Note: Descriptions are shown in the official language in which they were submitted.
CA 02514354 2005-07-29
[0001] COLLAPSIBLE PLAY YARD
[0002] FIELD OF INVENTION
[0003] The field of the invention generally is collapsible play yards or
playpens and more particularly to releasable locking mechanisms for such
collapsible devices.
[0004] BACKGROUND
[0005] A collapsible play yard provides a portable but stable structure in
which a small child can play and sleep. The essential features for such a
structure is that it be (1) lightweight enough to carry by one person, (2)
easy to
set up, and (3) stable enough to safely support the child. An example of a
portable
play yard is shown in U.S. Patent No. 4,811,437 to Dillner et al.
[0006] The Dillner play yard uses a center hub about which the uprights of
the play yard are pivoted. The hub employed in the Dillner play yard is a
complex device and the need exists for a simpler center hub design.
[0007] Similarly, Dillner provides a play yard having upper rails comprised
of several moving parts and a need exists for a simpler upper rail design.
[0008] SUMMARY
[0009] The present invention is characterized by a locking mechanism for a
foldable enclosure, which comprises: a) a hub movable between a raised
position
and a lowered position, comprising i) a pair of structures, each rotatably
mounted upon pivots extending through a common bracket wherein sector gears
of each structure meshingly engage each other causing the structures to rotate
in
unison about their respective pivots and ii) a locking assembly movably
mounted
upon the common bracket between a locked position that prevents rotation of
said structures about their respective axes and a released position that
allows
rotation of said structures their respective axes and iii) at least two rods
each
pivotally joined to an associated one of said structures. When a lock button
of the
locking mechanism is moved to an unlocked position, the hub is free to be
lifted
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toward the raised position, whereby the rods are moved together to be aligned
substantially in parallel. When the hub is pushed into the lowered position
from
the raised position, the cooperating structures rotate about their pivots
whereby
the rods are moved away from each other until the rods lie substantially in a
common plane, which constitutes the erected position. When the rods reach the
erected position, the locking button is automatically moved to its locked
position
which prevents accidental movement of the hub from the lowered position
(wherein the play yard is erected) to the raised position (wherein the play
yard is
collapsed).
[0010] The present invention is also directed to a play yard having a hub
movable between a raised position and a lowered position, with at least two
lower
rods pivotally joined to the hub, wherein when the hub is lifted toward the
raised
position, the outer ends of the lower rods move together so as to be
substantially
parallel, and when the hub is pushed toward the lowered position from the
raised
position, the outer ends of the lower rods are pushed away from each other
until
the rods lie substantially in a common plane. The play yard also has an upper
frame with upper frame rods substantially parallel to the lower rods when the
hub is in the lowered position. Finally, the play yard has at least one of the
upper
frame rods pivotable between a raised and lowered position, the pivoting axis
being substantially perpendicular to an axis of the vertical rails.
[0011] BRIEF DESCRIPTION OF THE DRAWINGS)
[0012] Figure 1 is an isometric view of the erected play yard.
[0013] Figure 2 is an isometric view of the collapsed play yard.
[0014] Figures 3, 3a, and 3b are isometric views that illustrate the
sequence of moving the frame between the erected and the collapsed position in
Figure 3b.
[0015] Figure 4 is a side elevation view of the frame of Figure 3.
[0016] Figures 4A, 4B, and 4C illustrate an alternate embodiment of the
frame.
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[0017] Figure 5 is a fragmentary view showing the center hub of Figure 3
in greater detail.
[0018] Figure 6 is a side elevational view of the center hub of Figure 5.
[0019] Figure 7 is a cross section of the center hub looking in the direction
of arrows 7-7 of Figure 6.
[0020] Figure 8 is a cross section of the center hub of Figure 6 looking in
the direction of arrows 8-8 of Figure 7.
[0021] Figure 9 is an enlarged cross section of the center hub looking in the
direction of arrows 9-9 of Figure 8.
[0022] Figure 10 is an isometric fragmentary view illustrating the center
hub in a collapsed condition.
[0023] Figure 11 is a cross section of the center hub looking in the direction
of arrows 11-11 of Figure 10.
