts of the body. The air pressure under the feet~ for example, would normally
be less than the air pressure under the hips of the patient. The theory behind the bed is that
the air-filled bags conform to the shape of the user's bod~, and support his weight evenly.
Uniike ~o..~ iu~l beds, bony protrusions experience no more pressure than other parts of
the user's body. By eliminating ail the high pressure points against the person's body, the
chances of developing bed sores is greatly reduced.
At present, most maftresses for therapeutic beds fall into one of two basic categories.
In a high air flow mattress, each air bag is connected to a blower at one end, and to an
exhaust porf at the opposite end. The pressure in each bag can be regulated either by
adjusting the air flow rate through an exhaust valve or through an intake valve or both. By
constantly cycling air through the bags, any leakage in the bags is easily . ~,..~1,. ..- ~ 1 for,
and it is thought that the chances for infection are reduced. Any infectious bacterium or
virus, as soon as it enters an air bag, is quickiy blown out through the exhaust valve and
often filtered out. Such a matfress is shown, for example, in U.S. Patent No. 4,935,968 to
Hunt. The air blower required to operate such a bed must necessarily be quite large, and
these beds are often restricted to specially dedicated bed frames which can support the heavy
air blower and the complex series of air tubes for the intake, exhaust and filtration systems.
More recently, a low air flow mattress has been developed. In a low air flow
mattress, there is no exhaust valve. Instead, air escapes only through the seams and through
holes and pores in the air bags. Holes are typically punched in the air bags in specific
locations in order to dry the l~atient's skin and reduce the likelihood of maceration. The
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medical beneflt of this is uncertain. An example of such a bed is shown is U.S. Patent No.
4,944,060 to Peery. A low air flow mattress still leaks ~ and requires constant
blower pressure to all air bags, aUhough the size of the blower and the air flow rate is
~ less than for a high air flow mattress, resulting in a quieter, lighter, and more
energy efficient mattress. The pressure in each zone is regulated by intake valves. Excess
blower pressure is sometimes released through a bypass waste gate before it reaches the
bags.
The existing inflatable air beds present a number of problems, many of which aremade worse because the patients who use these mattresses must normally use them for a
very long period of time. The cmlstant blower operation necessary to keep the air bags full
not only consumes large amounts of electricity, but is a constant annoyance to the patient.
It also makes the patient difficult to transport. In order to move the bed to another
location, the blower must be coupled to a portable power supply which can be moved along
with the bed. Many existing beds require a dedicated bed fralne which carries the blower,
the tubing, the valves, any co~trol circuitry, and a battery backup power supply. This
makes for an expensive, heavy and bulky piece of equipment which is not easy to move.
Existing beds also lack a ~ ~ . t, secure connector for at~aching the air bags to a
mattress base and, if they c~m be moved from one hospital bed frame to another, the task is
difficult and ~ ~
Summarv of the Invention
The present invention provides a mattress with little or no air loss. A controller
monitors the pressure in each air bag zone and activates a blower to make pressure
- l; to each zone 'i. "~ only when necessary. Ideally, the blower is turned
off most of the time. The air bags, which are of relatively , . . ~ . can be
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quickly and easily replaced and are securely held in their fittings. The entire mattress caneasily be moved to almost any . ~ ' hospital bed frame. The mattress connects to a
separate, rr. ` controller which is easy to operate and which can be wheeled about
with the bed or hung from the bed's frame.
According to one aspect of the invention, there is provided a mattress ~ a
pluralib of bags for . ~; ~ a user by containing fluid under pressure, each bag being
associated with one of a pluralib of separate mattress fluid pressure zones,
a variable speed blower operable for supplying fluid to the bags at an adjustable pressure
related to the ol ' rate of the blower, a separate duct ' ' between each
mattress pressure zone and an outlet from the blower via a respective one of a
pluralib of bistable fluid flOw control ON/OFF valves, the
of each bag to the blower outlet otherwise being an unvalved a
pluralib of fluid pressure sensors proximate the blower for measuring the
fluid pressure in a respective one of the mattress pressure zones, a pressure supply passage
I - from each mattress zone to the . , g pressure sensor, and a blower
regulator receiving output signals from the pressure sensors for ~ the ~
rate of the blower and for operating the valves to establish and to maintain in the bags in
each mattress zone a fluid pressure selected for that zone.
Ct .. '~, the blower, the valves the pressure sensors and the regulator are
~~ of a mattress controller which is physically ~, ' of the mattress and of
a bead on which the mattress may be located.
C~ Y ~ , the controller comprises: a keyboard for inpnting i . to the
controller; and a holder for receivhlg and holding the keyboard.
C~ . . '~, the controller includes a honsing and a handle which is adjustable to
different vertical positions and also is adapted to receive and hold the keyboard.
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C~ , the controller is adapted to engage the footboard of a bed frame so
that is can be received and held by a bed frame footboard.
C~ , the maffress comprises a tab for securing the mattress to a v~riety of
different bed frames, the tabs ~ . O a hand malleable plate bendable into a shape
sufficient to grasp an edge of a bed frame; and the hinge for fastening the plate to the
mattress.
C~ , means is provided for reversing the direction of flOw in the ducts
from the bags to the blower to deflate the bags.
~ , the bags each have a bead on one edge and wherein the mattress
comprises a mattress base for A I -^ i- o the bags and a pluralib of bag
fittings for attaching the bags to the mattress base, each bag ' fitting ~
means for receiving and holding captive ' "~ along its length a bag edge bead.
According to a further aspect of the invention, there is provided a
method for ~ desired fluid pressures in each of a pluralib of pressure zones in a
mattress which includes a pluralib of bags for . r i- ,, a mattress user by containing
fluid under pressure, individual ones of the bags being grouped in the mattress in
respective ones of the zones, the method . ~ the steps of ~ the bag group
in each zone to the output of a variable speed blower via a separate duct and via a
respective one of a ~ . ~ . ' O pluralib of bistable ON/OFF flow control valves
pro~imate the blower, measuring pro~imate the blower the pressure in each zone via a
respective one of a . . . ' ~ pluralib of fluid pressure sensors each coupled via a
separate pressure supply passage to the ~ I ~ . ' O mattress zone, O each
measured pressure to a ~ .id~t~ pressure to be ' in the I. .
zone, and in the event a l . indicates that the measured pressure differs from the
I ~ I pressure by more man a chosen amount, F f~ O the following steps in
,
rs sequence: operating the blower to generate a fluid pressure ' "~ equal to the
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measured pressure, opening the valve to the zone having that measured pressure, and
" ' l~ changing the speed of blower operation to a speed ~ of the
pressure.
