Granted Patent B2

US 12,514,376 · App. 18/435,583 · Granted Jan 6, 2026

Inventors: Anthony John Shakal (Rogers, MN); Casey Carlson (Independence, MN); Ryan Douglas (Stillwater, MN)

Assignee: Sleep Number Corporation

A47C27/082A47C27/083A47C27/10A47C31/008F16K31/0624F16K31/0655F16K31/0658F16K31/0689F16K31/0696

Abstract

Claims (62)

1 . A sleep system comprising:

at least one inflatable chamber;

a pump; and

a valve in fluid connection between the pump and the at least one inflatable chamber so as to selectively regulate fluid communication between the pump and the at least one inflatable chamber, the valve comprising:

a solenoid coil;

a plunger comprising a core, the plunger configured to respond to a magnetic field generated by the solenoid coil;

a valve seat;

a core spring at least partially abutting the core to push against the core to bias the plunger toward a closed position; and

a valve disc positioned at a head of the core, the valve disc configured to cushion impact when the valve is closed, the head of the core sized and shaped to abut an opposing surface of the valve disc at a center of the head and to be spaced from the opposing surface near a rim of the head when the valve is in an open position, the core spring positioned with respect to the core so as to bias the core such that the valve disc contacts the valve seat when the solenoid coil is not energized, wherein the valve disc is configured to curve such that the head of the core continues moving forward and a space in a receptacle of the valve disc between the head of the core and the opposing surface of the valve disc is reduced or eliminated when the valve is closed.

2 . The sleep system of claim 1 , wherein the core comprises:

a receptacle at a tail end of the core; and

a projection comprising an elastomeric bumper positioned partially in the receptacle, connected to the core, and extending distally out of the receptacle from the tail end of the core.

3 . The sleep system of claim 1 , wherein a front surface of the head gradually descends along a perimeter portion from the center to the rim of the head.

4 . The sleep system of claim 1 , wherein a front surface of the head is at least partially frustoconical at a location positioned across from a flat surface of the valve disc.

5 . The sleep system of claim 1 , wherein a front surface of the head gradually descends from a center portion of the front surface, along a perimeter portion of the front surface, to a radially outer rim of the head.

6 . A sleep system comprising:

at least one inflatable chamber;

a pump; and

a valve in fluid connection between the pump and the at least one inflatable chamber so as to selectively regulate fluid communication between the pump and the at least one inflatable chamber, the valve comprising:

a solenoid coil;

a plunger comprising a core, the plunger configured to respond to a magnetic field generated by the solenoid coil;

a valve seat;

a core spring at least partially abutting the core to push against the core to bias the plunger toward a closed position; and

a valve disc positioned at a head of the core, the valve disc configured to cushion impact when the valve is closed, the head of the core sized and shaped to abut an opposing surface of the valve disc at a center of the head and to be spaced from the opposing surface near a rim of the head when the valve is in an open position, the core spring positioned with respect to the core so as to bias the core such that the valve disc contacts the valve seat when the solenoid coil is not energized, wherein a front surface of the head is rounded, a surface of the valve disc opposing the front surface of the head is flat, and the surface of the valve disc opposing the front surface of the head is configured to bend around the front surface of the head when the head pushes the valve disc against the valve seat.

7 . A pump assembly comprising:

a pump; and

a valve in fluid connection with the pump and configured to fluidly connect to at least one inflatable chamber so as to selectively regulate fluid communication between the pump and the at least one inflatable chamber, the valve comprising:

a solenoid coil;

a plunger having a core configured to respond to a magnetic field generated by the solenoid coil;

a valve seat;

a core spring positioned with respect to the plunger so as to bias the plunger to a closed position; and

a valve disc positioned at a head of the core, the valve disc configured to cushion impact when the valve is closed, wherein the head of the core sized and shaped to abut an opposing surface of the valve disc at a center of the head and to be spaced from the opposing surface near a rim of the head when the valve is in an open position, wherein the core spring is positioned so as to bias the plunger such that the valve disc contacts the valve seat when the solenoid coil is not energized, and the core spring configured to push on the core which in turn pushes the valve disc against the valve seat and curves the valve disc such that the head of the core continues moving forward and a space between the head of the core and the opposing surface of the valve disc is reduced or eliminated when the solenoid coil is not energized.

8 . The pump assembly of claim 7 , further comprising:

an elastomeric bumper extending distally away from a tail end of the core; and

an elastomeric nub extending from the valve disc in a direction opposite of a forward-facing face of the valve disc.

9 . The pump assembly of claim 7 , wherein the valve seat has a diameter larger than that of the head of the core and less than that of the valve disc such that the valve disc bulges into a hole defined by the valve seat when the valve is closed.

10 . The pump assembly of claim 7 , wherein the core comprises:

a shoulder extending circumferentially around the core, the core spring wrapping at least partially around the core and abutting the shoulder to push against the core to bias the plunger toward the closed position;

a receptacle at a tail end of the core; and

an elastomeric bumper positioned partially in the receptacle, connected to the core, and extending distally out of the receptacle from the tail end of the core.

11 . A sleep system comprising:

at least one inflatable chamber;

a pump; and

a valve in fluid connection between the pump and the at least one inflatable chamber so as to selectively regulate fluid communication between the pump and the at least one inflatable chamber, the valve comprising:

a solenoid coil;

a plunger having a core configured to respond to a magnetic field generated by the solenoid coil; and

a valve disc positioned at a head of the core and configured to cushion impact when the valve is closed, the valve disc comprising:

a forward-facing surface;

a rear-facing surface;

a receptacle, the head of the core positioned in the receptacle; and

a plurality of projections attached to the rear-facing surface of the valve disc and extending in a rearward direction from the rear-facing surface away from the forward-facing surface, each of the plurality of projections sized and positioned to cushion the impact when the valve is opened, each of the plurality of projections extending from the rear-facing surface of the valve disc at a position that is adjacent to and along an outer surface.

12 . The sleep system of claim 11 , wherein the plurality of projections comprises nubs extending from the rear-facing surface of the valve disc in the rearward direction opposite of the forward-facing surface of the valve disc configured to compress toward the rear-facing surface of the valve disc to cushion the impact when the valve is opened.

13 . The sleep system of claim 12 , wherein the valve disc comprises a first elastomer and the plurality of projections comprises a second elastomer different than the first elastomer.

14 . The sleep system of claim 12 , wherein the valve comprises a valve seat having a diameter larger than that of the head of the core and less than that of the valve disc such that the valve disc bulges into a hole defined by the valve seat when the valve is closed.

15 . The sleep system of claim 11 , further comprising:

a support comprising the at least one inflatable chamber and means for surrounding the at least one inflatable chamber.

16 . The sleep system of claim 11 , wherein the head of the core comprises a chamfered front surface such that a center of the head of the core abuts an opposing surface of the valve disc and an outer portion of the head is spaced from the opposing surface of the valve disc.

17 . The sleep system of claim 16 , further comprising a core-head groove having a top wall defined by a bottom surface of the core and a bottom wall defined by a top surface of the head, a portion of the rear-facing surface of the valve disc adjacent to the bottom surface of the core, wherein the core-head groove is configured to mechanically couple the valve disc to the head and the core.

18 . The sleep system of claim 11 , wherein the at least one inflatable chamber is part of a bed.

19 . The sleep system of claim 11 , wherein:

a front surface of the head of the core and an opposing surface of the valve disc are shaped to space a portion of the front surface from the opposing surface; and

a center of the head of the core contacts the valve disc and a rim of the head is spaced apart from the valve disc.

Assignments (3)

Continuity (3)

References Cited (400)