Foldable bed

Abstract

The present invention relates to a self-inflating collapsible bed, comprising one or more self-inflating chambers, each of which has one or more polyurethane foam segments, and the chambers are formed between a first airtight layer and a second airtight layer. The self-inflating bed can be evacuated by a household or commercially available vacuum device, then sealed, rolled up or folded, and is easy to store or transport. The polyurethane foam segments can be provided with different members having different indentation hardness specifications suitable for the bed portion and the edges of the bed portion.

Description

[0001] Statement Regarding Government Interests

[0002] Not applicable

[0003] Copyright of Drawings

[0004] Part of the disclosure of this patent document contains copyrighted material. The patent owner does not oppose anyone to reproduce this patent document or the disclosure of this patent exactly as it appears in the patent files or records of the Patent and Trademark Office, but in other cases all copyright rights are reserved anyway.

[0005] Related Patent Applications

[0006] This application claims the priority of a prior U.S. Provisional Patent Application No. 62 / 832,019, filed on April 10, 2019, with the title of "Foldable Bed", the disclosure of which (including the specification, drawings and claims) is incorporated herein by reference in its entirety. Technical Field

[0007] The present invention relates to a self-inflating bed, and more particularly, to a self-inflating bed that includes a vacuum valve connected to a vacuum source for removing air from the self-inflating bed in an inflated state. Background Art

[0008] There is a continuing interest and need for improvements in self-inflating beds, particularly for designs that minimize storage space when not in use. The home bedding retail market is undergoing significant changes, recently adopting the "bed-in-box" model to send beds to today's internet users. Although the "bed-in-box" is a relatively new distribution model, there are still many deficiencies in the self-inflating bed products currently offered by existing distribution channels. For example, it is cumbersome, and for most consumers, once used, it is likely not to adopt many basic bed designs and then compress it into a "UPS-shippable" box. Many existing beds can never be put back into the shipping box once unpacked (unless the user also has access to a large compressor).

[0009] Therefore, it would be desirable if a self-inflating bed could be configured to eliminate many of the drawbacks of various boxed bed mattresses on the current market. For example, being easily repackaged into a compact, UPS-shippable box configuration would facilitate warranty returns, post-use storage, and the movement of the bed. Also, improved valve features that contribute to comfort adjustment would be beneficial.

[0010] Therefore, there remains a technical problem of providing a collapsible self-inflating bed with an improved design that can be easily repackaged for convenient storage and shipping. Additionally, it would be advantageous if such a design could simultaneously address various practical issues, including (a) minimizing the storage volume of the bed when air is expelled from the bed, (b) improved valves for comfort control, and (c) meeting government fire safety requirements for various components of the bed, including the mattress ticking.

[0011] Furthermore, although others have made numerous attempts to provide collapsible beds, for consumer acceptance, most versions known to the inventors have failed. Although there are exceptions, such as inexpensive Airbed, but its success mainly depends on its very low purchase cost. The currently available collapsible beds are at best a temporary or emergency bed solution. The existing designs known to the inventors perform poorly in terms of comfort, warmth, stability, adjustability, and durability. Therefore, there is still a need for improved collapsible beds to provide users with stability, adjustability, comfort, and warmth.

[0012] Objects, Advantages, and Novel Features of the Invention

[0013] Therefore, an object of the present invention is to provide a design for a collapsible bed that is simple and straightforward, and in a compressed and deflated state, its size, shape, and weight are restricted in a manner suitable for shipment by United Parcel Service (UPS) or similar parcel shipping and delivery providers.

[0014] Another object of the present invention is to provide a design for a collapsible bed that can be easily adjusted to provide the desired level of comfort, whether in a single bed or in a larger bed, such as a queen-size configuration.

[0015] Another important object is to provide a collapsible bed that meets the government flammability standards applicable to mattress ticking.

[0016] A related and important object is to provide a design for a collapsible bed that includes multiple inflatable sections, thereby enabling easy adjustment of the desired level of comfort.

[0017] Another important object is to provide sturdy edge portions that enable users to easily get out of the bed.

[0018] Furthermore, another important object is to provide a high-quality design for a collapsible bed that includes multiple foam sections with different degrees of indentation force deflection, thereby maximizing user comfort. Summary of the Invention

[0019] The present invention provides a collapsible self-inflating bed design. The core assembly of the bed includes one or more airtight enclosures that form plenums filled with and adhered to a breathable elastic foam material. The core assembly of the bed is covered by a traditional bed ticking, providing consumers with the expected appearance and feel of a traditional bed. The airtight plenums are controlled by at least two different types of purposeful-function air control valves. The traditional bed ticking design provides access to the air control valves without compromising the appearance and feel of a traditional bed. The air control valves include (a) a vacuum port valve and (b) a comfort adjustment valve. The vacuum port is configured to mate with a traditional household vacuum cleaner or a commercially available vacuum cleaner (using a simple adapter if necessary), allowing the consumer to deflate the bed to a flat, compacted structure that is a fraction of its normal operating thickness and volume. Benefits provided by this feature include the ability to easily shrink the collapsible bed for storage, transport it to another location for use, or for the consumer to return the bed to the manufacturer for warranty claims or other reasons. When ready to re-expand the bed, the consumer can reopen the vacuum port valve and allow the elastic foam material to draw air in through the vacuum port. Once re-inflated, the consumer can close the vacuum port valve, and the bed is ready for use again. Since there is no pump, this configuration allows for use in off-grid or rooms without an electrical connection.

[0020] The comfort adjustment valve provides the additional benefit of allowing the consumer to adjust the firmness of the bed. Additionally, including a comfort adjustment valve mounted on the bed, providing two or more separate airtight enclosures, enables two users to individually adjust the pressure and firmness of their side of the bed, independent of adjustments made by their partner on the other side of the bed.

[0021] In one embodiment, no electrical connection or Wi-Fi is required to operate the comfort adjustment valve. However, the comfort adjustment valve can be designed with multiple functions, including fully automatic types where the user does not have to manually adjust. Additionally, the use of multiple comfort adjustment valves along the length of the bed allows for a multi-chamber approach, where separate airtight enclosures are set at appropriate lengths from the top to the bottom of the bed, for example allowing for further firmness adjustment along the body.

[0022] In various embodiments, a self-inflating bed using one or more self-inflating chambers may be provided. In various embodiments, two or more self-inflating chambers may be provided. Each self-inflating chamber is formed between a first air-impermeable layer and a second air-impermeable layer. Both the first air-impermeable layer and the second air-impermeable layer comprise an elastomeric thermoplastic material having an inner side and an outer side, and the thickness T is between about two (2) mils (0.002 inches) and about five (5) mils (0.005 inches). A first adhesive layer adheres to the inner side of the first air-impermeable layer, and a second adhesive layer adheres to the inner side of the second air-impermeable layer. Both the first adhesive layer and the second adhesive layer comprise an extruded adhesive composition having a final thickness B between about one (1) mil (0.001 inches) and about four (4) mils (0.004 inches).