According to yet a further aspect of the invention, there is provided in a mattress
having a plurality of bags for ., i O a user, the bags being supported on a base, a bag
~it- ' ' fitting for O the bags to the base ~ an elongated sleeve
carried by the base and having an interior chamber with a "J uniform cross
section for receiving a bead on a bag; an elongated narrow slit extending along the sleeve
into the chamber for allowing a bag bead carrier to extend into the chamber; an opening
for allowing the bead to be inserted into the chamber.
C~ , the opening is in the slit.
A~ 'J to yet a further; 1-- ' of the invention, there is provided in a
maffress having a pluralib of bags ~ ' ' to a base for ~ ;' o a user, the bags
having elongated beads inserted into L . ~ , O elongated sleeves in me base for
holding the bags to the base, a method for removing a bag from the base ~
moving an end of the bead of the bag into an opening in the elongated sleeve by pulling
npon a portion of the bag adjacent the bead which extends through an elongated narrow
slit in the sleeve; and drawing the bead out of the sleeve through the opening.
According to still yet a further; ' - of the invention, there is provided in a
mattress: O an elongate base having a cushion; a plurality of bags connected to
and supported by the base for . r ~ ;' O a user by containing fluid under pressure, the
bags being deflatable to allow the user to be supported on the cushion; and a plurality of
elmlgate bag ~'- ' fiffings, each fitting being carried by and ' ~ imbedded
into the cushion to minimize the pressure of the fittings against the user when the bags are
denated.
crn"- . . WrD
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Brief D~crription of tt-^ r
'îhese and other aspects of the invention will be more fully understood by referring
to the following detailed description and the ac.. J~ i,.g drawings wherein: -
FIG. I is a side view of a manress, bed frame and controller according to the present
mvention with the top sheet partially cut away to reveal the air bags;
FIG. 2 is a top view of a mattress base, with the air bags removed, for use with the
present invention;
FIG. 3 is a side view of an air bag suitable for use with the manress base of FIG. 2;
FIG. 4 is a top view of a foam substrate ' ~Jola~l into the manress base of
FIG. 2;
FIG. 5 is a top view of a bag anachment fitting ill~ d into the mattress of
FIG. 2;
FIG. 6 is a cross-sectional view, taken alor,g line 6~ of FIG. 2, shov.~ing a bag
anachment fitting. a bag and the faam substrate;
: FIG. 7 is a cross-sectional view, taken along line 7-7 of FIG. 2 with an air bag
anached showing the manress base, air hoses, manifold and air bag to manifold coupling;
FrG. 8 is a cross-sectional view, taken along line 8-8 of FIG. 2, showing a pressure
~one manifold and its frame portions;
FIG. 9 is a bottom view of an air bag coupling for use in connecting an air bag to
a manifold frame section;
FIG. 10 is a cross-sectional vlew taken along line 10-10 of FIG. 9, and line 10-10
of FIG. I l, showing the air bag coupling at FIG. 9 with the manifold coupling of FIG. I l
installed into it;
FIG. I l is a top view of a manifold coupling for use in connecting to the air bag
coupling;
FIG. 12 is a plan view of a tab for use in securing the mattress to a bed frame;FIG. 13 is a cross-sectianal view through a tab and a manress edge along line 13-13
jn FIG. 2;
FIG. 14 is a front plan view of a hose connector with a threaded ring;
FIG. 15 is a front plan view of a second portion of a hose connector which can be
mated with the connector of FIG. 14;
FIG. 16 is a cross-sectional view of the connector of FIG. 14 taken along line 16-16
in FIG. 14 as coMected to the cormector of FIG. 15 with a threaded ring;
FIG. 17 is a front view of the controller;
FIG. 18 is a side elevation view of the controlier of FIG. 17 with its rear access
panel folded downward;
FIG. 19 is a rear view of the controller of FIG. 17 with its access panel opened;
FIG. 20 is an elevation view of the blower, CPR valve and solenoids within the
colltroller of FIG. 17;
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WO 92/07541 PCr/US90/06446
FIG. 21 is a functional block diagram of the mattress and controller system showing
the operation of the mattress;
- FIG. n is a plan view of the keyboard of the contro~ler of FIG. 17;
FIG. 23 is a front view of the controller of FIG. 17 with the keyboard removed from
- ~ its controller housing and attached to the controller handle;
FIG. 24 is a side view of the keyboard of FIG. 21 installed on the controller handle;
and
FIG. 25 is a side view of the keyboard of FIG. 21 installed on a bed frame footboard.
WO 92/07541 2 ~ 9 ~ 7 3 6 PCr/US90/06446
' " ' l~eScription
As shown in FIG. 1, the present invention has a mattress base 10 which can be
secured to any of a great variety of .:u~ .iUIldl hospital bed frames 12. A bed frame will
typically have a footboard 14 and a headboard 16, as well as wheels 18 to allow a patient
to be wheeled into different parts of a hospital. The mattress base supports a set of air bags
20 which are covered with a flexible top sheet 22. A duct 24, made up of a number of air
hoses, comnects into the mattress base at one end and into a controller 26 at the other. The
controller has wheels 28 and a handle 30 so that it can be moved about with the bed. As
explained below, the controller contains most of the hardware necessary for regulating the
air pressure within the bags 20.
