Radio frequency welding technology for coining pattern on drawsheet material

Abstract

A system includes a patient support surface including: a patient support surface including a core; a drawsheet covering the core; and the radio frequency welding equipment and the mold are used for coining the coining base material layer to the surface of the drawsheet so as to form a three-dimensional structure determined by the mold. The drawsheet is provided with a first surface opposite to the core body and a second surface facing the core body, and a three-dimensional structure is formed on the second surface.

Description

[0001] Related Applications

[0002] This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 63 / 393,014, filed on July 28, 2022, which is expressly incorporated herein by reference. Technical Field

[0003] The present disclosure relates to embossing a pattern on the surface of a sheet covering a core using welding techniques. More specifically, the present disclosure relates to a system and method for embossing or debossing a pattern on a covering material. Background Art

[0004] The sheet is made of a material that covers and / or protects a core that includes a mattress for a patient support device. Graphics or labels embossed on the sheet can be used by the user or caregiver to identify the sheet features. There are a variety of methods for applying graphics and / or labels to the surface of a sheet. Typical methods of embossing graphics include screen printing or digital printing. Such methods are not always effective and can be costly.

[0005] In view of this, it is urgent to develop novel systems and methods to improve the cost-effectiveness and convenience of applying graphics and / or labels to the surface of a sheet. The present disclosure relates to using a radio frequency welding device to emboss graphics and / or labels onto the surface of a sheet. Summary of the invention

[0006] The present disclosure includes one or more of the appended claims and / or the following features, which alone or in any combination may comprise patentable subject matter.

[0007] According to a first aspect of the present disclosure, a system includes a patient support surface, including: a patient support surface including a core; a sheet covering the core, the sheet having a first surface and a second surface, the first surface facing away from the core and the second surface facing the core; and a radio frequency (RF) welding device and a mold for embossing an embossed substrate layer applied to the second surface of the sheet. The sheet forms a three-dimensional structure determined by the mold.

[0008] The core may be a mattress having a plurality of inflatable zones. The first surface of the sheet may be polyurethane and the second surface of the sheet may be nylon. The embossed substrate is a thermoplastic substrate or a thermoplastic coated substrate.

[0009] The first surface may include polyurethane, the second surface may include nylon, and the three-dimensional structure may include an embossed substrate layer, a nylon layer, and a polyurethane layer.

[0010] The mold may include a graphic design, and the three-dimensional structure formed by the mold may include the same graphic design. The three-dimensional structure may include an additional color layer or foil layer. The additional color layer may include a thermoplastic substrate or a thermoplastic coated substrate.

[0011] According to a second aspect of the present disclosure, a cover for a patient support surface may include: a first surface and a second surface opposite to the first surface; an embossed substrate layer coated on the second surface of the cover; and a three-dimensional structure embossed on the cover. The three-dimensional structure may include the embossed substrate layer.

[0012] The cover may cover the core of the patient support device. The first surface of the cover may be polyurethane, and the second surface of the cover may be nylon. The embossed substrate may be a thermoplastic substrate or a thermoplastic coated substrate.

[0013] The three-dimensional structure may include an embossed substrate layer, a nylon layer, and a polyurethane layer.

[0014] Radio frequency welding equipment and molds can be used to emboss the three-dimensional structure onto the cover. The three-dimensional structure may include an additional color layer or foil layer on the first surface.

[0015] According to a third aspect of the present disclosure, a method for coating a three-dimensional structure onto a sheet includes the following steps: selecting a radio frequency (RF) welding device; selecting a mold compatible with the RF welding device; positioning a first side of the sheet that is not in contact with a core of a patient support surface and a second side of the sheet that is in contact with a core of the patient support surface; coating an embossed substrate layer onto the second side of the sheet; pressing the mold onto the embossed substrate; and manually or automatically activating the RF welding device.

[0016] The method may include using an embossed substrate, which is a thermoplastic substrate or a thermoplastic coated substrate. The method may include forming a three-dimensional structure determined by a mold. The method may also include applying a color layer or a foil layer to the three-dimensional structure. The additional color layer on the first surface includes a thermoplastic substrate or a thermoplastic coated substrate.

