Inflatable air mattress and method of construction thereof

Abstract

The invention is an inflatable air mattress and method of construction. The inflatable air mattress includes an inflatable shell defining an air chamber and capable of being inflated via a valve disposed at a surface of the inflatable shell. The air mattress includes a layer of self-inflating material (preferably self-expanding / self-inflating bubble wrap) with one side adhered to an upper side of the shell and the other side adhered to a top cover that forms a sleeping surface of the inflatable air mattress. The layer of self-inflating material provides improved thermal efficiency compared to conventional air mattresses.

Description

Technical Field

[0001] This invention relates to an inflatable air mattress and its construction method. The invention is particularly applicable to an inflatable air mattress including a self-inflating layer and suitable for camping, and its construction method. Background Technology

[0002] Inflatable air mattresses are a common form of sleeping equipment used while camping. When not in use, they are compact and easy to transport, and when needed, they can be easily inflated using an electric or mechanical hand pump. Once inflated, they provide a certain height off the base and act as cushioning. Therefore, inflatable air mattresses can potentially offer users greater comfort during sleep compared to traditional thin sleeping mats or similar items.

[0003] However, inflatable air mattresses do have problems. For example, they can be relatively elastic, and even slight movements can cause considerable displacement of the surface during use. Another issue with inflatable air mattresses is their low thermal efficiency; the filling medium (air) readily conducts heat.

[0004] Inflatable air mattresses are typically constructed from or coated with PVC (polyvinyl chloride). These types of materials generate relatively significant noise when deformed, so the sound from the fabric shifting position when the user changes position can disrupt sleep. Furthermore, such materials are not well-suited for bonding noise-reducing or shock-absorbing materials to address this issue without unduly compromising the structural integrity of the PVC.

[0005] To at least partially correct these problems, some air mattresses integrate a layer of self-inflating bubble foam into a sheet of material defining the air chamber. This self-inflating bubble foam layer is covered with a cap that forms the top side of the air mattress, i.e., the sleeping surface. This provides a degree of insulation off the ground, thereby improving thermal efficiency, and also has some shock-absorbing properties to mitigate the elasticity of the air mattress to some extent.

[0006] However, manufacturing inflatable air mattresses that include a self-inflating bubble layer can present problems and may require compromises in the overall height of the mattress.

[0007] In some cases, adhering the foam layer to the air mattress shell without unduly affecting its self-inflating properties can present problems. This can be mitigated by using a relatively thin layer of self-inflating foam, but this reduces the air mattress's thermal efficiency and the shock absorption it provides. A seam is formed by attaching the cover to the appropriate edge on the upper side of the air chamber. The presence of this seam complicates air mattress manufacturing because the foam layer may need to be compressed before the cover is secured to form it. The self-inflating layer may then be slightly tensioned, especially around its perimeter, even after the cover is secured, which can affect airflow through this self-inflating layer.

[0008] Alternatively, the surface area of ​​the self-inflating bubble layer can be reduced so that it does not adjoin the upper edge of the air chamber. However, this may compromise the comfort of the inflatable air mattress. Solutions to these problems are anticipated.

[0009] The purpose of this technology

[0010] The purpose of this technology is to provide an inflatable air mattress for camping and a method for constructing it.

[0011] Alternatively, the purpose of this technology is to provide an inflatable air mattress for camping that is comfortable when a person rests on it.

[0012] Alternatively, the purpose of this technology is to provide an inflatable air mattress for camping that has good thermal efficiency compared to conventional inflatable air mattresses.

[0013] The purpose of this technology is to provide an inflatable air mattress for camping, which includes an integrated self-inflating layer.

[0014] Alternatively, the purpose of this technology is to provide an inflatable air mattress with an integrated self-inflating layer, which is inexpensive to manufacture.

[0015] Alternatively, the purpose of this technology is to provide an inflatable air mattress suitable for its intended use.

[0016] At the very least, the purpose of this technology is to provide the public with useful options. Summary of the Invention

[0017] According to one aspect of the present invention, an inflatable air mattress is provided, the inflatable air mattress comprising:

[0018] An air chamber defined by a housing having a lower side and a upper side, the air chamber also defined by a sidewall connecting the lower side to the upper side; and

[0019] A self-inflating layer, wherein the self-inflating layer comprises:

[0020] A self-inflating material layer having an upper side and a lower side; and

[0021] Top cover, wherein the top cover is disposed on the upper side of the self-inflating material layer.

[0022] Its features

[0023] The lower side of the self-inflating material layer is bonded to the upper side of the outer shell of the air chamber, and wherein the foam layer is arranged relative to the air chamber such that the top cover provides a sleeping surface for the user.

[0024] This invention relates to an inflatable air mattress and its construction method. The inflatable air mattress includes an inflatable outer shell defining an air chamber and capable of being inflated via a valve disposed on the surface of the outer shell. The air mattress includes a self-inflating material layer (preferably self-expanding / self-inflating bubble foam), one side of which is bonded to the upper side of the outer shell, and the other side to a top cover forming the sleeping surface of the inflatable air mattress. Compared to conventional air mattresses, this self-inflating material layer provides improved thermal efficiency.