The mattress base 10, as shown in FIG. 2, has a Cu~ ..lliull.ll rectangular shape as
viewed from the top. with height and width dimensions adapted to suit a CU~ ,.Iliulldl
hospital bed frame. There are a set of tabs 32, which can he wrapped around the edges of
the bed frame to attach the mattress base to the bed frame. The mattress base has a series
of elongated bag anachment fittings 34 which extend across the majority of the width of the
base. Tbese attachment fittings allow the transverse bags to be held securely in place~ and
are each associated with an air outlet 36. The bags are installed by sliding a bead 44 on an
edge of the bag (FIG. 3) into tbe attachment fitting 34, and then coupling an air inlet 42 on
the bag onto the adjacent outlet 36 on the mattress base. The entire mattress base is enclosed
in a vinyl cover 58 tbat prevents the materials and cavities inside the mattress base from
being ~ by urine or other body materials.
The air bags are preferably constructed of nonallergenic, IlUll~Ulh.,.l(,
vapor-permeable, waterproof material. Since the ai} bags come very close to contact with
the patient, it is important that the air bags not become a habitat for undesirable bacteria or
viruses. It is presently preferred that each air bag be constructed from a single sheet of
nylon, coated on the inside with polyuretbane. Currently, a 70 denire taffeta nylon is
preferred. The l1l~ coating preferably allows about 1.33 grams of water vapor per
hour per square meter to pass under ASTM test E-96. The nylon sheet is wrapped around
to a seam 38 on one side (FIG. 3). The seam is made on the side so that it does not contact
and wear against the patient in use, and also so that it does not interfere with sealing inlet
port 42. The top corners of the bags 40 are cut diagonally so that they do not present a
sharp point against a patient when the patient is moving on and off the bed or if the patient
falls to one side of the bed. There is an air inlet coupling 42 at a bottom end of the bag
which connects to an air outlet 36 on the mattress base, and adjacent that is an elongated
bead 44 which fits into one of the bag attachment fittings 39 on the mattress base. It is
presently preferred that the bead be formed by placing a PVC cord along the bottom edge
of the bag and welding the pùl~ ., material of the bag together around the PVC cord
45 (FIG. 6) capturing the cord within the weld 46. This holds the cord securely in place
without cuts or stitches and insures that no leaks are introduced into the bag when the cord
is attached.
~'O 92/07541 2 ~ 9 ~ 7 3 6 PCT/US90/06446
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In contrast to other air mattresses, the air bags for the present mattress, along with
ail other mattress l f)mil~n~nlC, are preferably constructed to minimize leaking as much as
- possible. Accordingly, there are no stitches in tbe bag. All seams are formed by radio
frequency (rf) welding the ~ , ' coating together. The presently preferred
- 5 InJlyul~ ' coated nylon materiai leaks very littie, provided that there are no holes made
in it. The air iniet coupling is aiso welded to the ~)olyu~ fabric of the bag, as
explained below. There are, in contrast to many prior designs, no holes cut into the top
of the bag to dry the patient or ailow air to be released for regulating the pressure within the
bag. The top sheet 22 is preferably aiso constructed of the same waterproof nylon fabric,
but with a different moisture permeable polyurethane coating. The top sheet fabric
preferably allows about 3.02 grams of water vapor per hour per square meter to pass under
ASTM test E-96. This helps prevent any moisture or liquid from the patient from coming
into contact witb the bags, keeping the bags and the mattress base cleaner. The greater
vapor ~ y reduces perspiration build up to improve comfort and reduce the risk of
skin maceration. While the air bags and mattress base are easy to clean, it is much simpler
to clean tbe single top sheet than to clean each of the bags and the mattress base. The top
sheet can be dispensed with between patients to reduce the risk of cross (~.", ~ io~l If
desired, it can be eliminated entirely. The top sheet acts like a hammock between bags,
tending to pull on the user's skin and reduce his comfort.
The mattress base 10 is preferably formed from a large sheet of resilient polyurethane
foam 48 (FIG. 4). The foam sheet makes up the substrate upon which the air bags rest and
is ~ four inches narrower than the surface of the bed frame upon which it is to
rest. Preferably the mattress base supports 20 air bags along its length, and there are a
)UI-~ii..r number of lateral grooves 50 aiong the length of the foam sheet in its top
surface. The grooves are die cut with the proper dimensions to contain a bag attachment
fitting 34.
As shown in FIGS. 5 and 6, the bag attachment fitting has a shelf 52 on either side
of a narrow slit 54. The slit provides a long, narrow opening into an interior chamber 56
within the fitting. The chamber has a cross section which is somewhat iarger than the bead
at the bottom of the air bag, but-the narrow slit is narrower than the bead. The fitting has
an opening 58 which ailows the flexible bead on the bonom of the air bag to slide into the
chamber 56. Once the bead is inserted into the aKachment fitting chamber, it cannot be
removed through the slit but only by sliding motion through the opening 58. The vinyl
cover 58 on either end of the attachment fitting prevents the bead from sliding out of the
ends of the chamber so that a bag can oniy be removed by pulling the bead out the opening.
This prevents the bags from moving from side to side laterally.
An air bag can be installed into the aKachment fitting by first inserting one end of the
bead into the opening and then drawing the bag laterally along the narrow slit until the
majority of the bead has been drawn into the chamber. When the bead reaches the end cap
at one end, the opposite end of the bead is bent until it can be inserted into the chamber
through the opening in the opposite direction. To remove the air bag, the bag is simply
WO 92/07541 2 ~ 9 5 1 3 6 ~ PCT/US90/06446
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grasped near the opening and drawn upward to draw a portion of the bead out of the
opening. Once a portion of the bead is out of the opening, the bag easily slides along the
narrow slit until it is completely removed. The bag attachment fitting is not only simple to
operate, but also holds the air bag very securely to the mattress base. It evenly distributes
loads along the entire length of the bead, and eliminates movement toward the foot or head
of the bed along the entire length of the bead. Conventional two-point attachment fittings
often allow a bag to become partially trapped under an adjacent bag or allow the bags to
inflate unevenly. Straps are sometimes used around each bag to hold the bags in line. Since
the air bag attachment fittings secure the air bags along a substantial part of their length, no
such problems exist with the present finings. The bags inflate evenly and stay in their
proper positions. The same attachment fitting can also be used with a bead which is not
elongated. Preferably several beads would be captured in the base of the air bag which
would be inserted into the chamber through the opening in the same way as the elongated
bead. This may allow for simpler construction, but would only secure the bag at the specific
points along the edge of the bag where the beads are placed.