[0024] Figure 12 is a cross section of the center hub looking in the direction
of arrows 12-12 of Figure 11.
[0025] Figure 13 is an exploded view of the center hub, and Figure 13a is
an isolated view of the centerpiece of the hub of Figure 13.
[0026] Figure 14 illustrates a locking mechanism for locking the rails of the
play yard of the present invention.
[0027] Figure 15 is a cross section in the direction of arrows 15-15 of Figure
14.
[0028] Figure 16 is a cross section in the direction of arrows 16-16 of Figure
15.
[0029] Figure 17 illustrates the release button of the locking mechanism of
Figure 14.
[0030] Figure 18 is a cross section in the direction of the arrows 18-18 of
Figure 17.
[0031] Figure 19 is a cross section in the direction of arrows 19-19 of Figure
18.
[0032] Figure 20 is an exploded view of the locking mechanism of Figure 17
and Figure 20a is a fragmentary view of the interior of the bracket in Figure
20.
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[0033] Figure 21 is an exploded view of an upper corner assembly for the
play yard of the present invention.
[0034) Figure 22 is a cross section in the direction of arrows 22-22 of Figure
21.
[0035) Figure 23 illustrates a lower corner assembly for the play yard of
the present invention.
[0036) Figure 24 is a cross section in the direction of arrows of 24-24 of
Figure 23.
[0037) Figure 25 shows an isometric view of an alternate embodiment of
the frame.
[0038) Figures 26-28 show enlarged details of several features of the frame
shown in Figure 25.
[0039] Figures 29-31 show isometric views of the enclosure mounted on the
frame shown in Figures 25-28.
[0040] Figure 32 is an isometric view of a bassinet addition.
[0041] Figure 32A is an enlarged view of a portion of the bassinet addition.
[0042] Figures 32B, 33, and 34 are isometric views of the bassinet addition
mounted to the enclosure.
[0043] Figures 35A and 35B are front and side views of a clip.
[0044) DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS)
[0045] Figure 1 shows a fully assembled and erected play yard 10, which
has a flexible enclosure 14 that covers a foldable frame 20 formed of rigid
components (shown in Figures 2 and 3). The enclosure 14 is mounted upon the
frame 20 by means of extending upper horizontal rails 22 through hollow
horizontal sleeves 16 and also extending vertical rails 24 through vertical
sleeves
17. A removable mattress floor 18, placed upon a floor of the enclosure 14
provides a soft surface for child to sleep or play on.
[0046] Figure 2 shows the play yard 10' folded onto itself and enclosed
within the folded mattress 18'. Edge 18a' has strips which may be Velcro(R)
strips that cooperate with complementary Velcro~ pieces on end 18b'. Figures
3,
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3a, and 3b show the steps in folding the frame 20. For purposes of simplicity,
Figures 3, 3a, and 3b omit the flexible enclosure 12 and mattress floor 18.
[0047] Starting from the fully erected frame shown in Figure 3, the frame
20 is collapsed onto itself as shown in Figure 3b by releasing locking
mechanisms
200 and unlocking and raising the center hub 50. The releasable locking
mechanisms 200 are each joined to a cooperating pair of upper frame rods 28,
28.
The upper frame rods 28 are each hingedly joined at an inner end to an
associated locking mechanism 200 and at an outer end to an arm of an
associated
upper corner piece 30. .
[0048] Once the releasable center hub 50 and locking mechanisms 200 are
unlocked, raising the center hub 50 draws the four base frame rods 32 upward.
The base frame rods are each pivotally mounted at one end to an associated
structure 52, 52 forming part of the center hub 50, and at the other end to an
associated one of the lower corner pieces 34. As the base frame rods 32 are
drawn upward (Figure 3a), the vertical rails 24 draw inward towards the rising
hub 50, and the releasable locking mechanisms 200 move downward.
[0049] Figure 3b shows the hub 50 raised to its lifted position in which the
frame 20' is folded onto itself and is thus fully collapsed for ease of
storage/transport. In this position, the vertical rails 24, upper frame rods
28, and
base frame rods 32 are substantially parallel to one another.