[0023] Preferably, a single breathable open-cell polyurethane foam layer N is provided. Alternatively, X polyurethane foam layers may be provided, which form a stack S of a series of foam layers N1 to N X where X is a positive integer greater than 1. In the stack S, the first polyurethane foam layer N1 of the X polyurethane foam layers is attached to the first adhesive layer, and each successive polyurethane foam layer N2, N3 in the series ending with N X is attached to the immediately preceding foam layer N (X-1) . The bottom of the last polyurethane foam layer N X or the single foam layer N is attached to the second adhesive layer. The breathable open-cell polyurethane foam layer comprises an inner portion having a 25% indentation hardness (IFD) of about six (6) pounds-force to about twenty (20) pounds-force measured according to ASTM standard D3574. In various embodiments of the collapsible self-inflating bed, an inner portion having a 25% indentation hardness (IFD) of about ten (10) pounds-force to about nineteen (19) pounds-force measured according to ASTM standard D3574 may be provided. In addition, the single foam layer N or the stack S of polyurethane foam layers N X has an outer perimeter. Extending inward from at least a portion of the outer perimeter, there is an edge portion, and at least a portion of the edge portion comprises one (N) or more layers of polyurethane foam layer N X having a 25% indentation hardness of about thirty-five (35) pounds-force to about fifty (50) pounds-force measured according to ASTM standard D3574. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The present invention will now be described by way of exemplary embodiments of the present invention with reference to the accompanying drawings, in which like reference numerals refer to like elements, wherein:

[0025] Figure 1Exploded perspective view of an embodiment of a collapsible bed, showing a core assembly having an upper first air-impermeable layer and a lower second air-impermeable layer, and therebetween an open-cell polyethylene foam layer having an internal portion with a first indentation hardness specification and, at one edge, including an edge portion having a second indentation hardness specification. Also shown are a vacuum port valve and a comfort adjustment valve.

[0026] Figure 2 Perspective view of an embodiment of a collapsible bed, showing Figure 1 the components shown in

[0027] Figure 3 is a partial perspective view of a cross-section of an embodiment of the core assembly of a collapsible bed taken along line 3-3 of Figure 2 showing (not to scale) the components of the core assembly, namely the first air-impermeable layer and the second air-impermeable layer, where a first adhesive layer is adhered to the inner side of the first air-impermeable layer and a second adhesive layer is adhered to the inner side of the second air-impermeable layer, and a single open-cell polyurethane foam layer, where the upper side of the polyurethane foam layer is adhered to the first adhesive layer and the lower side of the polyurethane foam layer is adhered to the second adhesive layer. Also shown is a configuration where both the internal portion and the edge portion of the polyurethane foam layer have different indentation hardness specifications.

[0028] Figure 3A Similar to Figure 3 which shows, in the form of a longitudinal cross-sectional perspective view from the top to the bottom of a collapsible bed, the construction of an embodiment of a collapsible bed and where the elements of an embodiment for the core assembly are shown, namely the first air-impermeable layer and the second air-impermeable layer, where a first adhesive layer is adhered to the inner side of the first air-impermeable layer, a second adhesive layer is adhered to the inner side of the second air-impermeable layer, and a single polyurethane foam layer N1 is shown, where the upper side of the polyurethane foam layer is adhered to the first adhesive layer and the lower side of the polyurethane foam layer is adhered to the second adhesive layer.

[0029] Figure 4 、 Figure 5 、 Figure 6 and Figure 7 show different embodiments of the mattress construction.

[0030] Figure 4A partial cross-sectional view taken vertically shows the structure of an embodiment of a foldable bed, where elements of an embodiment for the core assembly and the mattress are shown. That is, starting from the top, a compliant fabric layer is shown, an adhesive layer that adheres the compliant fabric to a first air-impermeable layer, then a first adhesive layer adhered to the inside of the first air-impermeable layer, then a breathable open-cell polyurethane foam core, below which is a second adhesive layer located between the polyurethane foam core and a second air-impermeable layer, and finally an adhesive layer that adheres the second air-impermeable layer to the compliant fabric layer below it.

[0031] Figure 5 Similar to Figure 4 , although only half of the partial cross-section is shown (the bottom can be as shown at the top), which shows an embodiment for constructing a foldable bed, where elements of an embodiment for the core assembly and the mattress are shown. That is, starting from the top, a compliant fabric layer is shown, but there is no adhesive layer (different from the structure shown in Figure 4 ), then a first adhesive layer adhered to the inside of the first air-impermeable layer, and then a breathable open-cell polyurethane foam core.

[0032] Figure 6 Similar to Figure 4 and Figure 5 , although only half of the partial cross-section is shown (the bottom can be as shown at the top), which shows an embodiment for constructing a foldable bed, where elements of an embodiment for the core assembly and the mattress are shown. That is, starting from the top, a spandex fabric layer (spandex is a lightweight, soft, synthetic stretchable polyurethane-based fabric) is shown, then an adhesive layer that adheres the spandex fabric layer to a first air-impermeable layer, and then a first adhesive layer adhered to the inside of the first air-impermeable layer to adhere the first air-impermeable layer to the open-cell polyurethane foam core.

[0033] Figure 7 Similar to Figure 6 , which shows an embodiment for constructing a foldable bed, where elements of an embodiment for the core assembly and the mattress are shown. That is, starting from the top, a spandex fabric layer (but there is no adhesive layer to adhere the spandex fabric layer to the first air-impermeable layer) is shown, then a first air-impermeable layer, and then a first adhesive layer adhered to the inside of the first air-impermeable layer to adhere the first air-impermeable layer to the open-cell polyurethane foam core.

[0034] Figure 8 , Figure 9 and Figure 10 show embodiments of a foldable bed, where along the length of the bed, separate polyurethane foam parts with different structural properties are used, that is, different indentation hardness specifications, and where an edge part is shown that has a higher indentation hardness than the inner part.

[0035] Figure 8 Shows asFigure 9 and Figure 10 a perspective view of an embodiment of a foldable bed further described in Figure 9 and revealing separate polyurethane foam portions having different indentation hardness specifications.

[0036] Figure 9 shows a perspective view of a cross-section of an embodiment of a foldable bed taken along line Figure 8 9-9, which shows how separate polyurethane foam portions having different indentation hardness specifications are used.

[0037] Figure 10 is a plan view looking down on a cross-section taken along line Figure 8 10-10 in

[0038] Figure 11 , Figure 12 and Figure 13 shows an embodiment of a foldable bed where along the length of the bed, there is a polyurethane foam having uniform structural properties and composition, but different positions along the length of the bed have different indentation hardness specifications, which are achieved by removing vertically oriented foam stuffing at selected positions in the upper and lower bed positions as shown.

[0039] Figure 11 shows, as Figure 12 and Figure 13 further described in Figure 12 a perspective view of an embodiment of a foldable bed and having section lines to reveal in

[0040] Figure 12 that by removing foam stuffing from selected positions, a uniform polyurethane foam composition has different indentation hardness portions. Figure 11 shows a perspective view of a cross-section of an embodiment of a foldable bed taken along line

[0041] Figure 13 is a plan view looking down on a partial cross-section taken along line Figure 12 13-13 in

[0042] Figure 14 ,Figure 15 and Figure 16 shows an embodiment of a foldable bed, which along the length of the bed includes a polyurethane foam having uniform structural properties and composition, but at different positions along the length of the bed has different indentation hardness specifications, which are achieved by removing horizontally oriented foam stuffing at selected positions in the upper bed position and the lower bed position as shown in the figure.

[0043] <t Figure 14 Provides a perspective view of an embodiment of a foldable bed as further described in Figure 15 and Figure 16 and has hatching to reveal in Figure 15 how a uniform polyurethane foam composition has different indentation hardness sections by removing horizontally oriented foam stuffing from selected positions.