As shown in FIG. 6~ the shelves 52 on the bag attachment fitting extend opposite each
other above the chamber 56 away from the narrow slit 54. This allows the chamber to be
inserted into the grooves 50 of the foam sheet 48. The shelves then extend laterally along
the top surface of the foam sheet. This helps to flatten the surface of the mattress base when
the bag attachment finings have all been inserted into place. The flatter surface distributes
pressure more uniformly across the top of the mattress base, and therefore is more
comfortable to lie on when the air bags are deflated. The vinyl cover 58 is wrapped around
the mattress base including the bag attachment finings and the hose and manifold components
described below. Tbe vinyl cover secures the bag attachment fittings in place on the foam
and also protects the foam from absorbing any undesirable bacteria, viruses or other
I ~ . As shown in FIG. 2, the vinyl cover includes a slit for each bag attachment
fitting so that the bags can extend out of the bag attachment fittings when their beads are
installed .
Each air bag is coupled through a mattress air outlet 36 to an air supply manifold.
As shown in FIG. 7, the mattress base has a set of preferably flexible tubes or hoses 91, 93
which form the air duct 24. Above the hoses is a series of four air supply manifolds 59.
The manifolds are formed by rf welding a separate sheet of vinyl 61 to the inside of the
outer vinyl cover 58, to create four distinct sealed cavities within the mattress. Each
manifold serves a separate uniform pressure zone. Preferably, the 20 bags are divided up
into four uniform pressure zones: a first zone near the user's head having four bags, a
second and third zone, each having five bags, and a fourth zone near the user's feet having
six bags. More or fewer zones can be provided to suit specific ~,ill or the mattress
can be constructed so that the air pressure inside each bag is ' .,~ I.,...ly controlled. This
is not necessary in most ~.., It is preferred, however, that at least some variation
in pressure from one area of the mattress w anotber be allowed for. The four zones allow
for a higher air pressure to be used to support heavier parts of the patient's body. Typically,
=
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a higher pressure is desired, for example, to support the patient's hips than to support the
patient-s feet.
As shown in FIG. 8, each air supplS~ tube 91 comnects to a single one of the four
' . ' manifolds 59 and each manifold then distributes the supplied air to the air bags
associated with tbat zone. The supply tubes 91 extend beneath the manifoids until they reach
the appropriate manifold and then have a c~,.. . ~,...io.., i elbow (not shown) upward through
the separate vinyl sheet 61 to comnect near one end of the sealed vinyi air chamber of the
appropriate manifold 59. Each pressure sensor tube 93 simiiarly connects near the opposite
end of the manifold.
As explained below, the air supply tubes and manifolds are used both to pump air into
and out of the air bags. Accordingly, each manifold is f~ned with a set of rigid frame
sections60. Theseframesections,preferablyforme(ifroml,olyvi..~ h,lide(PVC),provide
a rigid structure to maintain the shape of the chamber regardless of the pressure on tbe
chamber. The separate vinyl sheets 61 which seal the manifold are welded to the frame
sections and drawn taught across the open bonom. The vinyl sheet fabric is preferabl~
strong enough so tilat it does not stretch S;~j..;r~ ...ly under the air pressures used to inflate
the bags. As shown in FIG. 8, each frame section 60 bears a number of separate manress
air outlet couplings 36; the number corresponds to the number of air bags associated with
that manifold zone. While a solid frame for each manifold or a single frame running the
entire length of the manress base can be used, this prevents the manress from bending when
the bed frame is articulated. A conYentionai hospital bed frame ailows a patient's head,
knees, and feet to be lifted, so it is preferrcd that the manress and its base aiso be flexible.
In order to ensure that the manress can be used with a variety of different bed frames, the
frames are kept short so tbat the manress can flex at many different points along its entire
length.
FIGS. 9 and 10 show the air supply coupling 4~ for an air bag in greater detail. The
coupling is essentia~ly annular with a central opening 62 and notches 64 on either side. The
manifold outlet 36 (FIG. 11) has a coupling plug 68 with oppositely facing tabs 70. The
tabs are inserted into the notches of the air bag coupling and then the two parts are rotated
with respect to each other. The tabs meet a ramp 66 on the air bag coupling which draws
the two coupling parts toward each other urging an outer flange 72 on the air bag coupling
against a resilient washer 74 on the manifold's coupling plug. This seals the connection
together and allows air to flow freely between the manifold and the air bag. After a bag is
instailed into an anachment fitting, the bag's air iniet coupling is simply piaced over the
manifold's plug and rotated. This completes the installation of the bag. Preferably, the
slope of the ramps is chosen so that the coupling is sealcd by rotation of the air bag coupling
no more than ninety degrecs. In order to prevent leaks around the two coupling parts, the
manifold coupling plug 68 is radio frequency welded ' 'S, to the fabric of the vinyl
manress base cover 58 and to tbe manifold frame 60. 'Similarly, the urethane coating on the
nylon air bag fabric is radio fre~iuency welded to the air bag coupling 42. The coupling
parts are welded in place S0 that the air bag is not twisted when the parts are joined and
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sealed. The coupling parts are preferably molded from a durable plastic material which
can be easily welded to the nylon and polyurethane fabrics, for example PVC or urethane.
The couplings described above are preferred for their reliability and easy operation.
However, any of a variety of coupling devices, known in the art, can be used instead.
As shown in FIG. 2, the mattress base preferably has a set of tabs 32 for securing
it on a bed frame. Ihe tabs extend outwardly from the outside lower edges of the mattress
base at suitably spaced locations around the base. The mattress can be secured in a variet~
of ways using straps, ropes, snap-comnected fittings and the like. In some cases, it may be
possible to simply place the mattress on a w..~ iOl-Gi bed frame without any fasteners.