[0050] Figure 3 also shows optional lower support rods 36 that are pivotally
mounted to brackets 37 which, in turn, are joined to the base frame rods 32
and
have their inner ends pivotally mounted to supplemental feet 38. Feet 38 are
optionally mounted to an associated pair of lower support rods 36 and have
base
portions 38a that provide additional support for the floor of the play yard.
The
base portions 38a of feet 38, the bottom of bracket 56 and the bottoms of
lower
corner pieces 34 are arranged to engage a planar floor or other supporting
surface
to stably support the playard.
[0051] Figures 5-13 show a more detailed view of the center hub 50~ of
those, Figure 13 shows the component parts of the hub 50 most clearly. The hub
50 comprises a pair of sector gear structures 52, a central piece 54, bracket
56 for
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supporting piece 54 and structures 52, and a movably mounted locking button
assembly 58. Pivot pins 66 secure the structures 52 to the bracket 56 and
central
piece 54. Each structure 52 rotates about its associated pivot pin as the
structures rotate, teeth 62 on each of the sector gear structures 52 meshingly
engage one another, to provide a smooth and yet positive rotation of the
structures 52 that raise and lower the hub 50, assuring that the rods ,
simultaneously swing through Iike angles when raised/lowered.
[0052] Structures 52 each have an integral hollow support arm 64 for
receiving overlapping ends of an associated pair of base frame rods 32. The
ends
of rods 32 each have a cutout 32a so that they closely overlap one another and
can pivot independent of to one another when held to an associated hollow arm
64 by pivot pin 60. When the center hub 50 is pulled upward in the direction
of
arrows, the vertical rails 24 are drawn inward due to movement of the ends of
base frame rods 32, mounted to lower brackets 34, which move towards each
other.
[0053] Each structure 52 is comprised of a pair of spaced apart gear sectors
53a, 53b. Sector gears 53a, 53a of the structures 52 are diagonally opposed to
one another and gear sectors 53b, 53b are likewise diagonally opposed to one
another. Gear sectors 53a, 53a each have a shoulder 79 and the gear sectors
53b
each have a shoulder 78-78. The shoulders 78-78 are each closer to a vertical
axis
which coincides with arrow A in Figure 13 such that the shoulders 78, 78 are
each closer to said central axis. Diagonally aligned sector gears 53a, 53a
mesh
with an associated diagonally aligned sector gear 53b, 53b.
[0054] The locking member 58 is held against axial movement within the
central piece 54 by bolt 68 and nut 70 while being capable of rotating about
the
vertical axis. A tab 72 is integrally joined to locking member 58. Distance D1
between ends 72a - 72b is greater than the distance D2 between ends 72c - 72d.
Tab 72 is positioned beneath side guides 74, 74. The opposite ends 72c, 72d of
tab 72 are engaged by shoulders 78 - 78 when the hub 50 is lowered to the
erected position to prevent hub 50 from being accidentally unlocked and to
thereby secure the locking button 58 in a locked position (shown in Figures 5-
9).
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A torsion spring 76 biases the locking member 58 to rotate in the counter-
clockwise direction shown by arrow B to move the tab 72 to the locked position
when the hub is in the erected position. Note that the shoulders 79-79 provide
sufficient clearance to permit the tab to move to the locked position.
[0055] With the hub 50 in the lowered position, the spring-biased tab 72
rotates counter-clockwise until ends 72a, 72b each engage an associated
shoulder
78, 78. Once opposing surfaces 72c, 72d of tab 72 each engage an associated
shoulder 78, the gear structures 52 cannot rotate in either direction about
pins 66
because tab 72 is prevented from rotating by shoulders 78, 78, retaining.the
tab
in a locked position. This is best seen in Figure 6. The locking surfaces 78a,
78a,
79a, 79a of the gears 53a, 53a, 53b, 53b, abut the underside 72c of tab 72
preventing the hub assembly 50 from being lifted. The underside of bracket 56
rests in a supporting surface when the play yard is fully erected (see Fig.
4).