[0044] Figure 15 Provides a perspective view of a cross-section of an embodiment of a foldable bed taken along line 15-15 of Figure 14 which shows how a single polyurethane foam section having a uniform composition and structural properties can have different indentation hardness specifications at selected positions by removing horizontally oriented stuffing from the polyurethane foam.

[0045] Figure 16 is a plan view of a partial cross-section taken along line 15-15 of Figure 14 which shows how a single, uniform polyurethane foam section can be used, but where indentation hardness specifications can be provided by removing horizontally oriented stuffing of the polyurethane foam at selected positions.

[0046] Figure 17 , Figure 18 and Figure 19 show an embodiment of a foldable bed, which has a vacuum port, and which has a user-adjustable comfort valve, and which includes a polyurethane foam core having a uniform composition and indentation hardness, and which includes an edge portion having a higher indentation hardness specification.

[0047] Figure 17 shows a plan view of a partial horizontal cross-section of an embodiment of a foldable bed as further described in Figure 18 and [[ID= and has hatching to reveal in ​ a uniform polyurethane foam composition.

[0048] ​ shows along ​A plan view of a horizontal cross-section of an embodiment of a foldable bed taken along line 18-18, which shows the use of a single polyurethane foam central portion with uniform composition and structural properties, but with a high-pressure indentation hardness specification for the edge portions, and shows the appropriate positions of the vacuum port valve and the comfort hardness regulating valve.

[0049] ​ is a vertical cross-sectional view taken along ​ line 19-19, which shows how a single uniform polyurethane foam core portion is used in combination with a high-pressure indentation hardness edge portion.

[0050] ​ and ​ show an embodiment of a foldable bed, in which a double bed size is provided, and in which both sides have edge portions having a higher indentation hardness specification than the single uniform polyurethane foam core portion.

[0051] ​ shows a perspective view of an embodiment of a foldable bed, in which a double bed size is provided, and in which a uniform polyurethane foam composition is provided for the core portion, and in which two edge portions having a high-pressure indentation hardness specification are provided.

[0052] ​ is a vertical cross-sectional view taken along ​ line 21-21, and shows how a single uniform polyurethane foam core portion is used in combination with two high-pressure indentation hardness edge portions.

[0053] ​ and ​ show an embodiment of a foldable bed, similar to ​ the embodiment first shown, but now showing a double bed design, in which along the length of the bed, separate polyurethane foam portions with different structural properties, i.e., different indentation hardness specifications, are used, and in which two edge portions having a higher indentation hardness specification than the inner portion are used.

[0054] ​ shows, as ​ and ​ further described, a perspective view of an embodiment of a foldable bed in a double bed design, and has section lines to reveal in ​ that the separate polyurethane foam core portions have different indentation hardness specifications.

[0055] ​ shows a perspective view of a cross-section of an embodiment of a foldable bed taken along ​ line 24-24, which shows how separate polyurethane foam portions with different indentation hardness specifications are used.

[0056] ​ A plan view showing a partial horizontal cross-section of an embodiment of a foldable bed, and revealing the use of a uniform polyurethane foam composition for the core in combination with two high-pressure indentation hardness edge portions, and the independent adjustment of multiple chambers by using hardness adjustment valves in each chamber.

[0057] ​ A plan view of an embodiment of an over-bed double bed design, in which the upper first airtight layer is partially removed to reveal separate polyurethane foam portions having different indentation hardness specifications along the length of the foldable bed, and showing the use of edge portions having a higher indentation hardness specification than the internal polyurethane foam portions, and the use of multiple independently pressure-adjustable compartments.

[0058] ​ 、 ​ and ​ Shows an embodiment of a double bed design for a foldable bed, which includes a polyurethane foam having uniform structural properties and composition along the length of the bed, but at different positions along the length of the bed, different indentation hardness specifications are provided, which are achieved by removing vertically oriented foam stuffing at selected positions in the upper bed position and the lower bed position as shown.

[0059] ​ Shows a perspective view of an embodiment of a foldable bed as further described in ​ and ​ and having section lines to reveal, in ​ different indentation hardness portions of a uniform polyurethane foam composition by removing foam stuffing from selected positions.

[0060] ​ Shows a perspective view of a cross-section of an embodiment of a foldable bed taken along line 27-27 of ​ which shows how a single polyurethane foam portion having uniform composition and structural properties can have different indentation hardness specifications at selected positions by removing vertical stuffing from the polyurethane foam.

[0061] ​ A plan view of an embodiment of an over-bed double bed design, in which the upper first airtight layer is partially removed to reveal that a single uniform polyurethane foam portion can be used for the internal core, but wherein the indentation hardness specification can be changed along the length of the bed by removing vertical stuffing of the polyurethane foam at selected positions.

[0062] ​An embodiment of a double bed design for a foldable bed is shown, which includes a polyurethane foam inner core portion having uniform structural properties and composition along the length of the bed, but where different positions along the length of the bed have different indentation hardness specifications, which are achieved by removing horizontally oriented foam stuffing at selected positions in the upper bed position and the lower bed position as shown.

[0063] ​ Shows a cross-sectional perspective view along ​ line 30 - 30 of an embodiment of a foldable bed, which shows how a single polyurethane foam portion with uniform composition and structural properties can have different indentation hardness specifications at selected positions by removing horizontal plugs from the polyurethane foam.

[0064] ​ Is a cross-sectional view showing the use of an adapter connected to a vacuum port, so that a vacuum source such as a household vacuum cleaner or a commercially available vacuum cleaner can be used to evacuate an inflated foldable bed in order to shrink the bed for storage.

[0065] ​ Is a perspective view showing a vacuum cleaner operatively connected to a vacuum port, so that a vacuum source such as a household vacuum cleaner or a commercially available vacuum cleaner can be used to evacuate an inflated foldable bed as shown, to shrink the bed from an inflated size to a foldable size, as ​ shown below, for storage.

[0066] ​ Is a perspective view showing the use of a vacuum cleaner operatively connected to a vacuum port, where a vacuum source such as a household vacuum cleaner or a commercially available vacuum cleaner is used to evacuate an inflated foldable bed and shrink the bed to a foldable size.

[0067] ​ Is a perspective view of a foldable bed in a foldable size, with its vacuum port closed to prevent the bed from reinflating, and it is recommended that the bed can be rolled up for storage.

[0068] ​ Shows a perspective view of a foldable bed in a deflated, foldable configuration, which has been rolled up and inserted into a transport box.

[0069] ​ Is a top, partial cross-sectional view, which depicts two single self-inflating beds provided in a mirror configuration, where the beds can be connected along parallel zippers, connecting the zipper portion on one bed to the zipper portion on the mirror bed.

[0070] The foregoing drawings are merely exemplary and include various elements that may be present or omitted in the final configuration of various embodiments of the self-inflating bed. Other variations of the self-inflating bed may use slightly different structural materials, mechanical structures, mechanical arrangements, airflow configurations, vacuum valve configurations, or hardness valve configurations, but employ the principles described herein and are generally described as in the provided drawings. The drawings have been attempted to be drawn in a manner that at least shows those elements that are significant for understanding the exemplary self-inflating bed design. These details are very useful for providing novel self-inflating bed designs for various applications.

