A multi-zone adjustable inflatable pillow with anti-collapse function

Abstract

This invention discloses an inflatable pillow with independently adjustable height and firmness in multiple zones, and its manufacturing method, belonging to the field of sleep bedding technology. The pillow body has at least two independent, non-communicating, sealed air chambers. Each air chamber has an internal limiting and shaping structure, which includes multiple discretely distributed heat-sealed connections. Each heat-sealed connection is formed by point-welding the upper and lower fabrics of the air chamber through heat sealing. These heat-sealed connections are arranged in a multi-row, multi-column array within the air chamber, with a spacing of 30mm to 60mm between adjacent connections. Each air chamber is equipped with an independent inflation / deflation valve. The manufacturing method involves simultaneously forming the pillow body sealing edge, longitudinal heat-sealed partition, and the arrayed heat-sealed connections in a single high-frequency hot-pressing molding operation. This invention solves the problems of inflatable bulge deformation, adjustment distortion, and stiff touch in existing multi-cavity inflatable pillows, making independent zone adjustment truly controllable; at the same time, the heat-sealed connection bears the expansion stress, keeping the supporting surface fabric relaxed and producing a soft touch; the internal limiting and shaping structure and the pillow body are integrally formed by high-frequency heat sealing, which is a mature process, airtight and reliable, and convenient for mass production.

Description

[0001] This invention relates to the field of inflatable bedding technology, specifically to an inflatable pillow with independently adjustable height and firmness in multiple zones and its manufacturing method. Background Technology

[0002] Inflatable pillows are widely used in travel, office, and home settings due to their portability and foldability. However, existing inflatable pillows generally suffer from the following technical problems: 1. Inability to achieve independent and precise adjustment of each zone. Most existing inflatable pillows have a single-chamber or interconnected-chamber structure, resulting in a generally uniform height and firmness across all areas of the pillow after inflation. However, in actual use, different sleeping positions such as back sleeping, side sleeping, and neck support require significantly different levels of support and firmness in the neck support area, head support area, and side-sleeping elevated area. When sleeping on your back, the cervical spine needs relatively firm, higher support to maintain its physiological curvature, while the head needs relatively soft, medium support to enhance comfort; when sleeping on your side, additional height is needed to compensate for the head being unsupported due to shoulder width. A single-chamber structure cannot simultaneously meet these differentiated needs.

[0003] 2. Free expansion of the air chambers after inflation leads to bulging deformation, unstable support, and a hard feel. Existing technologies include multi-chamber inflatable pillows. Chinese patent CN218685035U discloses a multi-chamber adjustable inflatable pillow with independent inflation valves on the side walls of each chamber, but none of the chambers have any limiting or shaping structures. After inflation, each chamber expands into a spherical shape, resulting in bulging on the upper surface. Not only is the support height unpredictable linearly, but the overall feel is also hard, lacking the necessary softness and support. No matter how the user adjusts the inflation level, they cannot obtain a smooth and soft support; the support is either insufficient or the feel is hard. Another early patent, CN1444893, discloses an inflatable pillow with reinforcing ribs inside the pillow body. However, the purpose of the reinforcing ribs is to make the pillow body form a shape with the four sides raised and the center concave. It belongs to the shape control type of reinforcing ribs, and the number of reinforcing ribs is limited (only 2 or more). It does not involve an array arrangement structure, nor does it solve the problem of maintaining a regular support plane and a soft touch.

[0004] 3. The scope of protection of existing technologies objectively allows for circumvention. Some existing inflatable pillow patents limit the valve installation position to a single form, allowing competitors to circumvent the relevant patent solutions simply by changing the valve installation method.

[0005] 4. Material and manufacturing process issues. Inflatable pillows made of ordinary PVC material are hard to the touch and prone to aging and becoming brittle; products made with traditional sewing techniques have the risk of air leakage through pinholes, and are not airtight or durable enough.

