An inflatable mat

Abstract

Inflatable mat, comprising: an upper outer layer and a lower outer layer defining a substantially enclosed interior space; at least one valve in selectable fluid communication with the interior; at least one insulating layer arranged between the upper outer layer and the lower outer layer; a plurality of connecting elements each extending between the upper outer layer and the lower outer layer and being directly connected thereto; and a plurality of belt elements each adapted to hold the insulating layer to one of the upper and lower outer layers, respectively.

Description

FIELD OF THE INVENTION

[0001] The present teachings relate to an inflatable mat. BACKGROUND

[0002] Modern sleeping mats, such as those used for camping, typically comprise a top and bottom layer that define an enclosed space. To enhance the comfort of the sleeping mat, the sleeping mat includes a valve or vent for inflating the sleeping mat. Reflective layers are known to be incorporated into the interior of the sleeping mat to improve its thermal properties. These insulating layers trap heat and reflect it back to the user. This improves the thermal efficiency of the mat by reducing the amount of heat energy transferred through the mat to the ground.

[0003] In addition to achieving the desired thermal performance of a sleeping mat, it is important that the sleeping mat provides optimal comfort for a restful sleep. Designing a sleeping mat that offers both effective thermal insulation and user comfort presents a significant challenge in the manufacturing of bedding solutions. Because the top and bottom layers, as well as the reflective layers, are made of different materials, the insulation layers cannot be heat-sealed or welded to the top and bottom layers.

[0004] The present teaching aims to overcome or at least mitigate one or more of the problems associated with the prior art. SUMMARY

[0005] A first aspect of the teaching provides an inflatable mat comprising: an upper outer layer and a lower outer layer defining a substantially enclosed interior space; and / or at least one valve in selectable fluid communication with the interior space; and / or at least one insulating layer disposed between the upper outer layer and the lower outer layer; and / or a plurality of connecting elements each extending between and directly connected to the upper outer layer and the lower outer layer; and / or a plurality of strap elements each configured to hold the insulating layer to one of the upper and lower outer layers, respectively.

[0006] Advantageously, the provision of the insulating layer helps capture heat and reflect heat back to the user, thereby improving thermal insulation from the ground. The thermal efficiency of the inflatable mat is improved by reducing the amount of heat energy transferred through the mat.

[0007] The plurality of connecting elements contribute to maintaining a desired distance between the upper outer layer and the lower outer layer when the inflatable mat is in an inflated configuration to maintain its generally planar shape with a desired thickness. The strap elements contribute to holding the insulating layers relative to the upper and lower outer layers, thereby holding the insulating layers in appropriate positions to effectively prevent heat loss when the mat is in an inflated configuration.

[0008] The provision of connecting and strapping elements to perform the aforementioned functions can help to improve ease of manufacture while maintaining the desired shape and arrangement of the insulating layer of the inflatable mat in the inflated configuration.

[0009] Optionally, the plurality of connecting elements are each discrete from one another. Optionally, the plurality of belt elements are each discrete from the plurality of connecting elements and from one another.

[0010] Advantageously, the provision of a plurality of discrete connecting elements and / or discrete strap elements improves ease of manufacture of the inflatable mat - for example, compared to a continuous arrangement of connecting elements and / or strap elements.

[0011] Optionally, the connecting elements are aligned essentially transversely to the belt elements.

[0012] Advantageously, the provision of the connecting elements transverse to the strap elements helps to provide support and shape to the inflatable mat in more than one direction.

[0013] Optionally, the plurality of connecting elements are aligned substantially transversely to the upper outer layer and the lower outer layer when the inflatable mat is in an inflated configuration.

[0014] Advantageously, the cross-connecting elements connect the upper outer layer to the lower outer layer and provide support and shape in the direction transverse to the upper outer layer and the lower outer layer.

[0015] Optionally, each of the plurality of belt elements extends from the respective upper or lower outer layer through the at least one insulating layer and back to the same respective upper or lower layer to connect the at least one insulating layer to the respective upper or lower outer layer.