[0071] It should be understood that, in accordance with the teachings of the present invention, within the scope of the teachings herein defined by the claims, various different features may be employed in different embodiments of various sizes and shapes of the self-inflating bed according to specific design requirements. Detailed Description

[0072] Referring to ​ , which provides an exploded perspective view of some basic elements 48 of an embodiment of a self-inflating bed 50. Among them, a self-inflating chamber 52 is provided, which is formed between a first airtight layer 54 and a second airtight layer 56. In other embodiments, as described below, there may be more than one self-inflating chamber. In various embodiments, the materials of the first airtight layer 54 and the second airtight layer 56 may be selected from the group consisting of: (a) fabrics, (b) non-woven fabrics, (c) knitted fabrics, and (d) polyvinyl chloride sheets, or (e) flexible polymer or copolymer plastic sheets. As shown, a polyurethane foam inner portion 58 may be provided, which has a 25% indentation hardness measured according to ASTM standard D3574 from about six (6) pounds force to about twenty (20) pounds force. In various embodiments of the foldable self-inflating bed, an inner portion 58 having a 25% indentation hardness measured according to ASTM standard D3574 from about ten (10) pounds force to about nineteen (19) pounds force may be provided. As shown, a polyurethane foam edge portion 60 having a 25% indentation hardness measured according to ASTM standard D3574 from about thirty-five (35) pounds force to about fifty (50) pounds force may be provided. Finally, an openable and closable vacuum valve 62 and an openable and closable hardness regulating valve 64 are provided.

[0073] As ​ can be easily seen, and as ​ , ​ and ​ shown, both the first airtight layer 54 and the second airtight layer 56 may be provided by a thermoplastic material, which has an inner side (e.g., 54 I , 56 I ) and an outer side (e.g., 54 X , 56X ), and the exemplary thickness T is between about 2 mils (0.002 inches) and about 5 mils (0.005 inches). The first adhesive layer 70 can be adhered to the inner side 54 of the first air-impermeable layer 54 I , and the second adhesive layer 72 can be adhered to the inner side 56 of the second air-impermeable layer 56 I . In various embodiments, the first adhesive layer or the second adhesive layer or both can comprise an extruded adhesive composition having final thicknesses B1 and B2 respectively between about 1 mil (0.001 inches) and about 4 mils (0.004 inches) (see ​ ). In one embodiment, the third adhesive layer 74 can be adhered to the outer side 54 of the first air-impermeable layer 54 X , and the fourth adhesive layer 76 can be adhered to the outer side 56 of the second air-impermeable layer 56 X . In various embodiments, the third adhesive layer or the fourth adhesive layer or both can comprise an extruded adhesive composition having final thicknesses B3 and B4 respectively between about 1 mil (0.001 inches) and about 4 mils (0.004 inches) (see ​ ). Any one or more of the first adhesive layer, the second adhesive layer, the third adhesive layer, and the fourth adhesive layer can comprise a polyurethane composition. In various embodiments, the interior portion 58 of the polyurethane foam or the edge portion 60 of the polyurethane foam or both can comprise an open-cell polyurethane foam composition. As ​ shows, the third adhesive layer 74 can be adhered to the first mattress layer 80. The fourth adhesive layer 76 can be adhered to the second mattress layer 82. The first mattress layer 80 can comprise a compliant fabric. Similarly, the second mattress layer 82 can comprise a compliant fabric.

[0074] As ​ shows, the third mattress layer 84 or the fourth mattress layer 86 (not shown, but having a structure as ​ shown for the third mattress layer 84) can comprise an elastic stretchable fabric. In one embodiment, a spandex-type fabric such as brand of stretchable fabric can be used as the outer mattress.

[0075] As ​ shows, a first outer cover 90 or a second outer cover 92 (not shown, but having a structure as ​ shown) can be provided instead of the mattress layers. In this case, the first outer cover 90 and the second outer cover 92 are not adhered to the adjacent air-impermeable layers (54 and 56 respectively), but remain unbonded as potential removable or replaceable outer covers. As ​ shows, the first outer cover 90 or the second outer cover 92 can comprise a compliant fabric layer.

[0076] Similarly, as ​As shown, a third outer cover 94 or a fourth outer cover 96 (not shown, but having a structure as ​ shown) can be provided instead of the mattress layer. In this case, the third outer cover 94 and the fourth outer cover 96 are not adhered to the adjacent air-impermeable layers (54 and 56 respectively), but remain unbonded as potential detachable or replaceable outer covers. In other words, in this embodiment, there is no third bonding layer 74 on the outer side 54 of the first air-impermeable layer 54, and there is no fourth bonding layer 76 on the outer side 56 of the second air-impermeable layer 56. In any case, as X shown, the third outer cover 94 or a similar fourth outer cover 96 can include an elastic stretchable fabric, such as a spandex-type fabric. X In various embodiments, the materials of the outer mattresses (80, 82 and 84, 86) comply with the flame retardant requirements specified by the U.S. Flammable Fabrics Act (Parts 1191 to 1204 of Title 15 of the United States Code). In various embodiments, the materials of the outer mattresses (80, 82 and 84, 86) comply with the cigarette ignition requirements specified by the U.S. Federal Flammability Standard (Part 1632 of Title 16 of the United States Code). In various embodiments, the materials of the outer mattresses (80, 82 and 84, 86) comply with the mattress open flame requirements specified by the U.S. Federal Flammability Standard (Part 1633 of Title 16 of the United States Code). ​ As

[0077] shown, the materials of the outer covers (90, 92 and 94, 96) comply with the flame retardant requirements specified by the U.S. Flammable Fabrics Act (Parts 1191 to 1204 of Title 15 of the United States Code). In various embodiments, the materials of the outer covers (90, 92 and 94, 96) comply with the cigarette ignition requirements specified by the U.S. Federal Flammability Standard (Part 1632 of Title 16 of the United States Code). In various embodiments, the materials of the outer covers (90, 92 and 94, 96) comply with the mattress open flame requirements specified by the U.S. Federal Flammability Standard (Part 1633 of Title 16 of the United States Code).

[0078] As

[0079] shown, in various embodiments of the collapsible bed 502, X polyurethane foam segments N form a stack S of polyurethane foam segments N1 to N along the length L of the self-inflating bed, where X is a positive integer; as ​ and ​ shown, which includes segments N1 to N4. In X this, these inner portions of the polyurethane foam are also denoted by reference numerals 581, 582, 583 and 584, applicable to the respective inner portions of the polyurethane foam. Each polyurethane foam segment N ​ and ​ shown, where including segments N1 to N4. In ​ these, these inner portions of the polyurethane foam are also denoted by reference numerals 581, 582, 583 and 584, applicable to the respective inner portions of the polyurethane foam. Each polyurethane foam segment N Xcan be fixed to the first adhesive layer and the second adhesive layer. One or more of the polyurethane foam segments, segment N (such as ​ and ​ shown, the four segments N1 to N4) have an inner or core portion for a collapsible bed and can thus be provided by the polyurethane foam design (either by selection and curing of the compound components or by the presence of cuts in the polyurethane foam as described elsewhere herein), which has a 25% indentation hardness (IFD) of from about 6 pounds force to about 20 pounds force measured according to ASTM standard D3574. In various embodiments, the inner portion of the polyurethane foam can have a 25% indentation hardness (IFD) of from about 10 pounds force to about 19 pounds force measured according to ASTM standard D3574. In such a multi-foam configuration (e.g., as shown in ​ or ​ ), one option is to provide low IFD foam in segment N1, medium IFD foam in segment N2, low IFD foam in segment N3, and medium or low IFD foam in segment N4.