Alternatively, a specially dedicated bed frame can be constructed for supporting the mattress
base, however, this is not presently preferred because of the additional expense and
illWII.~ . A preferred tab 32 for securing the mattress base to a bed frame (FIG. 12)
is constructed from a sheet of vinyl similar to the material used as the cover 58 for the entire
mattress base. The tab has a pocket 76 which contains a hand malleable aluminum plate 78
(FIG. 13). Opposite the alumirlum plate, the tab is rf welded to the nylon manress cover.
The flexible vinyl fabric between the bead and the aluminum plate constitutes a hinge 82
which allows the plate to be pivoted to a variety of different positions. The tabs are used
by bending the aluminum plate until it forms a hook which grasps a ponion of the hospital
bed frame to secure that portion of the mattress base in place. This allows the mattress to
be secured to a wide variety of different hospital bed frames by bending the aluminum plate
in different directions to suit particular situations. The seams on the tab are preferably RF
welded in order to provide a uniform look with the nylon cover sheet. The hinge can be
replaced with hooks, springs, shock cords, and a variety of other devices which can also be
adapted to connect to the aluminum plate. A variety of other hand malleable materials which
hold their shape can be substituted for the aluminum.
The hoses or tubes 24 which run below the manifold include four air suprly hoses91, one for each uniform pressure zone of air bags and four pressure sensor hoses 93, one
for each uniform pressure zone. The pressure sensor hoses allow the controller 26 to
monitor the pressure within each uniform pressure zone. These hoses all leave the respective
manifolds through W~ ullGi elbow fittings and are directed as a group to the controller.
The hoses are preferably W...~liiUllGI, commonly avaiiabie plastic tobing. Silicone rubber
or PVC tubing is presently preferred. This type of tubing is inexpensive, easy to replace,
and easy to clean. Tramsparent tubing is preferred so that the cleaniiness of the tobing can
be easily monitored. The tubing is preferably connected to the controller, all as a single
group, and a speciai hose connector is preferably provided for this purpose.
FIG. 14 shows an end view of a first portion 90 of a hose connection which connects
into the controller. The hose connector 90 has a set of foor larger annular seats 92 and a
set of four smaller ammular seats 94. The interior of each large seat is coupled to one of the
air; supply hoses 91, and the interior of each small seat is connected to one of the pressure
sensor hoses 93. The se~ts are all mounted in a round plate 96 with a solid rim 98 that has
. -
= = = = = = = = _ _ _, ,, ,, . . _ _ . .. .... . _ . , . . .... _ _ . ~ , . _ .. ,, ~ .. _ ......
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an aligmnent notch 100. The entire connector portion is surrounded by a rotatable ring 102
with internal thredds 104.
The other connector portion 106 (FIG, 15) is connected to the controller 26. It has
a set of four hollow nipples 108 which conduct fluid toward the blower and a set of small
- 5 hollow nipples 110 which conduct fluid to a set of pressure sensors. These nipples are all
mounted to a central round plate 112 which is surrounded by a protruding ring 114. An
alignment tab 116 extends radially outward from the protruding ring. Outside of, but set
back from the protruding ring is a fixed externally threaded ring 118.
The two connector portions are coupled together by pushing the first connector
portion toward the second connector portion so that the protruding rim travels inside the first
portion's rim and the alignment tab 116 enters the alignment notch 100. This brings the
nipples into contact with the seats. The connector ponions are &stened together by screwing
the rotatable, internally threaded ring 102 of the first portion onto the fixed, externally
thredded ring of the second portion. As shown in FIG. 16, the threaded ring has a shoulder
120 which engages a flange 122 on the first connector portion so that, as the threaded ring
is screwed onto the second connector portion, it pushes the two connector portions together,
pushing the nipples onto the seats to ensure a tight seal. This type of connector allows the
hoses to be comnected and dis - ' very quickly and easily by screwing and unscrewing
a single ring 102.
FIGS. 17-19 show the controller 26 with the hoses ~ rl1 The controller
i--.u.,uu,dlr,~ most of the monitoring, regulation, feedback and control functions of the
mattress into a single portdble housing 124. The housing is supported by its two wheels 28
and a third leg 126 that also prevents the housing from moving about l",i"l,..li".. lly The
front of the housing includes a keyboard 128 and two separate push bunons, an on/off s~itch
130 and a CPR mode switch 132. The function of these switches will be explained in
greater detail below. As best seen in FIGS. 18 and 19, the housing for the controller
includes a rear fold-down access panel 134 upon which most of the controller's electronics
136 are mounted for easy access. Near the controller's leg is a conventional AC outlet and
power supply 138 and a battery back-up system 139 consisting of a pair of batteries and
back-up ~ A separate access panel (not shown) provides access to the batter~
area. Normally, the controller is operated from the standard current net, i.e., ~ull~,,.l,iu-ldl
Iocal AC power; however, in the event of a power failure or when a user is in transit on the
mattress, the battery back-up system is employed to regulate the air bag pressure. Naturally,
because the blower is normally off, much smaller batteries are required than with prior
designs, reducing weight, size and cost.
The handle 30 is a horizontal bar with a pair of long vertical legs 140, one on either
side, which extend into the housing. The handle is locked in place by a spring mechanism
and can be moved to any desired vertical position by pushing a handle adjustment lever 141,
unlocking the handle, moving the handle while the lever is depressed. and then when the
desired position is reached, releasing the adjustment lever. The handle includes a pair of
hooks 143 which extend rearward from the handle. The hooks allow the controller to be
.. . . . . . . . . ..
WO 92/07541 2 0 9 i 7 3 6 PCr/US90/06446 1~
hung from the footboard of a bed. This eases Ll~ ulLdLiOIl of the mattress and bed frame.
The hooks are preferably formed from platcs through which the vertical legs of the handle
extend. The hooks can be rotated inward out of the way when not in use (FIG. 19).