[0025] Although the invention is described throughout the specification as an inflatable air mattress, in some jurisdictions these inflatable air mattresses are referred to as inflatable mattresses.

[0026] The inflatable air mattress includes a shell having length and width dimensions.

[0027] The outer shell should be understood as forming the air chamber of the inflatable air mattress. The outer shell includes: a first panel forming the upper side of the outer shell; a second panel forming the lower side of the outer shell; and a sidewall connecting the first panel to the second panel around the periphery of the outer shell.

[0028] In some examples, the sidewall may be integrally formed with either the first panel or the second panel.

[0029] It should be understood that each side of the inflatable air mattress is at least partially defined by the sidewall, which substantially defines the upper and lower surfaces of the housing around the respective peripheries of the first and second panels.

[0030] In one example, the shell is made of or coated with a material that is substantially impermeable, such as polyester, nylon, polyurethane (PU), polyvinyl chloride (PVC), or a mixture of one or more of these materials.

[0031] In a preferred example, the housing is constructed of a non-elastic fabric coated with a thermoplastic material (such as thermoplastic polyurethane (TPU)) or otherwise treated with such a thermoplastic material. In other examples, the housing may be constructed of PVC or a PVC-coated fabric / material.

[0032] In one example, the respective first and second panels and the sidewalls are formed of the same material. In another example, one or more of the respective first and second panels and the sidewalls of the housing may be made of a different material than the material used for the other of the first and second panels and the sidewalls.

[0033] In some examples, the second panel, which forms the lower side of the housing and may therefore come into contact with the substrate during use, may be made of a more durable and robust material or material grade compared to the material used for the first panel and / or the sidewall of the housing.

[0034] In one example, the outer surface of the sidewall is provided with a valve or similar structure that communicates with the interior of the air chamber. This provides a means to inflate or deflate the air chamber as needed.

[0035] In one example, the valve is configured to have flow control in at least one direction.

[0036] In a preferred example, the valve is a one-way valve configured to allow air in and removable to allow air out. In another example, the valve is a 360° two-way valve, which, depending on its orientation, can operate to allow air in and out as needed. The valve can be formed from a suitable, durable plastic material readily selectable by those skilled in the art.

[0037] The self-inflating layer should be understood as a self-inflating or self-expanding material layer or sheet. The length and width dimensions of the self-inflating layer substantially correspond to the length and width dimensions of the outer casing.

[0038] In a preferred example, the self-inflating material is open-cell foam. These types of foam should be understood as being made of a material that can be compressed when a force is applied, and then returns to its original state when the force is removed.

[0039] In each example, the open-cell foam may be formed from or otherwise made of materials such as polyurethane, latex, viscoelastic materials, ethylene-vinyl acetate copolymer (EVA), high resilience foam (HR).

[0040] In one example, the self-inflating layer of the inflatable air mattress consists of a single foam layer or sheet. In other examples, the single layer may be formed by two or more foam sheets laid end-to-end to form the layer.

[0041] The self-inflating material layer is bonded to or otherwise secured to the top panel of the housing. This can be achieved by applying an adhesive to one or both of the respective contact surfaces of the first layer and the top panel. In one example, the adhesive could be a polyurethane (PU) adhesive, but this is not intended to be limiting.

[0042] In another example, the self-inflating layer of the inflatable air mattress consists of a first layer and a second layer, each of which is essentially composed of a self-inflating or self-expanding material.

[0043] In this example, each layer is formed by a single foam sheet. In other examples, one or both of the first and second foam layers may be formed by two or more foam sheets; for example, two sheets may be laid end to end to form the first layer.

[0044] In this example, each layer of the self-inflating layer is formed from sheets of the same foam grade. In other examples, one of these layers may be formed from a different foam grade. For example, the second layer may have a higher density foam grade compared to the first layer, thereby improving the thermal efficiency of the user-lying side of the inflatable air mattress.

[0045] In this example, the second layer is thicker than the first layer. In this example, the second layer may include a core from which the foam material has been removed. This may be useful for reducing the weight of the inflatable air mattress, but may impair its self-inflating capability.

[0046] The first self-inflating material layer is bonded to or otherwise secured to the upper panel of the housing. This can be achieved by applying an adhesive to one or both of the respective contact surfaces of the first layer and the upper panel. In one example, the adhesive may be a PU adhesive, but this is not intended to be limiting.

[0047] In an alternative example, an intermediate layer may be disposed between the top panel of the housing and the first self-inflating material layer, and a chemical reaction may occur when heat is applied to bond the first layer to the top panel.

[0048] In embodiments where a second self-inflating material layer is present, the second self-inflating material layer is bonded to or otherwise secured to the first self-inflating material layer. This can be achieved by applying an adhesive to one or both of the respective contact surfaces of the first and second layers. In one example, the adhesive may be a PU adhesive, but this is not intended to be limiting.

[0049] In one example, an intermediate layer may be disposed between the first layer and the second layer, and a chemical reaction occurs when, for example, heat is applied, to bond the respective layers together.

[0050] In one example, the sidewall is a first sidewall, and the air mattress includes a second sidewall.

[0051] In one example, the first sidewall forms part of the outer shell, and the second sidewall forms the self-inflating layer.