[0080] Also as shown in ​ and ​ , the stack S of polyurethane foam segments has an outer perimeter P and extends inwardly from the outer perimeter P along the first side 100 or the second side 102 or both and has an edge portion 60. At least a portion of the edge portion 60 uses a polyurethane foam layer having a 25% indentation hardness of from about thirty-five (35) pounds force to about fifty (50) pounds force measured according to ASTM standard D3574. In one embodiment, the edge portion 60 can extend inwardly along the first side 100 or the second side 102 a distance E of at least three (3) inches. In one embodiment, the edge portion 60 can extend inwardly a distance E within the range of from about three (3) inches to about five (5) inches.

[0081] Now referring to ​ , ​ and ​ , an embodiment of the design of a collapsible bed 504 is depicted, which includes a single polyurethane foam inner portion (i.e., only N1). However, the inner portion has such a configuration that at least some portions of the single N1 portion include a cutout portion C defined by an inner edge wall, and the cutout portion C is characterized by the absence of polyurethane foam in the cutout portion C. Where, as shown in ​ , ​ and ​ , the cutout portion can extend generally vertically, and the inner edge wall is represented by reference numeral C V .

[0082] As shown in ​ , ​ and​ As shown, in an embodiment of the collapsible bed 506, a portion (or all - not shown, but for example, similar to ​ and ​ , and having no cut - out portion in the edge portion 60) of the cut - out portion C may extend generally horizontally. In this case, the reference numeral C H is used to denote the inner edge wall described therein. Further, in some embodiments, as ​ shown, there may be a cut - out portion C that extends generally vertically (defined by the inner edge wall C V ) and a cut - out portion C that extends generally horizontally (defined by the inner edge wall C H ). Further, also as ​ and ​ shown, a plurality of polyurethane foam segments N1 to N along the length L of the self - inflating bed X may be used in combination with the cut - out portion. Four polyurethane foam segments, namely N1 to N4, are shown in ​ and ​ . Three polyurethane foam segments, namely N1, N3, and N4, are shown with cut - out portions, while the fourth segment N2 has no cut - out portion, as ​ shown. As shown, some or all of the polyurethane foam segments in the stack S along the length L of the collapsible bed (e.g., bed 506) may be of different polyurethane foam compositions. Alternatively, all of the various polyurethane foam compositions in the stack S along the length L of the collapsible bed may have the same polyurethane foam composition. And, there may be an improved edge portion 601 having a cut - out portion C defined by an inner edge wall portion C V , wherein the cut - out portion C is characterized by the absence of polyurethane foam in the cut - out portion C.

[0083] Referring to ​ , ​ is a plan view of a horizontal cross - section of an embodiment of the collapsible bed 50 looking down along line 18 - 18 of ​ , which shows the use of a single polyurethane foam inner portion 58 having a uniform composition and structural properties, but a high - indentation - hardness - rated edge portion 60, and shows the proper positions of the vacuum valve 62 and the comfort - hardness regulating valve 64. ​ Similar, but looking down from above and partially removing the first air - impermeable layer 54 to expose the single polyurethane foam inner portion 58.

[0084] In ​ , a vertical cross - sectional view taken along line 19 - 19 of ​ is shown, which shows how a single uniform polyurethane foam core 58 is used in combination with the high - indentation - hardness edge portion 60.

[0085] Referring to​ and ​ , which shows a double - bed size embodiment of the collapsible bed 110, and wherein both the left side 112 and the right side 114 have edge portions (left edge portion 116 and right edge portion 118) which have a higher indentation hardness specification than the core 158 of a single uniform polyurethane foam. For this embodiment as the collapsible self - inflating bed 50, it is provided with the first air - impermeable layer 540 and the second air - impermeable layer 560 as described above.

[0086] ​ and ​ shows an embodiment of the collapsible bed 120, similar to ​ the embodiment first shown, but here shows a double - bed design, in which along the length L of the bed, separate polyurethane foam inner sections N1, N2, N3, and N4 with different structural properties (see the shading differences in ​ ) i.e., different indentation hardness specifications are used, and the left edge portion 116 and the right edge portion 118 have a higher indentation hardness specification than the inner sections. As ​ and ​ shown, the standard width of the double - bed configuration can be in the range of width W from 38 inches to 58 inches, and the length L is from about 72 inches to about 80 inches.

[0087] Referring to ​ and ​ , two different embodiments of the collapsible bed are shown, i.e., ​ the bed 200 in ​ and a plan view of a partial horizontal cross - section of the collapsible bed 202 in ​ The design of the collapsible double - bed 200 in 1A and N 1B uses a uniform polyurethane foam composition. Alternatively (not shown by shading), the polyurethane foam compositions for the cores N 1A and N 1B can be different. In addition, the design of the collapsible double - bed 200 incorporates the use of two high - indentation hardness left and right edge portions 116 and 118. In addition, a plurality of compartments are jointly defined by the internal air - impermeable partitions 180 and the first and second air - impermeable layers as described above. The use of a plurality of compartments, here the pressure envelopes (pressure envelope) P1 and pressure envelope P2, provides a design in which each pressure envelope (e.g., P1, P2, etc.) can be independently adjusted by a hardness regulating valve 64, and the hardness regulating valve can be provided in each pressure envelope P1, P2, etc. as shown, or alternatively between the pressure envelopes.

[0088] ​is a plan view looking down at an embodiment of a foldable double bed 202 design wherein the upper first airtight layer 54 is partially removed to reveal separate polyurethane foam sections (N) having different indentation hardness specifications that may be used along the length L of the foldable double bed 202. 1A and N 1B 、N 2A and N 2B 、N 3A and N 3B and N 4A and N 4B ). Similar to ​ The configuration described, in the foldable double bed 202 design, uses multiple compartments defined by the internal airtight partition 182 to provide a pressure envelope P1 and a pressure envelope P2, wherein each pressure envelope (e.g., P1, P2, etc.) can be independently adjusted by a hardness adjustment valve 64, which can be provided within each pressure envelope P1, P2, etc. as shown, or alternatively provided between the pressure envelopes (see valve 64 shown in dashed lines). A In one embodiment, a self-inflating mattress having at least two self-inflating chambers may be provided, wherein a hardness adjustment valve 64 is provided between two of the at least two self-inflating chambers. In one embodiment, the hardness adjustment valve 64 may be configured to allow one-way air flow between the self-inflating chambers (e.g., pressure envelopes P1 and P2). In various embodiments, the hardness adjustment valve 64 may be a manually adjustable structure. Alternatively, the hardness adjustment valve 64 may be a self-adjusting structure.

[0089] Reference ​ 、 ​ and ​ , and ​ The construction is similar to that described in , but here an embodiment of a double bed 204 design of a foldable bed is shown. Along the length of the double bed 204, a polyurethane foam having uniform structural properties and composition is provided, but wherein different locations along the length of the bed have different indentation hardness specifications. As shown in the figure, at the upper bed position 204 U and lower bed position 204 L In the middle, by the inner edge wall C V The configuration is mechanically formed by removing the vertically oriented wadding of the foam cutouts C at defined selected locations.

[0090] exist ​ and ​ A foldable double bed 206 that implements an alternative structure that provides variable firmness to the user is shown in FIG. In this design, the polyurethane foam inner core portion N1 has uniform structural properties and composition along the length L of the foldable bed 206, but varies in size at the upper position 206. U and lower position 206 LIn which, different indentation hardness specifications are provided by removing the foam at the horizontally oriented cut-out portion C at a selected position defined by the inner edge wall portion C as shown in the figure. In addition, the illustrated left edge portion 116 has a vertically oriented cut-out portion C defined by the inner edge wall portion C, which is also used to adjust the indentation hardness specifications of the selected lengths of the edge portions, such as 116 and 118. H Referring to V which describes various items helpful in providing a collapsible bed.

