US20070033739A1 - Inflatable support system having thermoplastic polyurethane construction - Google Patents
Inflatable support system having thermoplastic polyurethane construction Download PDFInfo
- Publication number
- US20070033739A1 US20070033739A1 US11/202,769 US20276905A US2007033739A1 US 20070033739 A1 US20070033739 A1 US 20070033739A1 US 20276905 A US20276905 A US 20276905A US 2007033739 A1 US2007033739 A1 US 2007033739A1
- Authority
- US
- United States
- Prior art keywords
- flange
- support system
- thermoplastic polyurethane
- layer
- inflatable support
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000004433 Thermoplastic polyurethane Substances 0.000 title claims abstract description 84
- 229920002803 thermoplastic polyurethane Polymers 0.000 title claims abstract description 84
- 238000010276 construction Methods 0.000 title description 4
- 239000000463 material Substances 0.000 claims abstract description 31
- 239000004744 fabric Substances 0.000 claims description 22
- 238000003466 welding Methods 0.000 claims description 21
- 238000000034 method Methods 0.000 claims description 19
- 239000007788 liquid Substances 0.000 claims description 10
- 238000002844 melting Methods 0.000 claims description 3
- 230000008018 melting Effects 0.000 claims description 3
- 239000008188 pellet Substances 0.000 claims description 3
- 229920000728 polyester Polymers 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 claims 3
- 238000001816 cooling Methods 0.000 claims 2
- 238000005520 cutting process Methods 0.000 claims 2
- 238000010030 laminating Methods 0.000 claims 2
- 238000004519 manufacturing process Methods 0.000 claims 1
- 239000004800 polyvinyl chloride Substances 0.000 description 9
- 229920000915 polyvinyl chloride Polymers 0.000 description 9
- 229920001971 elastomer Polymers 0.000 description 2
- 239000006260 foam Substances 0.000 description 2
- HGUFODBRKLSHSI-UHFFFAOYSA-N 2,3,7,8-tetrachloro-dibenzo-p-dioxin Chemical compound O1C2=CC(Cl)=C(Cl)C=C2OC2=C1C=C(Cl)C(Cl)=C2 HGUFODBRKLSHSI-UHFFFAOYSA-N 0.000 description 1
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
Images
Classifications
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/08—Fluid mattresses or cushions
- A47C27/087—Fluid mattresses or cushions with means for connecting opposite sides, e.g. internal ties or strips
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/08—Fluid mattresses or cushions
- A47C27/081—Fluid mattresses or cushions of pneumatic type
Landscapes
- Laminated Bodies (AREA)
- Mattresses And Other Support Structures For Chairs And Beds (AREA)
Abstract
Description
- 1. Field of the Invention
- The present invention relates to the field of inflatable support systems, particularly to an inflatable support system being constructed at least in part from thermoplastic polyurethane material.
- 2. Related Art
- Inflatable mattresses have been available for many years, and they are commonly used as both temporary and permanent sleeping arrangements. In addition, inflatable mattresses are often used outdoors on camping trips or other overnight trips. Because these mattresses are so often used while traveling, it is desirable to make them as light and portable as possible to minimize packing space and maximize convenience, while at the same time retaining the strength to resist punctures and leakage from the seams under normal use.
- Furthermore, new inflatable mattresses that more closely resemble conventional mattresses are often very large, sometimes even having multiple chambers. A king-size conventional inflatable mattress that inflates to a height of almost three feet can weigh nearly 125 pounds when deflated. This weight may severely limit its portability.
- These shortcomings are addressed by constructing a mattress from thermoplastic polyurethane (“TPU”), a recyclable material that is lighter than polyvinyl chloride (“PVC”) or rubber, materials that have been conventionally used to construct inflatable mattresses. In the past, it has been prohibitively expensive to work with TPU, and as it is very thin, it has been difficult to weld to form the material into inflatable objects that require a rigid structure.
- In the past, TPU material has been used in self-inflating mattress pads, but such pads incorporated a foam internal structure that was glued to the TPU sheets. The foam structure, while adding support to the pads, added a significant amount of weight. Such pads were much smaller than conventional inflatable mattresses, usually having a height of no more than two inches. Such a pad in the size of a conventional inflatable mattress would weigh ten pounds or more.