[0052] In an alternative example, the first sidewall forms part of the housing and part of the self-inflating layer, and the second sidewall forms another part of the self-inflating layer.

[0053] In one example, the second sidewall is made of a material with tensile properties. In a particularly preferred example, the second sidewall is made of an elastic fabric coated with TPU, preferably in a non-laminated form.

[0054] In one example, the second sidewall covers at least a portion of each side of the self-inflating layer of the air mattress during use.

[0055] In one example, the outer surface of the second sidewall is provided with a valve or similar structure that communicates with the interior of the self-inflating layer. This provides a means of introducing additional air into the self-inflating layer or allowing additional air to escape from the self-inflating layer.

[0056] In one example, the valve configuration of the second sidewall has flow control in at least one direction.

[0057] In a preferred embodiment, the valve on the second sidewall is a one-way valve configured to allow air in and removable to allow air out. In another embodiment, the valve on the second sidewall is a 360° two-way valve, which, depending on its orientation, is operable to allow air in and out as needed. The valve can be formed from a suitable, durable plastic material readily selectable by those skilled in the art.

[0058] In one example, the cover is made of an elastic fabric coated with a thermoplastic material (such as TPU) or otherwise treated with that thermoplastic material. In a particularly preferred example, the cover is made of laminated TPU elastic fabric.

[0059] In one example, the perimeter of the top cover is defined by two pairs of opposing edges, each pair corresponding to the width and length dimensions of the outer shell and the self-inflating layer.

[0060] In one example, the periphery of the top cover is bonded to the upper edge of the second sidewall.

[0061] In one example, the lower edge of the second sidewall is bonded to the edge of the first panel of the housing.

[0062] In one example, the adhesion is achieved by using TPU soldering.

[0063] According to another aspect of the present invention, a method for manufacturing an inflatable air mattress is provided, the inflatable air mattress comprising: a shell forming an air chamber and having an upper side; and a self-inflating layer composed of a self-inflating material layer, wherein the method comprises the following steps:

[0064] • Attach the lower edge of the first sidewall to the periphery of the lower surface of the housing;

[0065] • Attach the lower edge of the second sidewall to one or both of the following: a) the upper edge of the first sidewall; or b) the periphery of the upper side of the housing;

[0066] • Adhere the self-inflating material layer to the upper side of the outer shell;

[0067] • Provide a top cover to the upper side of the self-inflating material layer; and

[0068] • Attach the upper edge of the second sidewall to the periphery of the top cover.

[0069] According to another aspect of the present invention, a method for manufacturing an inflatable air mattress is provided, the inflatable air mattress comprising: a shell forming an air chamber and having an upper side; and a self-inflating layer composed of a self-inflating material layer, wherein the method comprises the following steps:

[0070] • Attach the lower edge of the first sidewall to the periphery of the lower surface of the housing;

[0071] • The upper edge of the first sidewall is bonded to the periphery of the upper side of the housing to form an air chamber;

[0072] • Adhere the self-inflating material layer to the upper side of the outer shell;

[0073] • Attach the lower edge of the second sidewall to the inner side of the upper periphery of the housing;

[0074] • Provide a top cover to the upper side of the self-inflating material layer; and

[0075] • Attach the upper edge of the second sidewall to the periphery of the top cover.

[0076] In one example, the adhesion between the lower edge of the first sidewall and the lower surface of the housing is achieved by applying TPU soldering.

[0077] In one example, the adhesion between the upper edge of the first sidewall and the periphery of the upper side of the housing is achieved by applying TPU or welding.

[0078] In one example, the adhesion between the self-inflating material layer and the upper surface of the housing is achieved by applying an adhesive. In another example, the adhesion can be achieved by applying a PU or TPU laminate.

[0079] In one example, the adhesion between the lower edge of the second sidewall and the periphery of the upper side of the housing is achieved by applying TPU soldering.

[0080] In one example, the adhesive between the first sidewall and the upper periphery of the housing is located in an area away from the adhesive between the second sidewall and the upper periphery of the housing and laterally offset from the adhesive.

[0081] In one example, the adhesive between the first sidewall and the periphery of the upper side of the housing is located on the lower side of the panel forming the upper side of the housing, and the adhesive between the second sidewall and the periphery of the top side of the housing is located on the top side of the panel forming the upper side of the housing.

[0082] In one example, the adhesion between the upper edge of the second sidewall and the periphery of the top cover is achieved by applying TPU welding.

[0083] In one example, there may be an additional step of bonding one or more support structures to the upper and lower surfaces of the housing before bonding the first sidewall to the periphery of either the lower or upper surface of the housing.

[0084] It should be understood that the order of execution of some of the steps detailed above may differ from the order described. For example, the step of providing the top cover to the upper side of the self-inflating material may be performed before the step of bonding the lower edge of the first sidewall to the periphery of the lower surface of the housing.

[0085] In one example, the material of the lower side, the upper side, and the first sidewall of the housing is a non-elastic fabric coated with TPU, preferably in a non-laminated form.

[0086] In one example, the material of the second sidewall is a TPU-coated elastic fabric, preferably in a non-laminated form.

[0087] In one example, the top cover is made of a TPU-coated elastic fabric, preferably in a laminated form.

[0088] In one example, the self-inflating material layer is an open-cell foam sheet.