[0091] Figure ​ is a cross-sectional view showing the use of an adapter 300 connected to a vacuum valve 62 so that a vacuum source 290 such as a household vacuum cleaner or a commercially available vacuum cleaner (the illustrated hose end 302 and flexible hose 304) can be used to evacuate an inflated collapsible bed (such as beds 50, 200, 202, etc.) to shrink the bed (typically 50, 200, 202, etc. and the like) for storage. In one embodiment, the vacuum valve 62 has an inner diameter D of about one inch (1”) or greater. ​ In one embodiment, the vacuum valve 62 can be a p, the inner diameter D of which I is between about one inch (1”) and about two inches (2”). More generally, a self-inflating bed has self-inflating chambers, each with a vacuum valve, and the vacuum connection ports are sized and shaped to fit a household vacuum device. By evacuating through the vacuum valve, the self-inflating bed can be deflated. I Once the size of the collapsible bed has been reduced by evacuating the pressure chambers (P1, P2, etc.), the vacuum port valve 62 is closed to prevent air from entering and re-inflating the bed (50, etc.), and the bed can be rolled up for storage.

[0092] Figure ​ shows a collapsible structure 50R of the bed (50, etc.) in a deflated state that has been rolled up and can be easily inserted into a transport box 400 as shown by the reference arrow 402.

[0093] In one embodiment, as ​ shown, two separate self-inflating beds 450 and 452 can be mirror-configured. In this way, beds 450 and 452 can be connected along parallel zipper portions Z 450 and Z 452 (for example, connecting the zipper portion on bed 450 to the zipper portion on bed 452). In this embodiment, a dual-custom storage / transport bag 460 (as an alternative to box 400, see ​) which houses a vacuum compressed single bed approximately 80 inches long (i.e., the size of a normal Queen bed, but the length can range from about 72 inches to about 80 inches), and then allows it to be folded in half so that each single bed 450 and 452 can be easily carried or stored as a bundle 40 inches wide. Thus, the user can create such a 40-inch-wide bundle that is both easy for an ordinary person to carry and can be transported through the guidelines of the standard United Parcel Service (UPS, see: https: / / www.ups.com / us / en / Home.page) regarding length and perimeter. A second carrying bag (not shown) can be provided, which is designed to carry the entire outer cover of such a bed under similar functional carrying or transportation conditions.

[0094] The above detailed description provides structural details and other requirements that apply to foldable beds in order to provide a higher level of performance for the end user / consumer over the expected lifespan (in the industry, currently considered to be at least 10 years) as required for a household bed. Due to the bonding requirements of the open-cell polyurethane foam inner part, various polyurethane coatings, films or extrusions generally must be provided in relatively thin gauges, for example, between about 1 mil and about 4 mil, only for the bonding layer as described above. In addition, the airtight layer can generally be crosslinked or can be made of a polyurethane coating or film / extrusion material with a higher melting temperature, also in a relatively thin gauge, for example between about 2 mil and about 5 mil. In addition, additional requirements for the polyurethane required to manufacture a product that consumers will accept include selecting suitable ingredients to prevent degradation due to humidity. And it is appropriate to carefully select the elongation properties of the materials used so that the selected materials have sufficient elasticity such that the mattress provided by the self-inflating bed described herein will conform to the user's body, thereby reducing the pressure exerted on the user at high-pressure points. It is worth noting that this factor is also the reason for keeping the thickness (material gauge) used in the construction to a minimum, which is actually an ideal way to improve the elongation properties.

[0095] In addition, the core portion of the polyurethane foam may need to have precise requirements. In most embodiments, two different grades of polyurethane foam compositions may be required to achieve the selected indentation hardness properties. One of the reasons for using multiple grades is related to the physical properties of compressing the polyurethane foam using a small vacuum device. Also, the physical principles of the compression of polyurethane foam by the human body must be understood. As mentioned above, IFD (Indentation Hardness) is a common measure of how many pounds of force are required to provide a specified percentage of compression (usually 25% or 50% in the test). In an exemplary embodiment, it is believed that a maximum limit of about 20 lbs IFD is preferred. This is because the above IFD specification will cause most foams to support the body without airbag assistance. Also, when the IFD of the inner core portion of the bed exceeds this limit, it is generally found that for a person of normal body type or a household vacuum device, the force required to achieve sufficient compression is too large for adjustability and storage.

[0096] In addition, since the inner core of the bed is filled with "soft" foam, the exemplary design needs to address the high-load situations that occur every night and morning, that is, the situation where we all sit on the edge of the bed. Therefore, in order to gain consumer acceptance, it must be addressed that sitting on the edge of a bed with a soft and compliant airbag is comfortable, but it compresses too easily at the outer edge and causes the user to slip off the bed, which of course is not a good feature. Therefore, to overcome this shortcoming of the prior art design, a foam with a higher IFD (e.g., in the range of 35 to 50 pounds of force) should be used along the outer edge of the bed. In one embodiment, a suitable width is between about three inches and about five inches.

[0097] Even with a more rigid edge portion, the design provided here offers a softer foam in the inner portion for the user to feel comfortable and easy to compress. And, as mentioned above, various embodiments can be provided to further divide the main soft and compressible foam inner or core portion. Such variations can be adapted to different users, for example, according to size, weight or height, or just for the comfort of the user, which is a subjective criterion. However, the variations described here allow the user or consumer to choose a design that can better match the comfort sensitivity and support requirements of a particular individual. One option could be to provide an inner foam with an IFD range from about 6 pounds of force to about 9 pounds of force. Also, the design as described above can also mimic this fine "body mapping" method by mechanically removing small pieces of foam, which can reduce the overall IFD in specific areas along the length of the bed.

[0098] In various embodiments, the internal foam portion is provided as an integral unit in the vertical direction, i.e., in the direction of user compression. In the designs disclosed herein, an air-assisted foam core is used, where the foam core serves as a tensile member. This means that when a user lies on a portion of the provided pressure chamber, the surrounding area is under tensile pressure, and thus the air inside tries to expand outward to other areas, but the fully bonded foam core holds the bed together.

[0099] In an exemplary embodiment, for the described self-inflating collapsible bed design, the valve requirements are very specific. As mentioned above, a vacuum port is required, and its size and shape should be such that it can match common household devices. Maintaining a large-diameter opening, such as having an inner diameter of at least one inch, is ideal for the inflation / deflation speed when folding up or re-spreading the bed. The upper size limit of the most common household devices is within the inner diameter size range of 1.5 inches to about 2 inches for vacuum connections.

[0100] Furthermore, a fine pressure regulation or hardness valve function is key to enabling each user to adjust the hardness of their own mattress. In one embodiment, this function can be automated by using a check valve with preset pressure settings for fine-tuning. In one embodiment, if desired, any or all of the vacuum, hardness adjustment, or automatic hardness adjustment can be provided through a single valve design.