- Disclosed herein is an inflatable support system comprised of at least one inflatable chamber that is defined by at least a top and a bottom layer of material. At least one of these layers of material is comprised of thermoplastic polyurethane. The inflatable support system includes at least one support structure that is also comprised of thermoplastic polyurethane. This support structure is attached to at least one of the layers of material that define the inflatable chamber.
- Also disclosed herein is a method for constructing an inflatable support system by forming a first layer comprised of thermoplastic polyurethane and a second layer comprised of thermoplastic polyurethane. At least one coil is formed from thermoplastic polyurethane and a first end of the coil is attached to the first layer. A second end of the coil is attached to the second layer.
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FIG. 1 is a perspective view of an embodiment of the present invention; -
FIG. 2 is an external view of the flange of the present invention; -
FIG. 3 is an internal view of the flange ofFIG. 2 ; -
FIG. 4 is an external view of the flange ofFIG. 2 with a valve attached; -
FIG. 5 is a cross-sectional view of an embodiment of the present invention showing the internal coils; -
FIG. 6 is an enlarged view of the coils ofFIG. 5 ; and -
FIG. 7 is a cross-sectional view of a coil ofFIG. 5 showing the fabric layer and the TPU layer. - Referring in combination to
FIGS. 1-6 , an embodiment of the present invention is shown. Thermoplastic polyurethane (“TPU”) 10, is utilized to create a lighter inflatable mattress that still retains the strength of a heavier, conventional polyvinyl chloride (“PVC”) mattress. At the same time, a mattress constructed from TPU will not leach harmful chemicals such as chloride and dioxin into the environment upon disposal. - While any shape or size mattress or inflatable object can be formed using TPU, the embodiment shown is a double-size inflatable mattress. Other sizes are envisioned, as well as thicker mattresses that incorporate more than one inflatable chamber, such as the raised mattress shown in U.S. Pat. No. 6,704,559.
- In the illustrated embodiment, the present invention has at least one inflatable substantially
airtight chamber 12. Thisinflatable chamber 12 has atop 14 and abottom 16 layer, eachlayer TPU material 10. TheTPU material 10 preferably has a thickness of no more than 0.2mm, and is cut to form the desired mattress size. Greater thicknesses of TPU could also be used if increased strength is needed, but this would also increase the weight of themattress 12. Another piece of TPU material is cut to form aside gusset 18 for themattress 12. Theside gusset 18 is welded via sonic or heat welding to theoutside edges 20 of thetop 14 and thebottom 16 layers. Alternatively, thetop 14 andbottom 16 layers can be welded to each other at theirouter edges 20, thereby eliminating the need for aseparate side gusset 18. - In order to prevent the
inflatable mattress 12 from ballooning out on its top and bottom sides, support structures in the form of internal coils, shown inFIGS. 5-7 , are provided. To create the internal coil construction, TPU is cut into belts, which are then welded via sonic or heat welding to theinternal sides 22 of thetop 14 andbottom 16 sheets ofTPU 10. Thecoils 24 in the illustrated embodiment are welded in a four-sided shape having slightly concave sides, but they could be welded to the top 14 andbottom 16 layers using a more conventional oval shape, or any other shape desired. Thecoils 24 are preferably aligned in parallel rows and have an elongated oval shape in cross-section. The overall effect of the coil shape and arrangement is to form a box-like construction, similar to a conventional mattress. This also adds support and strength to theinflatable mattress 12. - Referring to
FIGS. 1-4 , an embodiment of the present invention includes aflange 26 constructed from TPU material designed to have avalve 28 attached to it for inflation and/or deflation of theinflatable mattress 12. On conventional inflatable mattresses, such a flange would be formed from heavy PVC, thus adding more weight to the mattress. In the present embodiment, theflange 26 is preferably formed by melting TPU material, which can be in the form of TPU pellets, into a liquid form. This liquid is then poured into a flange-shaped mold to fill the entire mold cavity. The mold is then heated until the TPU material is set. At this point, the mold is opened and the TPU material is allowed to cool. An opening is defined in theside gusset 18, and the finishedflange 26 is attached via heat or sonic welding to theinternal wall 30 of theside gusset 18. The weld forms a substantially airtight seal around theflange 26. Alternatively, if aside gusset 18 is not used, theflange 26 can be welded to theinternal wall 22 of thetop 14 orbottom 16 layer of TPU. - The finished