[0056] To release the gear structures 52 so they can rotate, the locking
member is turned clockwise, preferably by gripping curved wire handle 80. The
gear sector structures 52 include diagonally opposed clearance shoulders 79,
79
that provide sufficient clearance for tab 72, allowing the tab 72 to rotate in
the
clockwise direction. When the tab 72 is so rotated, opposite ends 72c, 72d of
tab
72 each enter into one of the gap spaces 82 between the opposing pairs of gear
sectors wheels 53a-53b. Once the ends 72c, 72d of tab 72 each enter into one
of
the gap spaces 82, the blocking surfaces 79a, 79a, 78a, 78a are clear of tab
72,
enabling structures 52, 52 to rotate freely about their associated pivots 66
allowing hub 50 to be lifted to its raised position shown in Figures 10-12.
[0057] As is best seen in Figure 12, although the tab 72 is urged counter-
clockwise because of the spring bias, the tab 72 is prevented from rotating by
the
interior sidewalk of the gear sectors 53a, 53a and thus the tab is retained
within
the gap 82. Upon lowering to the erected position, tab 72 is clear of the
shoulders
79, 79 as well as surfaces 78a, 78a, 79a, 79a (see Figure 3), enabling the
spring
76 to urge the tab 72 toward the locked position shown in Figures 5-9 without
the
need for manually rotating the locking button 58 into the locked position.
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[0058] Figures 14-20 show one of the upper horizontal rail locking
mechanisms 200. Figures 14-16 show the locking mechanism 200 in its locked
position, while Figures 17-19 show the unlocked position.
[0059] The locking mechanism 200 comprises mounting bracket 202, a
locking wedge 204, a locking spring 206, a push button 208, and a cover 210.
The
bracket 202 optionally has a pin 212 and a spacer/bushing 214 that provide
structural support: the bushing 214 fills the gap between opposing walls W 1-
W2
of bracket 202, and thus inhibits their movement towards or away from each
other when under stress.
[0060] The push button 208 and locking wedge 204 engage one another in a
threaded, snap-fit, or other secure arrangement. The arm 205 of wedge 204
extends through spring 206, which spring has one end 206a which presses
against the push button 208 and an end 206b secured to the projection 203 of
bracket of 202. When assembled as shown in Figure 15, the spring 206 biases
the push button 208 in the direction of arrow C and away from bracket 202.
This
bias force also urges the wedge portion 207 of the locking wedge 204 in the
direction of arrow C. Depressing the push button 208 against the force of
spring
206, compresses the spring 206 and drives the wedge portion 207 into the
hollow
cover 210 attached to the bracket 202, as shown in Figure 18.
[0061] In the locked position (Figures 14-17), the wedge portion 207
engages inserts 29 provided in upper frame rails 28. Inserts 29 and rails 28
are
pivotally mounted to bracket 202 by a pin 216 which prevents inserts 29 from
moving along their axes and further prevents inserts 29 from rotation about
their
axes. The inserts 29 each have a cutout 218 that engages an associated end of
the
wedge portion 207 to achieve this locked position. To prevent inadvertent
unlocking, the cutouts 218 each preferably have a small integral protrusion
220
that engages an associated recess 222 in wedge 207.
[0062] To unlock the upper horizontal rails for folding, the protrusion 220
and the recess 222 must first be disengaged so that the push button 208 can be
depressed. Prior to this disengagement, the push button 208 cannot be
depressed
because of the engagement of the protrusion 220 and recess 222. In practice,
this
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disengagement is accomplished by lifting the bracket 202 slightly, which
swings
each protrusion 220 upward and away from its associated recess 222. To unlock
the mechanism 200, the push button 208 is pressed in to by a distance
sufficient
to assure that the wedge 207 is clear of the path of movement of the cutout
218 as
each rod 28 rotates about its associated pin 216.
[0063] Figures 21 and 22 show an upper corner piece 30 that engages
tapered outer ends 302 of associated upper frame rods 28. Each rod 28 fits
into
an associated slot 30b and rotates about a pin 304 extending through opening
307 each in arm 302 and openings 308 in corner piece 30. Corner piece 30
minimizes the possibility of trapping a finger in the corner piece 30, by
using the
narrow tapered end 302 and cooperating narrow slot 306.