The hose connector 106 is preferably attached to the side of the housing and connects
the air supply hoses through a set of short transparent plastic hoses 142 to four way valve
manifold unit 144. The valves are non throttling, two-stage, ON/OFF valves, and are
operated by a set of four independent solenoids 146. The valves are normally closed, but
upon activation of the respective solenoids, are fully opened to connect the ~ol~
air hose with the controller's air supply. The four-way valve unit is connected to a CPR
valve 148 which is connected to a blower ISû. The blower is the source of all a!r pressure
for the system and is operated from the AC outlet or the battery power supply. The blower
is preferably a multi-phase variable speed blower which can be operated at different speeds
to produce different air pressures. Presently a blower, Model No. 11645û-00, r ' ed
by the Lamb Division of Ametek Corporation is preferred: however, a variety of other multi-
phase variable specd blowers can be used instead. Alternatively, any other type of blower
or fluid pump capable of producing an adjustable fluid pressure or volume flow rate at its
outlet can be used. The pressure or flow rate need not be speed dependent. The blower has
a single low-pressure inlet port 152 and a single high-pressure outlet port 154 (FIG. 20).
These are both connected directly to the CPR valve 148.
2û In normal operation, when an air bag needs to be inflated, air is drawn through the
controller housing into an ambient air inlet 156 of the CPR valve. From there it is directed
into the blower through the low-pressure inlet where it is compressed and pushed out the
blower's high-pressure outlet. A high-pressure air hose 158 connects the air from the blower
outlet into a high-pressure inlet 159 in the CPR valve (FIG. 18). The CPR valve then
conducts this air into the four way manifold unit 144 from which the air is conducted to the
air bags. The purpoæ of the CPR valve is, when need be, to reverse the direclion of the
air flow between it and the blower.
If a patient using the bcd suffers a cardiac arrest, it may become necessary to
administer c~-diu~_~ y ~u~;L~ILiull (CPR). It is difficult to perform this when the air
bags are inflated. The air bags do not provide a sufficiently rigid surface to allow the chest
l,U~ iUll~ of CPR to have their proper effect. When CPR is necessary, an operator
depresses the CPR mode switch 132 on the front of the controller housing. This directly
activates a CPR release solenoid 160 which briefly draws a spring-loaded rod against the
force of the spring away from the CPR valve body, unlatching the valve. Once unlatched,
the valve, under the force of a different spring in a spring housing 162, is driven toward the
left in FrG. 20 to its CPR position. In the CPR position, the blower`s low-pressure inlet 152
is comnected directly through the CPR valve to the four-way manifold unit 144 and the high-
pressure outlet is connected to a CPR exhaust port 163 which vents air from the bags to the
atmosphere. A switch 165 is tripped when the CPR valve is in the CPR position and sends
a signal to a regulator 172, described in more detail below. The regulator instructs the
blower to operate at its maximum speed. This reverses the normal flow of air from the
~ WO 92/07v41 2 0 g 5 7 3 l~; PCT/US90/06446
-13-
blower toward the air bags to a flow from the air bags to the blower. The blo~er, with the
help of the patient's weight, quickly deflates the air bags so tbat the patient comes to rest on
the padded foam mattress base. The function of the CPR valve can also be achieved using
a reversible blower capable of operating in the opposite direction so that the high-pressure
- 5 outlet becomes the low-pressure inlet and vice versa.
During the ' ~iUII of CPR, it is particularly ~v v that the mattress
base include the foam substrate described above and that the air bag attachment fittings be
recessed into grooves in the foam layer. The shelves 52 on either side of the bag attachment
fittings greatly reduce the sharpness of the otherwise narrow fittings. To restore the mattress
back to normal operation, a CPR release mode knob 164, which extends from the controller
housing below the hose connector 106, is pushed. This knob is connected to a valve rod
166 which connects to tbe CPR valve body. When the CPR valve is released and travels
under the force ot the spring 162, the CPR valve rod 166 travels with it. This causes the
CPR release mode knob to be pushed outward away from the exterior of tbe controller
housing. Pushing the knob in toward the housing manually pushes the CPR valve back into
its normal position and allows the spring-loaded solenoid latch to move back up to latch the
valve in its normal position. With the valve back in its normal position, the blower outlet
is again cpnnected to the four-way valve manifold unit, and the blower inlet is connected to
ambient air.
The basic operation of the mattress is best understood referring to FIG. 21. As
explained aboYe, the controller 26 includes a blower 50 for supplying air to the air bags, a
CPR valve 148, and a four-way manifold and valve unit. This unit includes a four-way
manifold 144~ and four separate, normally closed, solenoid-operated valves 144-1, 144-2,
144-3, and 144-4. The duct 24, which conducts air between the blower and tbe air bags,
~ breaks into four separate parts, 24-1, 24-2, 24-3, and 24-4, between the four-way manifold
144-0 and the valves. The duct continues from the valves to the .ull~ul.dillg mattress base
manifold 59-1 to 59-4 for each valve. Between the valves and the manifolds, the duct is in
the form of transparent plastic tubing as the air supply tubes 91-1 to 91-4 described above.
Each portion of the duct enters a respective manifold to conduct air between the blower and
the air bags in the oll~u.ld;.. v uniform pressure zone.
The pressure sensor tubing part of the duct 93-1 to 93-4 is comnected at the opposite
end of each manifold from the air supply tubes to conduct air between the manifolds and
pressure sensors in the controller. As described above with respect to FIGS. 14, 15, and
16, the pressure sensor tubing is preferably connected to the controller in the same location
as the air supply tubing. Once inside the controller housing, the pressure sensor tubing is
separated from the air flow duct so that it can be comnected to the .u--,, ' v electronic
pressuresensortransducer170-1,170-2,170-3,170-4. Ap;~,u~ -icorelectricdiaphragm
type of sensor which produces an analog voltage signal in response to preSsure in the tubing,
for example, Microswitch Model No. 136PC01G2 is presently preferred, although a great
variety of different pressure sensors may be used. A flfth pressure sensor 170-5 is connected
tû a fifth pressure sensor tube 93-5 which is in fluid ~. with the blower
_ _ . . . . . . . . . .
2Q9~7~6
WO 92/07541 PCI`/US91~/06446
.-14-
high-prQsure outlet. Alternatively, a pressure sensor can be provided in each manifold and
connected electricaily to the controller.