[0101] The specific requirements for the outer mattress and cover must also be carefully addressed. While at first glance the goal is to make the designs described herein look very similar to using a traditional mattress and mattress cover, some specific requirements should be followed to achieve the above-mentioned specific performance. A key feature is that the user needs easy access to the vacuum valve and the hardness adjustment valve. The selected valve positions should be convenient for the user to locate as needed, but should not appear obtrusive or annoying when the bed is in use. Another important requirement for the bed design is good breathability and moisture absorption. In the various designs provided herein, the mattress may bear the entire load, so special attention must be paid when selecting materials, because an airtight bag under the mattress is neither breathable nor moisture-absorbent. Also, the top layer of the outer mattress or cover is elastic, providing the best results for the required compliance and comfort. Finally, the mattress must meet the applicable fire retardant requirements specified by the industry while avoiding interfering with the valve inlet or the compliance of the top surface.

[0102] Finally, in one embodiment, the dual-custom storage / transport bag accommodates a vacuum-compressed twin bed that is approximately 80 inches long (i.e., a typical Queen bed size, but the length can range from about 72 inches to about 80 inches), and then allows it to be folded in half so that two parallel zippers (i.e., the zipper portions on each half) create a 40-inch bundle that is convenient for an average person to carry and can also be shipped via the standard United Parcel Service guidelines for length and girth. The features described in detail herein provide a novel collapsible self-inflating bed design that provides a product that can be easily and economically shipped to consumers, can be easily moved into or out of one's home, or can be easily returned to the dealer for warranty or other reasons. Finally, large retailers will want such an easily-packaged product as described herein because the product can easily fit into existing shelving systems, takes up minimal space, and promotes customer self-service.

[0103] In the foregoing description, for purposes of explanation, numerous details have been set forth in order to provide a thorough understanding of the disclosed exemplary embodiments of the self-inflating collapsible bed design. However, certain of the details recited may not be required to provide a useful embodiment, or to practice the selected or other disclosed embodiments. Additionally, for descriptive purposes, various related terms may be used. Terms that are relevant only for reference purposes should not be construed as absolute limitations, but are included in the foregoing description to facilitate understanding of the various aspects of the disclosed embodiments. Also, the various acts or actions in any method described herein may be described as a number of separate acts in a manner that is most helpful in understanding the invention. However, the order of the acts described should not be construed as implying that such acts necessarily depend on the order. In particular, certain operations may not necessarily need to be performed precisely in the order presented. And, in different embodiments of the invention, one or more acts may be performed simultaneously, or one or more acts may be partially or fully removed while other acts may be added. Additionally, the reader will note that the phrase "in one embodiment" or "in an embodiment" has been used repeatedly. This phrase generally does not refer to the same embodiment; however, it may refer to the same embodiment. Finally, unless the context dictates otherwise, the terms "comprising," "having," and "including" should be regarded as synonyms.

[0104] Those skilled in the art will understand that the various embodiments of the self-inflating bed design are described herein only to the extent suitable for a person skilled in the art to manufacture and use the self-inflating bed. Those skilled in the art can develop other details for a selected set of specifications, service life, structural materials, and other design criteria.

[0105] Importantly, the aspects and embodiments described and claimed herein can be modified without materially departing from the novel teachings and advantages provided, and can be embodied in other specific forms without departing from their spirit or essential characteristics. Accordingly, the embodiments presented herein are to be considered illustrative in all respects and not restrictive or limiting. Thus, the present invention is intended to cover the structures described herein, including not only structural equivalents but also equivalent structures.

[0106] Although only certain specific embodiments of the present invention have been shown and described, the present invention is not limited to these embodiments. Rather, when taken in conjunction with the specification, the present invention is defined by the appended claims and their equivalents.

[0107] In view of the foregoing teachings, various modifications and variations can be made to the present invention. Accordingly, the protection provided for the present invention should be limited only by the claims described herein and their legal equivalents.

Claims

1. A self-inflating bed with a length of L, comprising: one or more self-inflating chambers, each of the self-inflating chambers being formed between a first air-impermeable layer and a second air-impermeable layer, the first air-impermeable layer and the second air-impermeable layer each comprising a thermoplastic material having an inner side and an outer side, and the thermoplastic material having a thickness T between 2 mils and 5 mils; a first adhesive layer adhered to an inner side of the first air-impermeable layer, and a second adhesive layer adhered to an inner side of the second air-impermeable layer, each of the first adhesive layer and the second adhesive layer comprising an extruded adhesive composition having a final thickness B between 1 mil and 4 mils; as well as X polyurethane foam segments N are located between the first air-impermeable layer and the second air-impermeable layer, and a series of foam segments N1 to N2 are formed along the length L of the self-inflating bed. X A stack S of polyurethane foam segments is formed, wherein X is a positive integer, and wherein the polyurethane foam segments N X each of which is adhered to the first adhesive layer and the second adhesive layer, and wherein the one or more segments N of the polyurethane foam segments include an inner portion having a 25% indentation hardness from 6 lbf to 20 lbf measured according to ASTM Standard D3574; wherein, in the one or more self-inflating chambers, the stack S of polyurethane foam segments has an outer periphery and an edge portion extending outwardly from and adjacent to the outer periphery, and wherein at least a portion of the edge portion comprises a polyurethane foam layer having a 25% indentation hardness of from 35 lbf to 50 lbf as measured according to ASTM Standard D3574, Each of the one or more self-inflating chambers further includes a vacuum valve having a vacuum connection port, the vacuum connection port being configured to close during use to contain air within the one or more self-inflating chambers, to open during inflation to allow the self-inflating chambers to draw air through the vacuum connection port, and to open during deflation, wherein the vacuum connection port is sized and shaped to connect to a vacuum device so that the self-inflating mattress can be deflated by drawing a vacuum through the vacuum valve, and At least one of the one or more self-inflating chambers further comprises a comfort adjustment valve, wherein the comfort adjustment valve is configured to be adjusted by a user to change the hardness of the self-inflating mattress.

2. The self-inflating mattress according to claim 1, wherein The edge portion extends inwardly from the periphery a distance E of at least 3 inches.

3. The self-inflating mattress according to claim 1, wherein The edge portion extends inwardly from the periphery a distance E in the range of 3 inches to 5 inches.

4. The self-inflating mattress according to claim 1, wherein The edge portion of the polyurethane foam has a 25% indentation hardness of from 35 lbf to 50 lbf as measured according to ASTM Standard D3574.

5. The self-inflating mattress according to claim 1, wherein The interior portion of the polyurethane foam has a 25% indentation hardness from 10 lbf to 19 lbf as measured according to ASTM Standard D3574.

6. The self-inflating mattress according to claim 1 or 5, wherein: The inner portion includes at least a portion of the polyurethane foam segments N1 to Nx, the portion including a cutout portion defined by an inner edge wall portion, the cutout portion being characterized in that polyurethane foam is absent in the cutout portion.

7. The self-inflating mattress according to claim 1, wherein: The first adhesive layer or the second adhesive layer or both include polyurethane.

8. The self-inflating mattress according to claim 1, wherein: At least one of the polyurethane foam sections comprises open-cell polyurethane foam.

9. The self-inflating mattress according to claim 1, wherein: The self-inflating mattress includes at least two self-inflating chambers, and further includes a hardness adjustment valve between two of the at least two self-inflating chambers, the hardness adjustment valve allowing one-way flow of air between the self-inflating chambers.

10. The self-inflating mattress according to claim 1, wherein The vacuum connection port has an inner diameter of 1 inch or greater.

11. The self-inflating mattress according to claim 1, wherein: The inner diameter of the vacuum connection port is between 1 inch and 2 inches.