[0006] Regarding foreign patents, US Patent 6151735A discloses an inflatable pillow with three independent compartments that inflate independently, but it does not disclose the internal limiting and shaping structure of the air chambers. Another US Patent 2009 / 0025147 discloses a baffle between the pillow chambers, but this baffle is used to prevent the filling material from shifting between adjacent chambers, rather than to constrain the expansion shape of the inflated air chambers, which is fundamentally different from the technical solution of this invention. In summary, neither domestic nor foreign existing technologies disclose a combination scheme of multiple independent air chambers arranged in an array with an internal limiting and shaping structure to achieve a relaxed and soft feel on the supporting surface fabric. Summary of the Invention

[0007] The technical problem to be solved by the present invention is to provide an inflatable pillow and its manufacturing method, which can achieve precise and independent adjustment of the height and firmness of different body support areas, and maintain a regular planar shape and soft touch in each area after adjustment, while having good airtightness, durability and industrialization potential. Technical solution

[0008] This invention employs a novel internal limiting and shaping structure, featuring multiple heat-sealed connection parts arranged in an array within each partitioned air chamber. These heat-sealed connection parts are formed by point-by-point hot-pressing and welding the upper and lower fabrics of the partitioned air chamber at predetermined positions using a high-frequency heat-sealing process. When the air chamber is inflated, the arrayed heat-sealed connection parts apply an inward tensile force to the upper and lower fabrics, limiting excessive expansion of the air chamber in the thickness direction and maintaining a regular supporting plane on the upper surface of the air chamber. Simultaneously, the heat-sealed connection parts bear the main expansion stress, ensuring that the supporting fabric between adjacent heat-sealed connection parts maintains appropriate relaxation when bearing head and neck pressure, producing a soft, enveloping, and conforming feel. This resolves the contradiction between support and softness inherent in traditional inflatable pillows.

[0009] Furthermore, this invention integrates the internal limiting and shaping structure with the pillow body in a single hot-pressing process using a high-frequency heat sealing process. This eliminates the need for sewing and gluing, eliminates the risk of pinhole leakage, ensures airtightness and durability, and features a mature process that facilitates mass production. Detailed Implementation

[0010] Example 1: Three-zone independent heat-sealing pull-point limiting array and embedded valve The pillow body is made of TPU composite fabric and sealed using a high-frequency heat-sealing process. Internally, two longitudinal heat-sealed partitions divide the cavity into three independent, non-communicating, sealed air chambers. From front to back, these three air chambers are: a neck support chamber, a supine support chamber, and a side-sleeping height adjustment chamber. Each chamber is completely isolated, with no air communication channels between them.

[0011] Each compartment of the air chamber is equipped with an internal limiting and shaping structure. In this embodiment, the internal limiting and shaping structure includes multiple heat-sealing connections, which are formed by heat-sealing pull points. These heat-sealing pull points are formed by high-frequency heat sealing and point-by-point hot-pressing of the upper and lower layers of fabric at predetermined positions within the air chamber. The heat-sealing pull points are arranged in a staggered array within the air chamber: 3 to 5 rows along the length of the pillow body and 4 to 8 columns along the width, with a spacing of 20mm to 70mm between adjacent heat-sealing pull points. A spacing of 30mm to 60mm between adjacent heat-sealing pull points represents the optimal range for simultaneously achieving flat support and a soft touch. When the spacing is less than 20mm, the supporting fabric is excessively stretched, resulting in a hard feel after inflation; when the spacing is greater than 70mm, the expansion constraint in the center of the air chamber is insufficient, leading to bulges. 20mm to 70mm is a feasible range for simultaneously achieving both regular support and a relaxed feel. Among them, the density of the thermal pull point array in the neck support air chamber is higher than that in the supine support air chamber.

[0012] When the partitioned air chambers are inflated to the operating pressure, the fabric tends to expand outwards. The heat-sealing points apply inward tension to the upper and lower fabrics, limiting excessive expansion of the air chambers in the thickness direction. This ensures that the air chambers maintain a flat and regular overall shape after inflation, preventing bulges or localized collapse or deformation. Simultaneously, because the limiting structure bears the main expansion stress, the supporting fabric maintains a certain degree of relaxation when subjected to head and neck pressure, producing a soft, enveloping, and conforming feel.

[0013] Each compartment is equipped with an independent inflation / deflation valve. The valve body is embedded in the valve mounting groove on the side wall of the pillow body, and the outer end face of the valve body is flush with the outer surface of the pillow body, forming a non-protruding embedded structure.

[0014] When in use, the user can inflate the neck support air chamber by adjusting the valve when lying on their back, increasing its height and enhancing support; and adjust the air volume by adjusting the valve of the supine support air chamber to achieve a moderate height and soft feel. When turning to the side, the side-lying height-adjustable air chamber can be inflated to fill the gap between the head and the bed surface caused by shoulder width. Each zone is adjusted independently, and adjusting one zone will not affect other zones that have already been adjusted.