[0089] According to another aspect of the present invention, a method for manufacturing an inflatable air mattress is provided, the inflatable air mattress comprising: a shell forming an air chamber and having an upper side; and a self-inflating layer composed of a first self-inflating material layer and a second self-inflating material layer, wherein the method comprises the following steps:

[0090] • Attach the lower edge of the first sidewall to the periphery of the lower surface of the housing;

[0091] • The upper edge of the first sidewall is bonded to the periphery of the upper surface of the housing to form an air chamber;

[0092] • Adhere the first self-inflating material layer to the upper surface of the housing;

[0093] • Attach the lower edge of the second sidewall to the upper edge of the first sidewall;

[0094] • Adhere the second self-inflating material layer to the upper side of the first self-inflating material layer;

[0095] • Provide a top cover to the upper side of the second self-inflating material layer; and

[0096] • Attach the upper edge of the second sidewall to the periphery of the top cover.

[0097] In one example, there may be an additional step of bonding one or more support structures to the upper and lower surfaces of the housing before bonding the first sidewall to the periphery of either the lower or upper surface of the housing.

[0098] It should be understood that the order of execution of some of the steps detailed above may differ from the order described. For example, the step of providing the top cover to the upper side of the second self-inflating material layer may be performed before the step of bonding the lower edge of the first sidewall to the periphery of the lower surface of the housing.

[0099] In one example, the adhesion between the first sidewall and the lower surface of the housing is achieved by using TPU soldering.

[0100] In one example, the adhesion between the first sidewall and the upper surface of the housing is achieved by using TPU soldering.

[0101] In one example, the adhesion of the first self-inflating material layer to the upper surface of the housing is achieved by applying an adhesive. In a particularly preferred example, the adhesive may be a PU adhesive.

[0102] In one example, the adhesion between the upper edge of the first sidewall and the lower edge of the second sidewall is achieved by using TPU welding.

[0103] In one example, the adhesion between the second self-inflating material layer and the first self-inflating material layer is achieved by applying an adhesive. In a particularly preferred example, the adhesive may be a PU adhesive.

[0104] In one example, the adhesion between the upper edge of the second wall and the cover is achieved by using TPU welding.

[0105] In one example, the material of the lower side, the upper side, and the first sidewall of the housing is a non-elastic fabric coated with TPU, preferably in a non-laminated form.

[0106] In one example, the material of the second sidewall is a TPU-coated elastic fabric, preferably in a non-laminated form.

[0107] In one example, the top cover is made of a TPU-coated elastic fabric, preferably in a laminated form.

[0108] In one example, the first self-inflating material layer and the second self-inflating material layer are open-cell foam sheets. Attached Figure Description

[0109] Referring to the following figures, one or more embodiments of the present technology will be described below by way of example only and are not intended to be limiting, in which:

[0110] Figure 1 This is a perspective view showing a first embodiment of an inflatable air mattress according to one aspect of the present invention;

[0111] Figure 2 yes Figure 1 A schematic cross-sectional view of an example of an inflatable air mattress;

[0112] Figure 3 This is a schematic cross-sectional view of a second embodiment of an inflatable air mattress according to another aspect of the present invention; and

[0113] Figure 4 This is a schematic cross-sectional view of a third embodiment of an inflatable air mattress according to another aspect of the present invention.

[0114] The same reference numerals are assigned to the same features. Detailed Implementation

[0115] 6.1 Inflatable Air Mattress

[0116] exist Figure 1 The diagram depicts an example of the invention in perspective view, taking the form of an embodiment of an inflatable air mattress (generally indicated by arrow 100). The air mattress has a length dimension of L and a width dimension of W, the latter being shorter than the former.

[0117] In use, the upper surface (US) of the air mattress 100 provides a surface for the user to lie on or otherwise recline on. The lower surface of the air mattress (not visible, but indicated by the LS) contacts the ground or base below; alternatively, the lower surface may contact the groundsheet of a tent or the frame of a camping bed.

[0118] In this external view of the air mattress 100, the air mattress has two distinct parts: an outer shell 102, which includes an air chamber 104, the air chamber including a lower surface LS; and a self-inflating layer 106, the self-inflating layer including an upper surface US. The presence of the self-inflating layer provides the air mattress with increased comfort and thermal efficiency.

[0119] The outer casing 102 of the air chamber 104 is formed by: a bottom panel (not visible) that serves as the lower surface LS; and a first sidewall 108 that defines the periphery of the bottom panel and connects the bottom panel to the upper panel (covered in this view by the self-inflating layer 106). The inner side or interior of the casing is the air chamber.

[0120] In the illustrated example, the sidewall 108 of the air chamber includes a seam 110 closer to the lower surface LS; this is for aesthetic and ease of manufacture purposes.

[0121] A valve 112 is positioned on the side wall 108 of the air mattress 100 along its width dimension W (which will correspond to either the head or tail of the air mattress in use). This valve is operable to allow air to enter and exit the housing 102 during inflation and deflation. The valve may be a two-way valve, which can be actuated by the user to control the airflow direction.