All of the prQsure sensors are connected to a regulator 172 which monitors the
prQssure output of tbe blower, as well as the prQsure in each uniform pressure zone of the
mattrQs. The regulator includQ a suitably 1,,,,, ' digitai U~)lU~,QaUI located
within the controller, aiong with the appropriate memory, power supply and interface
circuitry. The prQsure sensors are preferably mounted to the same circuit board as the
regulator. The regulator is aiso connected to the keyboard 128, the on/off switch 130, and
the CPR switch 132 and transmits control signais to components in the controlier housing
26. Tbe regulator has a control line 174 to the blower which ailows it to turn the blower
on and off and to regulate its operation rate. It has a detect line to the CPR valve release
switch 165 which allows it to determine the position of the CPR valve, and it has a control
line to each of the four independent vaive sûlenoids 146-1, 146-2, 146-3, 146-4, to ailow it
to open and ciose the ~ullca~O~ valves 144. It is preferre~i that tbe CPR switch have
1~ a direct connection (not shown) to operate the CPR valve release solenoid so that the CPR
mode can be engaged even if the regulator m~lfiln~til~n~
When the manress is first turned on using the on/off switch 130, it operates in a max-
inflate mode. Tbe regulator first turns on the blower to its maximum operation rate and then
opens all of the valves 144. This inflates all of the air bags in each zone as quickly as
possible. The max-inflate mode is continued for a ~ d~; ' amount of time and then
the regulator switches operation to a normal mode. In the preferred Pmho~limPrl-, the max-
inflate mode continues for <,~" ' ~y five minutes. The i~ax-inflate mode can be
selected by an operator at any time by pressing the max-inflate button 173 on the keyboard
(FIG. 22). The max-inflate m~de may be used not only tû inflate the air bags quickly, but
2~ aiso to make it easier to move a patient on or offthe bed and to perform other tasks. The
max-inflate mode established the firmestpossible condition in all zones of the mattress.
In the normai mode, the regulator monitors the p,essure ;n each air pressure zone and
- individually adjusts the air pressure to match a prQselected patient profile. The patient
profile is determined by the weight and height of the patient. The regulator storQ weight
and height vaiuQ so that when it is activated it sets the air pressure in each uniform pressure
zone for the pàtient with which the controller was last used. These numbers can be varied
using the keyboard. The keyboard (FIG. 22) includes a weight display 180 and a height
display ii82 which provide a numericai read out of the selected weight and height. Below
each weight and height display are a pair of adjustment bunons. The weight can be adjuste~i
upwardsby pushing a weight up adjustment bunon 184 and adjusted down by pushing a
weight down adjustment bunon 186. Similarly, the i eight can be adjusted up by pushing a
height up adjust bunon 183 and adjusted down by pushing a height down adjust bunon 190.
Once the weight and height are set to their proper levels. the regulator determinQ the
appropriate air pressure for each uniform pressure zone. This can be done using a memory
look-up table or, as preferred, it can be caiculated for each weight and height combination.
2~7~
WO 92/07541 ~ ~ PCI/US90/06446
-15-
Patient pressure profiles, currently used for low air flow mattresses, are equally applicable
to the present invention.
The zone pressures determined by the regulator should be sufficient for most patients
with normal proportions. For unusual patients or patients who are particularly sensitive in
one area, the operator can adjust the p~ t~ lc.l pressure in each of the four zones by
plus or minus 20 percent, in five percent increments, using a set of zone pressure adjustment
keys. There are four up adjustment keys 192, one for each zone, and a set of four down
adjustment keys 194, one for each zone. An LED display 196 indicates the adjustment
which has been made to the ~l eAci ' patient profile. Once the patient profile has been
determined, it is stored in the form of an air pressure value for each zone in a memory in
the regulator.
In the normal mode, the regulator monitors the pressure in each zone by reading the
pressure sensor output for that zone, compares the measured pressure to the ~"t`d.,.~llllill~
desired pressure for that zone and then, if the pressure in that zone differs from the desired
pressure by greater than a threshold amount, the regulator drives the blower to adjust the
pressure in that zone until it equals the desired pressure. As presently preferred. the
regulator polls the reading in each of the zone pressure sensors every quarter second. The
polled values are I~tPA in groups of four. Each second the values are averaged and
compared to the wll~LIulllil~r l)le~l~ .rl ",i",~.l, desired pressure for that zone. Averaging
the pressures over a period of a second prevents the regulator from responding to the
patient's movements which can increase or decrease the pressure in a particular zone for a
very brief period of time. As long as the pressure in the zones remains within plus or minus
ten percent of the desired pressure for that zone, no adjustment to the pressure is done and
the blower remains shut off. Since the bag's tubing and connectors are all designed to
minirnize air leakage as much as possible, most of the time that the mattress is in this mode,
the blower is off and the mattress consumes very little energy and makes essential~y no
noise.
If the pressure in the zone falls to between 20 percent and 90 percent of the desired
pressure or increases to above ~l0 percent of the desired pressure, the regulator acts to
30 . correct the pressure in the problem zone. First, the regulator turns on the blower and drives
it to produce an air pressure which ~ul,aLh.l~ equals the air pressure in the zone to be
corrected. The regulator does this by monitoring the air pressure at the output of the blower
154 through the fifth pressure sensor 170-5, and comparing the reading at that pressure
sensor with the pressure sensor for the zone to be corrected. When the pressures are as
equal as possible within the limits of blower operation, and if the pressure in the zone still
differs from the desired pressure by more than ten percent, then the valve between the
blower and the zone to be corrected is opened. Opening this valve should produce no net
air flow between the blower and the pressure zone because the pressure at the blower outlet
is the same as the pressure in the zone. The blower's operation rate is then slowly adjusted,
either upward or downward, until it produces the desired pressure. If the pressure produced
by the hlower is higher than the pressure in ~he zone, then air flows from the blower into
.. .. . . . . .
WO 92/07~41 2 0 ~ ~ ~ 3 6 PCI /US90/06446
-16-
the bags of the zone to be corrected. If the air pressure produced by the blower is iower
than the air pressure in the zone to be corrected, then air flows from the air bags into the
blower and out the blower inlet. When the pressure at the blower outlet and the pressure
in the zone both equal the desired pressure, the ~ULIC~ valve is closed and, unless
amother pressure zone requires adjustment, the blower is shut off.