[0015] Example 2: Wave-shaped limiting ribs combined with tension point array This embodiment is basically the same as embodiment 1, except that a wave-shaped heat-sealing limiting rib is added to the internal limiting and shaping structure. The wave-shaped heat-sealing limiting rib is a series of continuous wave-shaped heat-sealing indentations extending along the length of the pillow body, forming a composite limiting structure with the heat-sealing pull point.

[0016] Example 3: Pull-point array combined with longitudinal support air column Based on Example 1, this embodiment adds a longitudinal support air column inside each partitioned air chamber. The longitudinal support air column is a tubular airtight cavity independent of the partitioned air chamber, extending vertically along the height direction of the partitioned air chamber. After being fully inflated, it forms a rigid vertical support column, which complements the in-plane constraint force formed by the thermally sealed point array, thereby improving the vertical bearing rigidity.

[0017] Manufacturing method examples This embodiment provides a method for manufacturing the above-mentioned inflatable pillow, including the following steps: ① Provide a flexible airtight fabric, wherein the flexible airtight fabric is a TPU composite fabric, a PVC mesh fabric, or a TPU bonded knitted fabric; ② Using a high-frequency heat-sealing mold, in a single hot-pressing molding operation, the sealing edge of the outer periphery of the pillow body, the longitudinal heat-sealing partition that separates each partition air chamber, and each heat-sealing connection part arranged in an array in each partition air chamber are formed by hot-pressing and welding the upper and lower fabrics corresponding to the partition air chamber at predetermined positions. ③Insert the independent inflation / deflation valve into the pre-formed valve mounting port.

[0018] The technical features in the above embodiments can be combined to form new implementation methods. Beneficial effects

[0019] 1. The internal limiting and shaping structure is formed by the array of heat-sealed connecting parts, which fundamentally solves the problems of bulging, collapse and deformation after inflation of existing multi-cavity inflatable pillows. The support height and softness and hardness can be truly controlled after the independent adjustment of the zones.

[0020] 2. The heat-sealed joint bears the main expansion stress, allowing the fabric on the bearing surface to maintain an appropriate degree of relaxation, thus achieving a balance between support regularity and softness to the touch, and solving the inherent contradiction of traditional inflatable pillows where support and softness cannot be achieved at the same time.

[0021] 3. The unique product manufacturing method claims mean that even if competitors design the same product, if they use traditional sewing or gluing methods to produce it, it may still fall within the scope of protection of the method claims, thus filling the gap of product protection alone.

[0022] 4. The independent inflation / deflation valve can be embedded in the valve mounting groove on the side wall of the pillow body, forming a non-protruding structure, which is comfortable to use and does not cause any discomfort. At the same time, the valve installation position is not limited to the single external form, making it difficult for competitors to circumvent infringement by simply changing the valve position.

[0023] 5. The pillow body is integrally molded using a high-frequency heat sealing process, eliminating the need for sewing and gluing. It is airtight, durable, reliable, and easy to mass-produce. Attached Figure Description Figure 1 This is a schematic diagram of the overall external structure of the present invention; Figure 2 This is a cross-sectional view of the internal multi-zone air chamber and internal limiting and shaping structure of the present invention; Figure 3 This is a schematic diagram of the assembly structure of the valve mounting groove and the independent charging / discharging valve of the present invention. Figure 4 This is a cross-sectional schematic diagram showing the relationship between the internal limiting and shaping structure and the air chamber expansion constraint in the single-partition air chamber inflation state of the present invention. Figure 5 This is a comparative schematic diagram showing the independent pressure adjustment of each zone without interference under different inflation levels in the multiple zone air chambers of the present invention. Figure 6 This is a top view of the arrangement of the heat-sealed connection array in the partitioned air chamber of the present invention. The component names corresponding to the markings in the attached diagram are as follows: 1. Pillow body; 2. Longitudinal heat-sealed partition; 3. Zoned air chamber; 31. Neck support air chamber; 32. Supine support air chamber; 33. Side sleeping height adaptation air chamber; 4. Internal limiting and shaping structure; 41. Heat-sealed connection part (heat-sealed pull point); 5. Independent inflation and deflation valve; 6. Valve mounting groove.