[0122] The self-inflating layer 106 is surrounded on each side by a second sidewall 114 and on its top side by a cover 116. Like the outer casing 102, the sidewalls of the self-inflating layer are provided with valves 118 along its width dimension W. These valves are operable to allow air to enter and exit the self-inflating layer.

[0123] Although the self-inflating layer 106 automatically expands or inflates after the compressive force restraining it is released, the process can be accelerated or enhanced by adding additional air to the self-inflating layer via a pump (not shown). Conversely, air can escape from the self-inflating layer via a valve when the air mattress 100 is packed (which involves considerable compression of both the outer shell 102 and the self-inflating layer).

[0124] The air mattress 100 shown can be constructed in such a way that it has good thermal efficiency compared to traditional inflatable air mattresses, without significantly affecting its inflation / deflation performance.

[0125] Figure 2This is a schematic diagram of a cross-section along the length dimension L of one end of the air mattress 100, from which an example of how the air mattress can be constructed can be best understood.

[0126] First, regarding the housing 102, which comprises a bottom panel 120, a top panel 122, and sidewalls 108. These collectively define an airtight structure that defines an air chamber 104. The respective panels and sidewalls of the housing may be made of a substantially airtight material such as polyester, nylon, polyurethane, or polyvinyl chloride (PVC). The sidewalls may be integrally formed with one of the bottom or top panels, or alternatively, may be separate components.

[0127] In a preferred example, a non-laminated, non-elastic fabric coated with thermoplastic polyurethane (TPU) can be used. The desired properties of the material chosen for the housing 102 are that it is used to contain or restrict gas (i.e., air) under pressure for the purpose of keeping the air mattress inflated. Those skilled in the art will readily identify materials suitable for use in this invention.

[0128] The sidewall 108 is bonded to the corresponding bottom panel 120 and top panel 122 using TPU soldering (invisible), a particularly robust and durable technique for bonding adjacent TPU material panels using heat and pressure. However, this is not intended to be limiting, and other suitable bonding techniques, as determined by a technician, can be readily employed to construct the housing.

[0129] The aim is to control the inflation level of the housing 102 in such a way that it maintains its substantially rectangular shape. To help achieve this, the interior of the housing includes a support structure in the form of support pillars or baffles 126. This is constructed from non-elastic fabric strips. The respective ends of the support pillars are bonded to the respective panels using TPU welding 124 or another suitable method, such as adhesive.

[0130] As previously noted, the self-inflating layer 106 is formed of a self-expanding or inflatable material; the self-inflating layer is in the form of an open-cell foam made of materials such as polyurethane, latex, viscoelastic materials, ethylene vinyl acetate (EVA), high resilience foam (HR), etc. These materials have a natural tendency to rebound / expand after being compressed.

[0131] As can be seen, the self-inflating layer 106 consists of two separate self-inflating layers, each composed of an open-cell foam sheet. The first sheet forms the first layer 106a, and the thicker second sheet 106b forms the second layer. Providing the second layer with the thicker foam sheet allows this part of the air mattress (actually the side where the user lies) to have relatively good thermal efficiency. The corresponding thickness may vary depending on manufacturing preferences and the properties of the selected foam; in the illustrated example, the thickness of the first layer is approximately 25 mm, and the thickness of the second layer is approximately 75 mm. These are not intended to be limiting.

[0132] It should be understood that the corresponding first foam layer 106a and second foam layer 106b can be composed of two sheets with different performance characteristics. For example, the second layer, closest to the user, is already composed of foam that is softer and less dense than the first layer. This can provide greater comfort to the user. Conversely, the opposite approach is preferred; the second layer can be composed of foam with a higher density than the first layer.

[0133] In another example not shown here, the second layer, thicker than the first layer, may comprise one or more die-cuts, preferably extending between opposite sides of the foam sheet forming the second layer. This could be useful for reducing the weight of the air mattress and improving its self-inflating properties; however, there may be trade-offs in terms of user comfort.

[0134] The bottom side of the first foam layer 106a is bonded to the top panel 122 of the housing 102 using a suitable adhesive 128A. One factor in determining the suitability of an adhesive is its performance at low temperatures. For example, polyurethane adhesives are more flexible than polyvinyl chloride adhesives at lower temperatures; therefore, PU adhesives are preferred in the manufacture of this invention. However, this is not intended to be limiting, and other adhesives and even bonding techniques recognized as suitable by those skilled in the art can be used alternatively.

[0135] Furthermore, the bottom side of the second foam layer 106a is bonded to the top side of the first foam layer. This can also be achieved by using a suitable adhesive 128B with appropriate performance characteristics as noted above. As will be understood, this will integrate the self-inflating layer 106 with the housing 102 to form the air mattress 100.

[0136] It is advantageous for the self-inflating layer 106 to be formed by two different foam layers 106a and 106b, because this allows the manufacturer to customize the air mattress 100 to a greater extent, for example by providing a series of air mattresses with increasingly firm (or increasingly soft) self-inflating air mattresses.

[0137] The self-inflating layer 106 is surrounded at its edges by sidewalls 114 of an elastic fabric coated with non-laminated TPU. The lower edge of this wall is bonded to the upper edge of the wall 108 of the housing 102 by means of welding 130.