flange 26 may be designed to accept avalve 28 that allows both inflation and deflation of theinflatable mattress 12 such as that shown in U.S. Pat. Nos. 5,627,363; 5,367,726; and 6,237,621. Alternatively, other types of valves could be used as well as different flange shapes adapted to the specific valves. - In an alternative embodiment of the present invention (not shown), a second flange can be formed from TPU and defined on the
side gusset 18 for receiving a pump. - In another embodiment of the present invention, a
fabric layer 32 is utilized to provide even more strength without significantly increasing the weight of theinflatable mattress 12. As in the previous embodiment, atop layer 14,bottom layer 16, and aside gusset 18, if desired, are formed fromTPU 10. A thin layer of fabric or flocking is then laminated or applied to one side of the TPU sheets using polyurethane glue. Theopposite side 34 of the TPU sheets is left bare, in order to allow welding of the TPU coils 24 to theinternal sides 22 of the top 14 and bottom 16 layers. In a preferred embodiment, the fabric is 150 Denier polyester, but other types of thin fabric layers could also be utilized. This allows the design of different colored beds, beds having soft coverings or beds having a silk screened design on them. If no fabric is used, the beds can even have a clear construction. An example of a TPU layer laminated to afabric layer 32 and incorporating aTPU coil 24 support structure is most clearly shown inFIGS. 2-4 and 7. Thefabric layer 32 is shaded for clarity in these figures. InFIG. 2 , theinternal wall 30 of theside gusset 18 is shown. - As a comparative example of the decreased weight of this inflatable mattress, a double bed formed from TPU including a fabric layer and a TPU flange weighs only about eight pounds, nearly ⅓ less than a conventional PVC inflatable double bed. A bed constructed according to the present invention is also able to withstand a 650 pound dead weight test and a life roller test consisting of an octagon roller weighing 180 pounds rolled side to side over the
mattress 12 30,000 times. - Another embodiment of the present invention encompasses a method of constructing an inflatable mattress. First 14 and second 16 layers of
TPU 10 are cut from a TPU sheet. If desired, aside gusset 18 is also cut from a TPU sheet. If desired, a layer offabric 32 is laminated to one side of theTPU sheets TPU coil structures 24 are then formed fromTPU material 10, and thesecoil structures 24 are welded via sonic or heat welding to thesides 22 of the top 14 and bottom 16 TPU sheets opposite the fabric covered sides. Theside gusset 18 is then welded to theoutside edges 20 of the top 14 and bottom 16 sheets in a manner such that TPU is welded to TPU. - An additional step of forming a
flange 24 from TPU may also be included in the method of the present invention. A flange mold is supplied and TPU pellets are heated until a liquid is formed. This liquid is poured or injected into the flange mold and the mold may be heated to set the material. Alternatively, the TPU may simply be allowed to cool in the mold until it sets. The fully-formedTPU flange 26 is then removed from the mold. An opening is formed in theside gusset 18,top sheet 14 orbottom sheet 16 to accept theflange 26. Theflange 26 is then welded via sonic or heat welding in the opening of theside gusset 18 of the inflatable mattress, or to the opening in the top 14 or bottom 16 layer of theinflatable mattress 12 if aside gusset 18 is not provided. Theflange 26 is welded to theinternal wall 30 of theside gusset 18 or theinternal wall 22 of the top 14 or bottom 16 sheet of TPU such that TPU is welded to TPU, creating a substantially airtight weld. Avalve 28 such as thevalve 28 shown inFIG. 4 can then be attached to theflange 26. - It should be noted that a wide range of changes could be made to the present embodiments without departing from the scope of the claimed invention. As noted, the welding pattern could take different forms. The entire mattress could also be constructed in any number of shapes and sizes. Furthermore, other methods known in the art can be used to weld the top and bottom layers and side gusset together, as well as attaching the coils and the flange. Additionally, the flange could take any number of shapes, dependent on the type of valve that it is designed for. The coils could also be replaced by other structural supports formed from TPU, such as TPU strips that are attached to the top and bottom layers to prevent the top and bottom layers from ballooning out upon inflation.
- The TPU material used to form the top and bottom layers of the bed and the flange can be any type of TPU known to one of skill in the art. The TPU can also be mixed with other materials, such as conventional PVC or rubber, before being formed into sheets. The TPU used to mold the flange can also contain other materials. Additional layers of material other than fabric could also be incorporated, such as PVC layers which could be laminated or otherwise attached to the TPU layers. If desired, an inflatable mattress could be formed from conventional PVC material and incorporate a TPU flange.
