Under base integral climate control for an articulating bed

Abstract

An environmental control assembly has a case configured for attachment to a bottom surface of an articulation assembly. One or more inlet fans is attached to a first wall of the case. An inlet plenum receives air provided by the one or more fans and extends from the first wall to a central chamber. An outlet plenum extends from the central chamber to a second wall of the case. A first pair of outlet ports extends from the outlet plenum proximate the central chamber through side walls of the case and a second pair of outlet ports extends from the outlet plenum distal the central chamber through side walls of the case. A cylindrical flow diffuser is positioned in the outlet plenum between the side walls and controls airflow into the first pair of ports and second pair of ports, each of said outlet ports configured for attachment to one of a plurality of flexible air conduits.

What is claimed is: 
     
         1 . An environmental control assembly comprising:
 a case configured for attachment to a bottom surface of an articulation assembly;   one or more inlet fans attached to a first wall of the case,   an inlet plenum receiving air provided by the one or more fans and extending from the first wall to a central chamber;   an outlet plenum extending from the central chamber to a second wall of the case, and   at least one first outlet port extending from the outlet plenum proximate the central chamber through side walls of the case; and,   at least one second outlet port extending from the outlet plenum distal the central chamber through side walls of the case.   
     
     
         2 . The environmental control assembly as defined in  claim 2  wherein the at least one first outlet port comprises a first pair of outlet ports and the at least on second outlet port comprises a second pair of outlet ports; and,
 a cylindrical flow diffuser positioned in the outlet plenum between the side walls and controlling airflow into the first pair of ports and second pair of ports, each of said outlet ports configured for attachment to one of a plurality of flexible air conduits. 
 
     
     
         3 . The environmental control assembly as defined in  claim 2  wherein longitudinal positioning of the cylindrical airflow diffuser for equal flow into the proximate ports and distal ports is accomplished with a center axis of the cylindrical air diffuser at a first distance. 
     
     
         4 . The environmental control assembly as defined in  claim 3  wherein the first distance is between 30% and 45% of a distance between an axis of the proximate ports and an axis of the distal ports. 
     
     
         5 . The environmental control assembly as defined in  claim 1  further comprising a heating element supported in the central chamber between the inlet plenum and outlet plenum. 
     
     
         6 . The environmental control assembly as defined in  claim 5  wherein an upper cover and a lower cover of the case converge vertically between the inlet plenum and central chamber to further increase flow velocity of air provided by the one or more fans over the heating element. 
     
     
         7 . The environmental control assembly as defined in  claim 5  wherein the side walls of the case converge in the inlet plenum from the first end wall to the central chamber thereby increasing effective flow velocity of air provided by the one or more fans. 
     
     
         8 . The environmental control assembly as defined in  claim 5  wherein the heating element comprises a metal support folded with a curved leading edge, the heating element mounted to the upper cover with standoffs and a laminated copper heater circuit adhered to the metal support. 
     
     
         9 . The environmental control assembly as defined in  claim 8  wherein the radius of curvature of the leading edge spaces an upper flange and lower flange from the upper cover and lower cover forming an upper flow channel and a lower flow channel and the curvature of the leading edge is configured to smoothly transition flow of incoming air from the inlet plenum into the upper and lower flow channels. 
     
     
         10 . The environmental control assembly as defined in  claim 8  wherein the copper heater circuit is laminated inside a Kapton-Polyimide film sandwich. 
     
     
         11 . The environmental control assembly as defined in  claim 1  further comprising:
 at least one cooling unit having 
 a thermoelectric device with an array of thermoelectric plates supported by a frame, 
 a finned heatsink mounted to the frame contact with a hot side of the thermoelectric plates, said finned heatsink extending outward from a side wall of the case, 
 a finned coldsink mounted to the frame in contact with a cold side of the thermoelectric plates, the coldsink extending into the inlet plenum in flow contact with air provide by the one or more inlet fans whereby in operation the thermoelectric device cools the coldsink thereby cooling the airflow in the inlet plenum. 
 
     
     
         12 . The environmental control assembly as defined in  claim 11  wherein the at least one cooling unit further comprises a heatsink fan mounted to a channel cover surrounding the finned heatsink, said channel cover attached to one of said side walls, said heatsink fan providing cooling air for efficiency of the thermoelectric device during operation. 
     
     
         13 . The environmental control assembly as defined in  claim 12  wherein the heatsink fan is angularly mounted to the channel cover to provide airflow with a longitudinal component across the finned heat sink. 
     
     
         14 . The environmental control assembly as defined in  claim 1  further comprising:
 a heating element having
 a metal support folded with a curved leading edge, the heating element mounted to the upper cover with standoffs and 
 a laminated copper heater circuit adhered to the metal support, said heating element supported in the central chamber between the inlet plenum and outlet plenum; 
 
 at least one cooling unit having
 a thermoelectric device with an array of thermoelectric plates supported by a frame, 
 a finned heatsink mounted to the frame contact with a hot side of the thermoelectric plates, said finned heatsink extending outward from a side wall of the case, 
 a finned coldsink mounted to the frame in contact with a cold side of the thermoelectric plates, the coldsink extending into the inlet plenum in flow contact with air provide by the one or more inlet fans whereby in operation the thermoelectric device cools the coldsink thereby cooling the airflow in the inlet plenum; 
 a heatsink fan mounted to a channel cover surrounding the finned heatsink, said channel cover attached to one of said side walls; 
 
 a control electronics printed circuit board (PCB) mounted in a compartment in the case, the PCB receiving AC power at an input and having
 a regulator circuit providing AC to DC power conversion and regulation of power ; 
 a controller receiving temperature signals from an outlet plenum temperature sensor and user desired controls for ventilation and temperature on an input; 
 a heater drive circuit receiving a heater element temperature and a heater control signal from the controller and providing a heater control output to the heater circuit; 
 a cooling unit drive circuit receiving a cooler temperature from the cooling units and a cooler control signal from the controller and providing a cold plate power output to the thermoelectric device and heatsink fan; 
 a fan control output provided by the controller through the regulator circuit to power the one or more inlet fans responsive to a user desired ventilation input. 
 
 
     
     
         15 . An under base integral climate control system for an articulating bed, the system comprising:
 an environmental control assembly attached to a bottom surface of an articulation assembly and having
 a case; 
 one or more inlet fans attached to a first wall of the case, 
 an inlet plenum extending from the first wall to a central chamber; 
 an outlet plenum extending from the central chamber to a second wall of the case, and 
 a plurality of outlet ports extending from the outlet plenum through side walls of the case; 
   a plurality of flexible air conduits extending from the plurality of outlet ports to connection flanges on bottom surfaces of support panels of the articulation assembly;   a plurality of mattress feeder hoses in flow communication with the plurality of flexible air conduits, said mattress feeder hoses extending through tube channels in a mattress supported on the articulation assembly;   an air distribution mesh layer supported in a relief in an upper surface of the mattress, said relief surrounded by a barrier preventing peripheral flow out of the mesh layer to enhance the desired mattress surface ventilating, heating and cooling effects.