[0138] An important aspect of the construction of the air mattress 100 is the relative height of the walls 108 of the outer shell 102; as can be seen, the walls are welded to the top panel 122 at a position 132 below the upper edge of the walls. This forms a shallow recess into which the first foam layer 106a can be placed. The sidewalls of the outer shell at least partially overlap the edges of the first foam layer. This facilitates a simpler manufacturing process, as the first foam layer can be bonded to the upper side of the outer shell before the sidewalls are welded to the top panel.

[0139] The upper side of the self-inflating layer 106 includes a cover 134 formed from a panel of laminated TPU-coated elastic fabric. Given that this is the surface of the air mattress where the user lies, using laminated TPU on the cover provides a degree of abrasion protection. The perimeter of the cover panel is welded 136 or otherwise bonded to the upper edge of the second wall.

[0140] The configuration of the air mattress 100 gives the self-inflating layer 106 a distinct three-dimensional profile, particularly around its perimeter. The depth of the self-inflating layer does not gradually decrease towards the edges, which can help provide the user with greater security and support during sleep. This also simplifies manufacturing, as the cover 134 may not necessarily need to be pulled as tightly as before, since it is now fixed to the sidewall 114 of the self-inflating layer, rather than to the panel 122 of the outer shell 102.

[0141] Figure 3 Another example of how the air mattress 100 can be constructed is shown. (Compared to the previous...) Figure 1 Sample, Figure 3 This is a schematic diagram of a cross-section along the length L of one end of the air mattress.

[0142] and Figure 2 Compared to other embodiments, the air mattress 100 has only a single foam layer or foam sheet forming a self-inflating layer 106. (As mentioned above regarding...) Figure 2 As discussed in the first foam layer of the embodiment, this self-inflating layer is bonded to the top panel 122 of the housing 102 using PU adhesive 128A. This simplifies the construction of the air mattress.

[0143] Another difference lies in the bonding method of the corresponding sidewalls of the air mattress 110. In a preferred embodiment, this is the final stage, or near the final stage, of the air mattress manufacturing process.

[0144] As can be seen, a first sidewall 108, which forms and defines a portion of the outer casing 102, is bonded at its upper edge to the lower periphery of the panel 122. A second sidewall 114, covering the inflatable layer 106, is bonded at its lower edge to the top side of the panel 122. However, the corresponding bonding areas R1 and R2 do not overlap, but are offset from each other.

[0145] The method of bonding the respective sidewalls 108, 114 to the top panel 122 is by using PU welding; since this bonding technique requires heating, the respective bonding areas R1, R2 that are offset from each other mean that the integrity of the weld of the bonded sidewalls is not affected when the second sidewall of the sidewalls is welded to the panel (regardless of whether the first sidewall 108 is the first or the second to be bonded).

[0146] Although the adhesive region R1 is shown here as being further away from the adhesive region R2, in some examples not shown here, the opposite may be true. Additionally, although the adhesive region R2 is shown as being substantially continuous with the adhesive 128A used to bond the self-inflating layer 106 to the top panel 122 of the housing 102, in some examples, this adhesive region may be different from and separate from the adhesive.

[0147] Figure 4 Another embodiment of the air mattress 100 is shown, illustrated as a schematic cross-sectional view along a length dimension L at one end of the air mattress. As will be understood from the narration, this embodiment differs from the previous embodiment in some respects.

[0148] As mentioned above Figure 3 As discussed in the embodiments, the self-inflating layer 106 is formed as a single foam sheet. One advantage of using a single foam sheet for the self-inflating layer is that its center can be hollowed out at regular intervals across the width dimension. This removes the cylindrical portion of the foam, thereby forming a cavity 138 along the length of the air mattress 100.

[0149] The presence of these cavities 138 is useful because it allows for improved self-inflating properties of the foam material forming the self-inflating layer 106, i.e., the self-inflating layer inflates more quickly. Additionally, it reduces the overall weight of the air mattress 100. It should be understood that the self-inflating layer accounts for a considerable proportion of the total weight of the air mattress due to its density. Figure 2 In some embodiments, this configuration may not be practical, where the self-inflating layer is formed by two (or more) thinner sheets or layers of foam. More core would be needed to achieve the same weight reduction, but this could come at the expense of user comfort, as support may be reduced while sleeping.

[0150] exist Figure 4In the illustrated embodiment of the air mattress 100, the construction of the outer shell 102 (particularly the interior of the shell) also differs. As mentioned earlier, in Figure 2 In the outer shell 102 of the air mattress 100 shown, a support structure in the form of support pillars 126 spans the top panel 122 and the bottom panel 120. These are used to control the distance between the respective panels.

[0151] exist Figure 4 In the air mattress 100, the support structure can employ a TPU filament construction technique as will be understood by those skilled in the art. As can be seen, this involves using hundreds of TPU filaments or TPU-coated filaments 140 extending between opposing fabric sheets 142, 144. These opposing sheets are then anchored to the side walls 108, top panel 122, and bottom panel 120 of the housing 102 via PU adhesive or TPU welding 146 and intermediate support members 148. The presence of numerous filaments is useful for providing support to the housing, imparting greater rigidity, and thus providing support for the person using the air mattress 100. Additionally, this can also help reduce the overall weight of the air mattress.