[0064) Figures 23 and 24 show one of the lower corner pieces 34. The lower
support rod 32 rotates about pivot pin 400 within the opening 402 within the
lower corner piece 34. It should be noted that the tapered end/narrow slot
design
for the upper corner piece may also be incorporated into the lower corner
piece
34.
[0065] Vertical arm 24 is force-fitted into bore 403 of corner piece 34. Arm
24 has an integral tab 24a which is normally biased in an outward radical
direction and which snap-fits against an upper edge 404a in opening 404 in
corner piece 34 when the rod 24 is pushed into bore 403 by an amount
sufficient
to clear edge 404a of opening 404. Rod 24 may be removed from lower corner
piece 34 by pressing tab 24a inwardly sufficient to clear edge 404a. Foot 405
is
preferably provided with a "tread" to provide a non-slip grip with a surface
supporting the play yard.
[0066] Several alternate embodiments of the play yard will now be
described.
[0067] Figures 4A-C show a play yard frame having rails or legs 24 that
include a telescoping rail portion 25 that extends therefrom to lengthen the
legs,
and thereby increase the overall height of the play yard. The legs are
lengthened
by pulling the telescoping leg portion 25 out from the leg 24 until the push-
button
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27 engages hole 29 in leg 24. Cross-section Figure 4C shows the push button 29
mounted to a leaf spring 27a contained within telescoping rail portion 25.
[0068] Although one extendible position is shown in Figures 4A-4C,
multiple positions would be possible of the leg 24 had multiple holes 29 to
engage
the push button 29 along its length.
[0069] The advantage of the extendible legs is twofold. First, it allows the
play yard to have an even more compact folded form. Second, the play yard's
height can be adjusted, which is particularly important if the portable play
yard
is used as a bedside bassinet (see below).
[0070] Figures 25-35 show a play yard with a fold-down arm 528. Figures
25-28 show the frame for the play yard having the fold down arm Figures 28-31
show the play yard having the fold-down arm with the enclosure mounted
thereon and Figures 32-35 show the play yard having the fold-down arm with
the bassinet attachment mounted thereto.
[0071] As is best seen in Figures 25-28, the play yard frame has an arm
528 pivotable between a raised position (see Figure 27) and a lowered position
(see Figures 25 and 26). The arm 528 pivots about pin 531 in its raised
position,
the arm 528 is at the same height as rods 28. In the lowered position, the
fold-
down arm 528 is lower than the frame rods 28.
[0072] At each position, the arm 528 is locked in place. In the raised
position, pin 530 engages hole 532 on corner piece 540, and in the lowered
position, pin 530 engages hole 534 on rail 24 (note that the hole 534 is shown
within the rail 18, although in practice, it may be preferred that the hole
534 is
contained within a thickened portion of the rail 18 or an extension from the
rail
18). The pin 530 extends from locking corner piece 550, which comprises a
fixed
portion 552 and a sliding portion 554. The sliding portion 554 moves parallel
to
the axis of the arm 528 as shown in phantom in Figure 27. The pin 530 moves
with the sliding portion 554 such that movement to the phantom position shown
in Figure 27 withdraws the pin 530 from engagement with either of the holes
532, 534. The pin 530 and sliding portion 554 are spring-biased (spring not
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CA 02514354 2005-07-29
shown) toward the locked position so that releasing the sliding portion 554
extends the pin 530 to the position shown in Figure 28.
[0073] Having described the frame, now the enclosure 514 mounted on the
frame will be described in more detail. As best seen in Figures 29-31, the
enclosure 514 is similar to that shown in Figure I, with notable differences
necessitated by the fold-down arm 528. First the enclosure sleeve 517a that
encloses the vertical rails 24 near the drop down arm 528 extends only part
way
up the rail 24 to end at point 517. This leaves the hole 534 exposed so that
it can
engage push button 530.
[0074] When the fold-down arm 528 is in the lowered position as shown in
Figure 30, the enclosure 514 bends to allow the arm to freely pivot into the
lowered position. The ability of the enclosure 514 to allow the arm 528 to
lower is
important, but so is the ability of the enclosure 514 to tightly close up when
the
arm 528 is raised, so as to discourage a child from reaching into any openings
in
the enclosure 514. This feature is best shown in Figure 31.