[0017] Additional features (including those listed above and / or those listed in the claims) may constitute patentable subject matter alone or in combination with any other features, and these additional features will become apparent to those skilled in the art from the detailed description of the following exemplary embodiments illustrating the best way to implement the disclosed embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The following is a detailed description with reference to the accompanying drawings, in which:

[0019] Figure 1 is a schematic diagram of a core body covered by a sheet according to the present disclosure;

[0020] Figure 2It is a schematic diagram of a double-layer mattress sheet;

[0021] Figure 3 A perspective view of a patient support device including a mattress covered by a sheet;

[0022] Figure 4 is a schematic diagram of a pad having an embossed pattern on the top side;

[0023] Figure 5 A schematic diagram of a pad having an embossed pattern on one side surface;

[0024] Figure 6 For creating Figure 4 A schematic diagram of a mold for embossing a pattern shown;

[0025] Figure 7 A schematic diagram of a radio frequency device for embossing a pattern on a pad;

[0026] Figure 8 A step-by-step diagram of a method for implementing the imprinted graphics on a mat sheet. DETAILED DESCRIPTION

[0027] Figure 1 Schematic diagram of a sheet 10 is shown. The sheet 10 is used to cover the core 20 and may include one or more layers of material. Figure 2 As shown, the sheet includes a nylon lower layer 12 and a polyurethane upper layer 14.

[0028] like Figure 3 As shown, the core 20 covered by the sheet 10 may be a mattress 20 on a patient support device 30. The patient support device 30 is embodied as a hospital bed. Figure 2 The bed 30 in the embodiment includes a frame 32 supporting a mattress 20. The mattress 20 is covered with a sheet 10.

[0029] The sheet 10 can be used to cover a core 20, which can include an inflatable pressure zone or other filler, such as foam. The core 20 can include a variety of core materials, such as the core materials disclosed in U.S. Pat. No. 11,135,110, entitled "PATIENT SUPPORT APPARATUS," which is incorporated herein, and discloses examples of core structures that can cover the sheet 10. The core can be used in patient support devices, including but not limited to beds, chairs, wheelchairs, operating tables, and changing tables.

[0030] The sheet 10 may include one or more embossed graphics or labels. A user or caregiver may use the embossed graphics or labels on the sheet 10 to identify features of the sheet 10 and / or the core 20. Figures 3 to 5As shown, the drape 10 may include embossed graphics 24, 26 on one or more surfaces. The embossed graphics 24, 26 are three-dimensional structures added to the drape 10 to convey information to the patient or caregiver. The embossed graphics 24, 26 may represent a product name, instructions for use, a specific location (e.g., an X-ray cuff location), etc.

[0031] Figure 6 Shows the method used to create Figure 4 A mold 50 for embossing a pattern 24 is shown. Figure 7 A typical radio frequency device 52 for creating the embossed pattern 24, 26 is shown. The embossed pattern 24, 26 is applied by using a radio frequency (RF) welding technique that uses the radio frequency welding device 52 and a mold 50. The structure of the embossed pattern 24, 26 is determined by the mold 50. The radio frequency welding device 52 creates the embossed pattern 24, 26 by applying radio frequency energy to an area of ​​the sheet 10 when creating the embossed pattern 24, 26. A high frequency electromagnetic field is applied between two metal strips 54, 56, which are also used to apply pressure to an area of ​​the sheet 10. The radio frequency causes the molecules to oscillate to generate friction, which generates heat, thereby embossing the pattern onto the sheet 10.

[0032] Figure 8 A step-by-step diagram of a method for creating embossed graphics 24, 26 on a pad sheet 10. The embossed graphics creation method includes: step 62, identifying the correct radio frequency welding equipment 52; step 64, identifying the appropriate mold 50. Step 66, identifying the side of the pad sheet 10 to be embossed. Step 68, adding an embossed substrate layer to the side of the pad sheet 10 to be embossed. Step 70, pressing the mold 50 onto the side of the pad sheet 10 to be embossed. Step 72, activating the radio frequency welding equipment 52 to place the mold 50 onto the pad sheet 10. The radio frequency welding equipment 52 can be operated manually or automatically. The embossed side of the pad sheet 10 can be the back side of the pad sheet 10 that contacts the core 20, or it can be the top surface of the pad sheet 10 that faces away from the core 20.

[0033] The embossed substrate can be a thermoplastic substrate or a thermoplastic coated substrate. The embossed substrate can be ethylene, polypropylene, polyester or polyurethane. The embossed substrate can be transparent or colored. In one embodiment, the thickness of the embossed substrate can be about 0.15 inches. In other embodiments, the thickness of the embossed substrate can be about greater than or less than 0.15 inches.