[0152] Another difference lies in the bonding of the first sidewall 108, the second sidewall 114, and the top panel 122. It can be seen that the first sidewall is directly bonded to the second sidewall at the bonding area R1 via TPU welding. This is different from... Figure 3 In contrast, the first sidewall is bonded to the underside of the top panel in this figure.

[0153] Return to Figure 4 As previously described, the second sidewall is secured to the upper side of the top panel at adhesive area R2. Note that it does not overlap with adhesive area R1.

[0154] configuration

[0155] When constructing the air mattress 100, one approach is to proceed from the lower surface LS upwards; thus, the outer shell 102 is first made by welding or otherwise bonding the sidewalls 108 at their respective lower and upper edges to the bottom panel 120 and the top panel 122, as well as the support 126 (the latter of which may be completed before bonding the sidewalls).

[0156] Figure 2 The air mattress 100 can then have a first self-inflating bubble layer 106a applied to the top panel 122 of the housing 102 and secured in place with adhesive 128A. Then, before, simultaneously with, or after bonding the sidewalls 108, 114 that respectively surround the air chamber 104 and the self-inflating bubble layer 106, a second self-inflating bubble layer 106b is secured to the first layer 106a using adhesive 128B.

[0157] for Figure 3 The application of the self-inflating bubble layer 106 to the air mattress 100 is simpler and more direct; it can be simply laid on the top panel 122 of the housing 102 and secured with a suitable adhesive (such as PU adhesive 128A). Alternatively, a TPU laminate can be used.

[0158] The final step involved in the construction of the air mattress 100 is to weld the upper edge of the sidewall 114 of the self-inflating layer 106 to the periphery of the material sheet 134, which forms a cover protecting the upper surface US of the air mattress 100.

[0159] However, it is not required to strictly follow the sequence of steps described above.

[0160] For example, Figure 3 The construction of the air mattress 100 can begin by welding its cover 134 around its perimeter to the self-inflating bubble layer 106, and then the construction begins on the outer shell 102. Before the sidewalls 108 are welded into place, the supports 126 are welded to the corresponding bottom panel 120 and top panel 122.

[0161] The lower surface of the self-inflating bubble layer 106 is coated with PU adhesives 128A and 128B, and then placed onto the top panel 122 that partially defines the air chamber 104. The sidewalls 114 of the self-inflating layer are then welded along their lower and upper edges to the upper edge of the sidewalls of the housing 102 and the periphery of the cover 134, respectively. Finally, the sidewalls 108 of the housing 102 are bonded to the top panel at their upper edges around the adhesive area R1, taking care not to overlap with the adhesive area R2.

[0162] use

[0163] As will be obvious from the preceding discussion, Figure 1 , Figure 3 and Figure 4 The usage of the illustrated invention 100 is simple and straightforward. Starting in a compressed state, this typically involves the air mattress being rolled up and packaged for transport. When the mattress is desired for use, the air mattress is then unpacked and unfolded, and the corresponding valves 118, 112 of the self-inflating layer 106 and the outer shell 102 (only when...) are opened. Figure 1 As shown in the diagram, air can be allowed to enter, in the case of this housing, via a pump (not shown). If additional inflation of the self-inflating layer is desired, this can be achieved using a pump. Deflating the air mattress 100 involves actuating corresponding valves 112, 118 to allow air to escape. The air mattress can then be compressed to expel air from the housing 102 and the self-inflating layer 106, typically into a rolled configuration for compact storage and transport.

[0164] The use of a housing 102 with defined air chambers 104 and a self-inflating layer 106 is useful because it provides an air mattress 100 that can have different cushioning properties. For example, for greater stability, the air chambers can be inflated to a relatively high pressure, while for user comfort, the self-inflating layer can be intentionally kept soft. Additionally, due to its relatively low density compared to the self-inflating layer, condensation between the bottom side and the underlying substrate may be reduced compared to conventional self-inflating air mattresses. Furthermore, the construction (where the air mattress is provided with discrete sidewalls to which the top cover is fixed) allows the self-inflating layer to have a consistent thickness / depth throughout the length and width dimensions of the air mattress.

[0165] Unless the context explicitly requires otherwise, throughout the specification and claims, the words “comprising” and “including” should be interpreted as inclusive rather than exclusive or exhaustive, that is, meaning “including but not limited to”.

[0166] All disclosures of all applications, patents and publications cited above (if any) are incorporated herein by reference.

[0167] Any prior art mentioned in this specification does not constitute and should not be construed as an acknowledgment or any form of implication that such prior art is part of the common general knowledge of the field in any country in the world.

[0168] In a broader sense, the technology refers to any or all combinations of two or more of the parts, elements, and features mentioned or indicated individually or jointly in the specification of this application.

[0169] In the preceding description, any reference to integers or components having known equivalents shall be incorporated into this text as if they were described separately.

[0170] It should be noted that various changes and modifications to the presently preferred embodiments described herein will be readily apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present invention and without diminishing its incidental advantages. Therefore, such changes and modifications are intended to be included in the present invention.