Alternatively, the adjustrnents can be made by driving the blower to produce thedesired pressure and then opening the valve between the blower and the zone to be corrected.
lIowever, this results in a quick rush of air between the blower and the air pressure zone as
the pre~sure is equalized, causing a rapid change in the pressure in the air bag supporting
the patient. At best, this is a minor irritant to the patient and at worst, it can cause anxiety
and prevent the patient from sleeping. Nevertheless, the mode is preferred for gross
ctm~ntc for example, when several zones are at pressures very different from their
respective desired pressures. This can occur when there is a major leak in the system or
when a user is first placed onto the mattress. In this mode one or mole valves may be
opened even before the blower reaches the desired pressure in order to speed the
ctm~ntc _ ,
The controller continues in its normal operation until instructed otherwise. As
explained above, the controller engages the CPR mode when it detects that the CPR valve
is in the CPR position. It engages the max-inflate when the max-inflate button is pushed.
In the normal mode, if the pressure in any one zone falls below 20 percent of the desired
pressure, then the regulator switches operation to the max-inflate mode and sounds an alarm
indicating a significant leak in the mattress system. The alarm system monitors several
aspects of the mattress's operation and features both an audible alarm and a set of blinking
LED's which indicate the general reason for the alarm. The audible portion of the alarm can
2~ be silenced by pushing an alarm silence button 198 on the keyboard. The blinking alarm
cannot be silenced. A significant leak is indicated by a blinking SYSTEM FAILURE LED
display 202. The regulator monitols how frequently a pressure adjustment must be made.
If the pressure in any one zone falls to below 75 percent of the desired pressure more often
than every ten minutes, Khe alarm also sounds, indicating a system failure. When the CPR
mode is activated, a CPR RESET LED 204 blinks in conjunction with the audible alarm.
Preferably, the regulator also monitors the voltage produced by the back-up baneries, and
when the back-up baKery voltage falls below an acceptable level for driving the controller,
a BATTERY LED 206 fla hes along with the audible alarm. The keyboard also features a
Iock out key 200 which shuts down all other keyboard buttons to minimize the likelihood Khat
the seKings will be tampered with.
In the event of any of the above failures and for regular , it is preferred
tbat the regulator include a port 2û8 hidden within the housing which allows
it to be coupled to a ponable computer. Preferably the . port is a
u~ RS232-type interface, although any oKher type of interface can be used if
desired. The . port preferably allows am operator to monitor the entire
operation of the regulator, including reading all pressure sensor inputs and control outputs.
.... ... . ...... . .. _ = = .. _ ... _ .. _ _ _ ...... .. .. . ... . ., _ _ _ = =
~ WO 92/07541 2 0 ~ S ~ 3 $ PCT/US90/06446
-17-
ln the event of a leaky air bag which has resulted in activation of the system failure alarm,
the port allows the operator to quickly determine the pressure zone to which
the leaky bag belongs and the severity of the problem. The results of any diagnostic
subroutines can also be . ' to the ~ u , , and additional diagnostic
- S subroutines can be performed by the ~ lU~,U~ /uiel through the I port on the
regulator and the other system .
The keyboard is preferably mounted to its own independent housing 210 which setsinto a recess or holder 212 on the controller housing (FIG. 23). Magnetic strips 213 can be
used to hold the keyboard in place. This allows the keyboard to be lifted up and out of the
controller housing amd moved to different locations for greater ~:u.. ~, Electrical
with the controller housing is maintained through a keyboard umbilical cord
214 which is stored in the controller housing when the keyboard is restored to its holder.
The bottom side of the keyboard housing has a contour 216 which is designed to match the
shape of the top bar of the handle 30 (FIG. 24). A pin 218 extends from the approximate
center of this contour and fits into a bore 220 through the top bar of the handle. When the
pin on the keyboard is hooked into the bore on the handle, the keyboard is held and retained
by the pin on the top bar of the handle. The contour enhances the stability of the keyboard
on the handle and prevents it from rotating about the pin. Since the handle is vertically
adjustable using the handle adjustment lever 141, the position of the keyboard can be moved
up or down to maximize the comfort of the operator and to make its display easier to read
as the status of the mattress system is monitored by hospital staff. When the controller is
to be moved, the keyboard can be easily lifted up off of the handle and replaced in its recess
on the controller.
The keyboard housing can also be hung from a bed footboard. The keyboard housingincludes a pair of bottom stays 222 (only one of which is shown in FIGS. 23 and 25) which
extend parallel to and spaced apart from the pin 218. The keyboard is hooked onto the
footboard 14 or headboard 16 of a bed by bracketing the footboard between the pin and the
stays. The distance between the pin and the stays is chosen to correspond ~.l ly to
the width of the most common footboards in hospital use. These stays also have a horizontal
surface 224 which allows the keyboard to be placed on a flat surface and still be supported
in a convenient angled position. The length of the pin matches the level of the horizontal
- surface so that the base of the keyboard is supported by the pin.
While the present invention has been described in the context of a particular
t, a great variety of adaptations and ~ ;"-- can be made. The invention
may be used outside of a hospital anywhere that an extremely comfortable, adjustable bed
is desired. The invention has been described as an air mattress; however7 it is not necessary
that air be used. Any variety of fluids, the pressure or volume of which can be adjusted,
may be used with appropriate adjustments to the materials involved. Water and any of the
inert gases are examples. The air can also be enriched with moisture or some type of
medication to further reduce the likelihood that the air will become infected. The air
temperature can also be regulated in a variety of ways. A ~U~ iOl~l low air-loss mattress
WO 92/07541 2 ~ 9 ~ 7 3 6 PCT`/US90/06446
typically ~oldLG~ a heater in the air supply in order to keep the patient warm. Because
of the virtual lack of air flow in the present invention, this is presently considered
ur~necessary, however, heating could be provided, for example, in the air supply or adjacent
the air bags below the user.
A great variety of other ,,~ ;r;, ~ ; and adaptations are possible without departing
from the spirit and scope of the present invention. It is not intended to abandon any of the
scope of the claims below by describing only the embodiment above.