Claims

1. Claim 1: An inflatable pillow with independently adjustable multi-zone height and firmness, comprising a flexible, airtight pillow body, characterized in that: The pillow body has at least two independent, non-communicating, sealed air chambers inside. Each of the partitioned air chambers is provided with an internal limiting and shaping structure, which includes multiple discretely distributed heat-sealing connection parts. Each heat-sealing connection part is formed by point-welding the upper and lower fabrics of the partitioned air chamber at a predetermined position by heat sealing. The heat-sealing connection parts are arranged in an array of multiple rows and columns in the partitioned air chamber, and the spacing between adjacent heat-sealing connection parts is 30mm to 60mm. Each of the aforementioned partitioned air chambers is individually equipped with an independent inflation / deflation valve, and each independent inflation / deflation valve is installed on the pillow body at an installation position that is directly connected to its corresponding partitioned air chamber. Claim 2: The inflatable pillow with independently adjustable multi-zone height and firmness according to claim 1, characterized in that, The spacing between adjacent heat-sealed joints is 20mm to 70mm. Claim 3: The inflatable pillow with independently adjustable multi-zone height and firmness according to claim 1, characterized in that, The heat-sealed connection is a heat-sealed pull point, which is formed by hot-pressing and welding the upper and lower fabrics of the partitioned air chamber at predetermined positions; the rows of heat-sealed pull points are arranged alternately and in an alternating array within the partitioned air chamber. Claim 4: The inflatable pillow with independently adjustable multi-zone height and firmness according to claim 3, characterized in that, The partitioned air chambers include a neck support air chamber and a supine support air chamber, wherein the density of the thermal pull point array in the neck support air chamber is higher than that in the supine support air chamber. Claim 5: The inflatable pillow with independently adjustable multi-zone height and firmness according to claim 1, characterized in that, The heat-sealed connection is a wavy heat-sealed limiting rib or a heat-sealed limiting line. The wavy heat-sealed limiting rib is a continuous wavy heat-sealed indentation extending along the length direction of the pillow body, and the heat-sealed limiting line is a continuous straight heat-sealed indentation extending along the width direction of the pillow body. Claim 6: The inflatable pillow with independently adjustable multi-zone height and firmness according to claim 1, characterized in that, The partitioned air chamber is also provided with a longitudinal support air column, which is a tubular airtight cavity independent of the partitioned air chamber, extending vertically along the height direction of the partitioned air chamber, and is staggered with each of the heat-sealed connection parts. Claim 7: The inflatable pillow with independently adjustable multi-zone height and firmness according to claim 1, characterized in that, The pillow body is formed by sealing flexible airtight fabric through a high-frequency heat sealing process. The internal limiting and shaping structure and the pillow body are integrally formed by hot pressing in the high-frequency heat sealing process. The flexible airtight fabric is TPU composite fabric, PVC mesh fabric or TPU bonded knitted fabric. Claim 8: The inflatable pillow with independently adjustable multi-zone height and firmness according to claim 1, characterized in that, The partitioned air chambers include a neck support air chamber, a supine support air chamber, and a side-sleeping height adjustment air chamber arranged sequentially from front to back along the length of the pillow. Claim 9: The inflatable pillow with independently adjustable multi-zone height and firmness according to claim 1, characterized in that, The independent inflation / deflation valve is an embedded structure without protrusions, with its surface flush with the outer surface of the pillow; or it is an external protruding structure located on the outer surface of the pillow. Claim 10: A method for manufacturing an inflatable pillow with independently adjustable multi-zone height and firmness as described in any one of claims 1 to 9, characterized in that... include: ① Provide a flexible airtight fabric, wherein the flexible airtight fabric is a TPU composite fabric, a PVC mesh fabric, or a TPU bonded knitted fabric; ② Using a high-frequency heat-sealing mold, in a single hot-pressing molding operation, a sealing edge of the outer peripheral boundary of the pillow body, a longitudinal heat-sealing partition separating each of the partitioned air chambers, and each of the heat-sealing connecting parts arranged in an array in each partitioned air chamber are formed by point-to-point hot-pressing and welding the upper and lower fabrics corresponding to the partitioned air chambers at predetermined positions. ③Insert the independent inflation / deflation valve into the pre-formed valve mounting port.

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