Claims

1. An inflatable air mattress, the inflatable air mattress comprising: An air chamber defined by a housing having a lower side, a upper side, and a sidewall connecting the lower side to the upper side; A self-inflating layer, wherein the self-inflating layer includes an upper side and a lower side; and Top cover, wherein the top cover is disposed on the upper side of the self-inflating layer, Its features The lower side of the self-inflating material layer is bonded to the upper side of the outer shell of the air chamber, and wherein the foam layer is arranged relative to the air chamber such that the top cover provides a sleeping surface for the user.

2. The inflatable air mattress according to claim 1, wherein the outer shell comprises: A first panel, the first panel forming the upper side of the housing; A second panel, the second panel forming the lower side of the housing; and sidewalls, which connect the first panel to the second panel around the periphery of the housing.

3. The inflatable air mattress of claim 2, wherein the corresponding first panel and second panel and the sidewall are formed of the same material.

4. The inflatable air mattress according to any one of claims 1 to 3, wherein the outer shell is made of or coated with a substantially airtight material.

5. The inflatable air mattress of claim 4, wherein the substantially airtight material is a non-elastic fabric coated with thermoplastic polyurethane (TPU) or otherwise treated with the thermoplastic polyurethane (TPU).

6. The inflatable air mattress according to any one of claims 1 to 5, wherein the outer surface of the sidewall of the outer shell is provided with a valve or similar structure, wherein the valve communicates with the interior of the air chamber.

7. The inflatable air mattress according to any one of claims 1 to 5, wherein the self-inflating material layer is composed of open-cell foam.

8. The inflatable air mattress of claim 7, wherein the open-cell foam is formed or otherwise constituted by one or more of the following: polyurethane, latex, viscoelastic material, ethylene-vinyl acetate copolymer (EVA) and / or high resilience foam (HR).

9. The inflatable air mattress according to claim 7 or claim 8, wherein the self-inflating material layer is formed from a single foam sheet.

10. The inflatable air mattress according to any one of claims 1 to 9, wherein the self-inflating material layer is bonded to the upper side of the outer shell by an adhesive.

11. The inflatable air mattress of claim 10, wherein the adhesive is a polyurethane adhesive.

12. The inflatable air mattress according to any one of claims 1 to 11, wherein the sidewall is a first sidewall, and the air mattress includes a second sidewall.

13. The inflatable air mattress of claim 12, wherein the first sidewall forms part of the outer shell and the second sidewall forms part of the self-inflating layer.

14. The inflatable air mattress according to claim 12 or claim 13, wherein the second sidewall is made of a material having tensile properties.

15. The inflatable air mattress of claim 14, wherein the second sidewall is made of an elastic fabric coated with TPU.

16. The inflatable air mattress according to claim 15, wherein the TPU is in a non-laminated form.

17. The inflatable air mattress according to any one of claims 12 to 16, wherein the outer surface of the second sidewall is provided with a valve or similar structure, wherein the valve communicates with the interior of the self-inflating layer.

18. The inflatable air mattress according to any one of claims 12 to 17, wherein the upper edge of the first sidewall is bonded to the lower edge of the second sidewall.

19. The inflatable air mattress of claim 18, wherein the adhesion between the first sidewall and the second sidewall is TPU welding.

20. The inflatable air mattress according to any one of claims 12 to 17, wherein the upper edge of the first sidewall is bonded to the lower side of the upper edge of the outer shell.

21. The inflatable air mattress of claim 20, wherein the lower edge of the second sidewall is bonded to the upper side of the edge of the upper side of the outer shell.

22. The inflatable air mattress of claim 21, wherein the adhesion between the first sidewall and the second sidewall is located in a non-overlapping region of the upper edge of the outer shell.

23. The inflatable air mattress according to any one of claims 12 to 22, wherein the top cover is bonded to the upper edge of the second sidewall.

24. The inflatable air mattress according to any one of claims 1 to 23, wherein the top cover is made of an elastic fabric coated with a thermoplastic material or otherwise treated with the thermoplastic material.

25. The inflatable air mattress of claim 24, wherein the thermoplastic material is TPU.

26. The inflatable air mattress of claim 25, wherein the thermoplastic material is laminated TPU.

27. The inflatable air mattress according to any one of claims 1 to 26, wherein the outer shell includes a support structure for connecting the lower side and the upper side of the outer shell.

28. The inflatable air mattress of claim 27, wherein the support structure comprises a TPU filament structure.

29. A method for manufacturing an inflatable air mattress according to any one of claims 1 to 28, wherein the method comprises the following steps: a) Adhere the lower edge of the first sidewall to the periphery of the lower surface of the housing; b) Adhere the lower edge of the second sidewall to one or both of the following: i) the upper edge of the first sidewall; or ii) the periphery of the upper side of the housing; c) Adhere the self-inflating material layer to the upper side of the outer shell; d) Provide a top cover to the upper side of the self-inflating material layer; as well as e) Adhere the upper edge of the second sidewall to the periphery of the top cover.

30. The method of claim 29, wherein the adhesion of the self-inflating material layer to the upper surface of the housing is achieved by applying an adhesive.

31. The method according to any one of claims 28 to 30, wherein the adhesive comprises one or more of the following: i) The first sidewall is bonded to the lower surface of the housing; ii) The second sidewall is bonded to the first sidewall and / or the upper side of the housing; as well as iii) The second sidewall is bonded to the top cover; It is achieved through TPU soldering.

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