12. The self-inflating mattress according to claim 9, wherein The hardness regulating valve is manually adjustable.

13. The self-inflating mattress according to claim 9, wherein: The hardness regulating valve is automatically regulated.

14. The self-inflating mattress of claim 1, further comprising an outer mattress comprising an elastic stretchable fabric.

15. The self-inflating mattress of claim 14, wherein: The outer mattress meets the flame retardant requirements of the United States Flammable Fabrics Act, 15 U.S.C. Parts 1191 through 1204.

16. The self-inflating mattress of claim 14, wherein: The outer mattress meets the cigarette ignition requirements of the United States Federal Flammability Standard as set forth in Title 16, United States Code, Part 1632.

17. The self-inflating mattress of claim 14, wherein: The outer mattress complies with the open flame requirements for mattresses as set forth in the United States Federal Flammability Standard of Title 16, United States Code, Part 1633.

18. The self-inflating mattress of claim 14, further comprising a cover comprising an elastic stretchable fabric.

19. The self-inflating mattress of claim 18, wherein: The outer cover complies with the flame retardant requirements of the United States Flammable Fabrics Act, 15 U.S.C. Parts 1191 to 1204.

20. The self-inflating mattress of claim 18, wherein The housing complies with the cigarette ignition requirements of the United States Federal Flammability Standard as set forth in Title 16 of the United States Code, Part 1632.

21. The self-inflating mattress of claim 18, wherein: The cover complies with the open flame requirements for mattresses as set forth in the United States Federal Flammability Standard, 16 United States Code, Part 1633.

22. A self-inflating bed with a length of L, comprising: one or more self-inflating chambers, each of the self-inflating chambers being formed between a first air-impermeable layer and a second air-impermeable layer, the first air-impermeable layer and the second air-impermeable layer each comprising a thermoplastic material having an inner side and an outer side, the first air-impermeable layer and the second air-impermeable layer each comprising a material selected from the group consisting of a) a woven fabric, b) a nonwoven fabric, c) a knitted fabric, and d) a polyvinyl chloride sheet, or e) a flexible polymer or copolymer plastic sheet; a first adhesive layer adhered to an inner side of the first air-impermeable layer, and a second adhesive layer adhered to an inner side of the second air-impermeable layer, each of the first adhesive layer and the second adhesive layer comprising an extruded adhesive composition having a final thickness B between 1 mil and 4 mils; X polyurethane foam segments N are located between the first air-impermeable layer and the second air-impermeable layer, and a series of foam segments N1 to N2 are formed along the length L of the self-inflating bed. X A stack S of polyurethane foam segments is formed, wherein X is a positive integer, and wherein the polyurethane foam segments N X each of which is adhered to the first adhesive layer and the second adhesive layer, and wherein the one or more segments N of the polyurethane foam segments include an inner portion having a 25% indentation hardness from 6 lbf to 20 lbf as measured by ASTM Standard D3574, wherein, in the one or more self-inflating chambers, the stack S of polyurethane foam segments has an outer periphery and an edge portion extending outwardly from and adjacent to the outer periphery, At least one of the one or more self-inflating chambers further comprises a vacuum valve having a vacuum connection port, wherein the vacuum connection port is sized and shaped to be connected to a vacuum device, so that the self-inflating mattress can be deflated by drawing a vacuum through the vacuum valve, and At least one of the one or more self-inflating chambers further comprises a comfort adjustment valve, wherein the comfort adjustment valve is configured to be adjusted by a user to change the hardness of the self-inflating mattress.

23. The self-inflating mattress of claim 22, wherein at least a portion of the edge portion comprises a polyurethane foam layer having a 25% indentation hardness of from 35 lbf to 50 lbf as measured according to ASTM Standard D3574.

24. The self-inflating mattress of claim 23, wherein: The edge portion extends inwardly from the periphery a distance E of at least 3 inches.

25. The self-inflating mattress of claim 23, wherein: The edge portion extends inwardly from the periphery a distance E in the range of 3 inches to 5 inches.

26. The self-inflating mattress of claim 23, wherein: The edge portion includes one or more polyurethane foam portions, and wherein the one or more polyurethane foam portions vertically have a 25% indentation hardness of from 35 lbf to 50 lbf as measured according to ASTM Standard D3574.

27. The self-inflating mattress of claim 22, wherein: At least one of the polyurethane foam sections each comprises open-cell polyurethane foam.

28. The self-inflating mattress of claim 22, wherein: The inner portion has a 25% indentation hardness from 10 lbf to 19 lbf as measured according to ASTM Standard D3574.

29. The self-inflating mattress of claim 28, wherein: The polyurethane foam segments in the stack S have the same 25% indentation hardness.

30. The self-inflating mattress of claim 22 or 29, wherein: The inner portion includes at least a portion of the polyurethane foam segments N1 to Nx, the portion including a cutout portion defined by an inner edge wall portion, the cutout portion being characterized in that polyurethane foam is absent in the cutout portion.

31. The self-inflating mattress of claim 22, wherein: The first adhesive layer or the second adhesive layer or both comprise polyurethane.

32. The self-inflating mattress of claim 22, further comprising an outer mattress comprising an elastic stretchable fabric.

33. The self-inflating mattress of claim 32, wherein: The outer mattress meets the flame retardant requirements of the United States Flammable Fabrics Act, 15 U.S.C. Parts 1191 through 1204.

34. The self-inflating mattress of claim 32, further comprising a cover comprising an elastic stretchable fabric.

35. The self-inflating mattress of claim 34, wherein: The outer cover complies with the flame retardant requirements of the United States Flammable Fabrics Act, 15 U.S.C. Parts 1191 to 1204.

36. The self-inflating mattress of claim 35, wherein: The stack S of polyurethane foam inner sections has an outer periphery, and an outer ring portion extending outward from the outer periphery, and wherein at least a portion of the outer ring portion comprises one or more layers N of polyurethane foam having a 25% indentation hardness of from 35 lbf to 50 lbf as measured according to ASTM standard D3574.

37. The self-inflating mattress of claim 36, wherein: The outer ring portion extends outwardly from the outer periphery a distance E of at least 3 inches.

38. The self-inflating mattress of claim 37, wherein: The outer ring portion extends outwardly from the outer periphery a distance E in the range of 3 inches to 5 inches.

39. The self-inflating mattress of claim 1 or claim 22, further comprising: A third bonding layer adhered to the outer side of the first air-impermeable layer, the third bonding layer comprising an extrusion bonding composition having a final thickness B between 1 mil and 4 mils.

40. The self-inflating mattress of claim 1 or claim 22, further comprising: A fourth bonding layer adhered to the outer side of the second air-impermeable layer, the fourth bonding layer comprising an extrusion bonding composition having a final thickness B between 1 mil and 4 mils.

41. A self-inflating air mattress, comprising: The first self-inflating mattress of claim 1 , wherein the first self-inflating mattress comprises a first outer edge portion and a first inner edge portion along a side opposite to the first outer edge portion, the first inner edge portion further comprising a first zipper portion; A second self-inflating bed according to claim 1, wherein the second self-inflating bed is configured as a mirror image of the first self-inflating bed, the second self-inflating bed further comprising a second inner edge portion, the second inner edge portion further comprising a second zipper portion; in, The first zipper portion and the second zipper portion are configured as complementary zipper portions such that the first zipper portion and the second zipper portion can be connected together to connect the first self-inflating mattress with the second self-inflating mattress.

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