(0075] Figure 31 shows the enclosure 514 from an interior perspective with
the fold-down arm 528 in the raised position. Two flaps 560 and 570 form the
upper corner of the enclosure. Flap 570 has three Velcro(R) tabs 572, 574, 5?6
attached thereto. Tab 572 engages a protruding slot 525 attached to rail 24
and
secures back on itself with a mating Velcro(R) connection 572a. Tab 574
extends
through the slot 525 to engage flap 560 at mating Velcro(R) connection 574a.
Finally, tab 576 extends across leg 24 to mate with flap 560 at mating
Velcro(R)
connection 576a. The Velcro(R), tabs, and slot form a tight fit that
discourages a
child from passing their hand through the corner of the enclosure. It should
be
understood that although Figure 31 shows some gaps between parts, these would
be minimized in practice.
[0076] Figures 32-35 show an optional bassinet (or bedside sleeper or
changing table) padded addition 600 that fits over the upper rods 28 and arm
528. The addition 600, like the enclosure 514 and frame, has raised (Figure
32,
32A, and 32B) and lowered (Figures 33 and 34) positions corresponding to the
position of the arms. The addition 600 slips over and engages the frame upper
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rails 28 and arm 528, as will be discussed in more detail. The addition 600
has a
bottom 618, preferably cushioned, that receives the padded mattress 18. The
mattress 18 can be used with the addition 600 or the play yard.
[0077] Figures 32 and 32A, however, show the addition 600 unmounted on
the frame. Figures 32 and 32A are rear views of Figure 32B showing the
interior
face 602a of the front flap 602. In the raised position, the front flap 602
has an
interior tab 604 that mates with a side 606 of the addition 600 using a
Velcro(R)
connection 604a (shown in phantom since it is on the opposite tab face from
that
as shown), 604b. The remainder of the joint between the front side 608 and the
side 606 is a seam 610 that is preferably sewn. As can be seen from Figures 32
and 32A the interior of the addition 600 is, in this way, sealed off when
mounted
on the frame.
[0078] Figure 32B shows the addition 600 mounted to the play yard frame
with the enclosure 14 mounted thereon. The addition has inner sides 606, the
front side 608, and a back side 609 that all slide within the enclosure 14.
Exterior
sides 626, back 629, and exterior front flap 628 slide over the outside of the
enclosure 14. Within the joint between the interior and exterior sides, clips
630
snap fit over rails 528. The clips have a tab 630a with a slot 630b that
engages a
strap 630c that is attached to the addition 600. Further, snaps 632 on the
addition 600 engage corresponding snaps 632a on frame corners (frame snaps
shown in Figure 25). The clips 630 and snaps 632 insure a secure connection
between the addition 600 and the frame.
[0079] Figure 32B shows the addition 600 mounted to the frame. Exterior
addition side 628 engages a first exterior flap 629, also part of the addition
600,
using a Velero(R) connection 629a, 629b. A second exterior flap 640 attached
to
the addition 600 engages the enclosure 14 using a Velcro(R) connection 640a,
640b. The combination of these padded flaps insures that the hard frame
corners
are not exposed.
[0080] When the arm 528 is in the lowered position, as shown in Figures 33
and 34, the clips 630 are disengaged from arm 528, the Velcro(R) connections
at
604a,604b~ 629a, 629b~ and 640a, 640b are detached, and the front flap 602 is
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CA 02514354 2005-07-29
folded down. In this position, first exterior flap folds inward to engage the
side
wall 606 in a Velcro (R) connection 629c, 604b. Second clips 631, identical in
structure to first clips 630 but located on a lower side of the exterior face
of the
interior side 602a, attach to rail 528 in its fold down position.
[0081] When used as a bedside sleeper, front flap 602 can slide under a
mattress of a parental bed. The adjustable leg feature discussed above allows
the
height of the bedside sleeper to be adjusted for mattresses with different
heights.
This is important since the height of a top surface of a parental mattress
cannot
be known in advance. .
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