- It is therefore intended that the foregoing detailed description be regarded as illustrative rather than limiting, and that it be understood that it is the following claims, including all equivalents, that are intended to define the spirit and scope of this invention.
Claims (33)
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/202,769 US20070033739A1 (en) | 2005-08-12 | 2005-08-12 | Inflatable support system having thermoplastic polyurethane construction |
PCT/US2006/031026 WO2007021739A1 (en) | 2005-08-12 | 2006-08-09 | Inflatable support system having thermoplastic polyurethane construction |
EP06801028A EP1924171A1 (en) | 2005-08-12 | 2006-08-09 | Inflatable support system having thermoplastic polyurethane construction |
US11/800,930 US20070214575A1 (en) | 2005-08-12 | 2007-05-08 | Method of constructing an inflatable support system having thermoplastic polyurethane constuction |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/202,769 US20070033739A1 (en) | 2005-08-12 | 2005-08-12 | Inflatable support system having thermoplastic polyurethane construction |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/800,930 Division US20070214575A1 (en) | 2005-08-12 | 2007-05-08 | Method of constructing an inflatable support system having thermoplastic polyurethane constuction |
Publications (1)
Publication Number | Publication Date |
---|---|
US20070033739A1 true US20070033739A1 (en) | 2007-02-15 |
Family
ID=37441482
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/202,769 Abandoned US20070033739A1 (en) | 2005-08-12 | 2005-08-12 | Inflatable support system having thermoplastic polyurethane construction |
US11/800,930 Abandoned US20070214575A1 (en) | 2005-08-12 | 2007-05-08 | Method of constructing an inflatable support system having thermoplastic polyurethane constuction |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/800,930 Abandoned US20070214575A1 (en) | 2005-08-12 | 2007-05-08 | Method of constructing an inflatable support system having thermoplastic polyurethane constuction |
Country Status (3)
Country | Link |
---|---|
US (2) | US20070033739A1 (en) |
EP (1) | EP1924171A1 (en) |
WO (1) | WO2007021739A1 (en) |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20070056114A1 (en) * | 2005-09-09 | 2007-03-15 | Corey Lewison | Multi-zone coil construction airbed |
US20180326641A1 (en) * | 2016-07-15 | 2018-11-15 | Swo-Chung Chai | Method for manufacturing inflatable mattress and inflatable mattress |
US20190069691A1 (en) * | 2017-09-06 | 2019-03-07 | Tsung Hsi LIU | Inflatable bed |
US10631659B2 (en) * | 2016-02-23 | 2020-04-28 | Zhejiang Natural Outdoor Goods Inc | Inflatable product and inflatable product fusing process |
US11330914B2 (en) * | 2018-12-18 | 2022-05-17 | Belgravia Wood Limited | Internal support system for an inflatable air mattress |
USD1002241S1 (en) * | 2022-12-12 | 2023-10-24 | Zhejiang Natural Outdoor Goods Inc. | Air mattress |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US8225443B2 (en) * | 2008-11-26 | 2012-07-24 | Sandra Stefano | Bedpan system |
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Cited By (6)
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US20070056114A1 (en) * | 2005-09-09 | 2007-03-15 | Corey Lewison | Multi-zone coil construction airbed |
US10631659B2 (en) * | 2016-02-23 | 2020-04-28 | Zhejiang Natural Outdoor Goods Inc | Inflatable product and inflatable product fusing process |
US20180326641A1 (en) * | 2016-07-15 | 2018-11-15 | Swo-Chung Chai | Method for manufacturing inflatable mattress and inflatable mattress |
US20190069691A1 (en) * | 2017-09-06 | 2019-03-07 | Tsung Hsi LIU | Inflatable bed |
US11330914B2 (en) * | 2018-12-18 | 2022-05-17 | Belgravia Wood Limited | Internal support system for an inflatable air mattress |
USD1002241S1 (en) * | 2022-12-12 | 2023-10-24 | Zhejiang Natural Outdoor Goods Inc. | Air mattress |
Also Published As
Publication number | Publication date |
---|---|
US20070214575A1 (en) | 2007-09-20 |
WO2007021739A1 (en) | 2007-02-22 |
EP1924171A1 (en) | 2008-05-28 |
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