[0034] In some embodiments, additional layers of color or foil may be added to the embossed graphics 24, 26. Figure 8, the above method may include: step 74, determining whether a foil layer is required. The foil can be added as a metal layer. If it is determined in step 74 that a foil layer is required, step 76 is performed in step 70 before the pressing mold 50 to apply the foil layer. Alternatively, the foil layer can be added after the embossed pattern is added to the pad 10 in step 72. The foil layer can be embossed onto the pattern 24, 26 by heating. The foil layer can be applied to the side of the pad 10 that does not contact the core 20 and / or is visible to the caregiver.

[0035] The method may further include: step 78, determining whether a color layer is needed. The color layer may include a thermoplastic substrate or a thermoplastic coating substrate. If it is determined in step 78 that a color layer is needed, step 80 is performed, in which the color layer is applied before the pressing mold 50. The color layer may be applied to the side of the pad 10 that is not in contact with the core 20 and / or visible to the caregiver.

[0036] Alternatively, the color layer may be added after the embossed graphics 24, 26 are added to the backing sheet 10 on top of the polyurethane layer 14 in step 72. The color layer or foil layer may be added to the backing sheet 10 before, during, or after the embossed graphics 24, 26 are created using the radio frequency welding equipment and mold 50.

[0037] Although the present disclosure relates to specific embodiments, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the subject matter described in the claims.

Claims

1. A system comprising: a patient support surface including a core; a sheet covering the core, wherein the sheet has a first surface and a second surface, and wherein the first surface faces away from the core and the second surface faces the core; and A radio frequency welding device and a mold for embossing an embossing substrate layer applied to the second surface of the pad, Wherein, the pad forms a three-dimensional structure determined by the mold.

2. The system according to claim 1, wherein: The core is a mattress having multiple inflation zones.

3. The system according to claim 1, wherein: The first surface of the sheet is polyurethane and the second surface of the sheet is nylon.

4. The system according to claim 1, wherein: The embossed substrate is a thermoplastic coating substrate or a thermoplastic coating substrate.

5. The system according to claim 1, wherein: The first surface comprises polyurethane and the second surface comprises nylon, and wherein the three-dimensional structure comprises the embossed substrate layer, a nylon layer, and a polyurethane layer.

6. The system according to claim 1, wherein: The mold includes a graphic design, and a three-dimensional structure formed from the mold includes the same graphic design.

7. The system according to claim 1, wherein: The three-dimensional structure comprises additional color layers or foil layers.

8. The system according to claim 7, wherein: The additional color layer includes a thermoplastic coating substrate or a thermoplastic coating substrate.

9. A cover for a patient support surface, the cover comprising: a first surface and a second surface, the second surface being opposite to the first surface; embossing a substrate layer, applied to the second surface of the cover; as well as {HRBTL-23011-CNPT / 02132454v1} -1- A three-dimensional structure is embossed onto the cover, wherein the three-dimensional structure includes the embossed substrate layer.

10. The sheath according to claim 9, wherein: The cover covers the core of the patient support device.

11. The sheath according to claim 9, wherein: The first surface of the cover is polyurethane and the second surface of the cover is nylon.

12. The sheath according to claim 9, wherein: The embossed substrate is a thermoplastic coating substrate or a thermoplastic coating substrate.

13. The sheath according to claim 9, wherein: The first surface comprises polyurethane and the second surface comprises nylon, and wherein the three-dimensional structure comprises the embossed substrate layer, a nylon layer, and a polyurethane layer.

14. The sheath according to claim 9, wherein: Radio frequency welding equipment and a mold are used to emboss the three-dimensional structure onto the cover.

15. The sheath according to claim 9, wherein: The three-dimensional structure includes an additional color layer or foil layer on the first surface.

16. A method of applying a three-dimensional structure to a sheet, comprising the steps of: Select RF welding equipment; Selecting a mold compatible with the radio frequency welding equipment; Positioning a first side of the sheet that does not contact the core of the patient support surface and a second side of the sheet that contacts the core of the patient support surface; applying an embossed substrate layer to the second side of the sheet; pressing the mold onto the embossing substrate on the first side of the sheet; and The radio frequency welding device is activated manually or automatically.

17. The method according to claim 16, wherein: The embossed substrate is a thermoplastic coating substrate or a thermoplastic coating substrate.

18. The method according to claim 16, wherein: The method comprises: forming {HRBTL-23011-CNPT / 02132454v1} -2- The three-dimensional structure is determined by the mold.

19. The method according to claim 18, wherein: The method further includes applying a color layer or a foil layer to the three-dimensional structure.

20. The system of claim 19, wherein: The additional color layer on the first surface includes a thermoplastic coating substrate or a thermoplastic coating substrate.

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