[0016] Advantageously, the provision of strap elements extending through the at least one insulating layer and back to themselves connects the upper or lower outer layer to the at least one insulating layer, thereby providing support and shape to the inflatable mat.

[0017] Optionally, each of the plurality of connecting elements is connected to the upper outer layer at an upper connection point and to the lower outer layer at a lower connection point, and wherein the upper and lower connection points are transversely aligned with each other.

[0018] Advantageously, the provision of transversely aligned joints provides support and shape in the direction transverse to the upper outer layer and the lower outer layer, which helps to support the weight of a user.

[0019] Optionally, the plurality of strap elements are directly connected to the respective upper or lower outer layer at a first connection point and at a second connection point spaced from the first connection point. Optionally, the first connection point is longitudinally aligned with the second connection point.

[0020] Advantageously, the first and second connection points enable the connection of the at least one insulating layer to the upper or lower outer layer. Additionally, the provision of longitudinally aligned connection points provides support and shape in the longitudinal direction.

[0021] Optionally, the plurality of connecting elements are arranged in an array of rows. Optionally, each row extends in a direction substantially perpendicular to the central longitudinal axis of the inflatable mat.

[0022] Advantageously, providing an array of rows provides uniform support and helps maintain the shape of the inflatable mat along each row. Furthermore, rows are easy to manufacture.

[0023] Optionally, adjacent rows of the plurality of connecting elements are arranged offset in the longitudinal direction.

[0024] Advantageously, the provision of longitudinally staggered rows contributes to supporting a larger area with a given number of connecting elements. Furthermore, the spacing created by the longitudinally staggered rows can be utilized for the belt elements.

[0025] Optionally, the plurality of strap elements are arranged in an array of rows. Optionally, each row extends in a direction substantially perpendicular to a central longitudinal axis of the inflatable mat.

[0026] Advantageously, providing an array of rows provides uniform support and helps maintain the shape of the inflatable mat along each row. Furthermore, rows are easy to manufacture.

[0027] Optionally, adjacent rows are arranged offset in the longitudinal direction.

[0028] Advantageously, the provision of longitudinally staggered rows contributes to supporting a larger area with a given number of connecting elements. Furthermore, the spacing created by the longitudinally staggered rows can be utilized for the belt elements.

[0029] Optionally, each of the plurality of belt elements is arranged between adjacent connecting elements.

[0030] Advantageously, the provision of belt elements arranged between the connecting elements helps to provide uniform support and uniform shape, and the spaces between the adjacent connecting elements are efficiently used for arranging the belt elements.

[0031] Optionally, the at least one insulating layer comprises a plurality of openings each adapted to receive a connecting element therethrough.

[0032] Advantageously, the openings in the at least one insulating layer are easy to produce and enable a connection and support between the upper outer layer and the lower outer layer.

[0033] Optionally, the at least one insulating layer comprises a plurality of openings. Optionally, each opening is configured to receive a respective belt element therethrough. Optionally, each belt element extends through more than one of the plurality of openings of the at least one insulating layer.

[0034] Advantageously, the openings in the at least one insulating layer are easy to produce and enable a connection and support between the at least one insulating layer and the upper outer layer or the lower outer layer.

[0035] Optionally, the at least one insulating layer comprises an upper insulating layer connected to the upper outer layer by a plurality of upper belt elements and a lower insulating layer connected to the lower outer layer by a plurality of lower belt elements.

[0036] Advantageously, the provision of more than one insulating layer helps to enable additional capture and reflection of heat back to the user, thereby reducing the amount of thermal energy transferred through the inflatable mat and improving the thermal efficiency of the inflatable mat.

[0037] Optionally, the first and second connection points of each of the plurality of upper belt elements are arranged between the upper outer layer and the upper insulating layer and / or the first and second connection points of each of the plurality of lower belt elements are arranged between the lower outer layer and the lower insulating layer.

[0038] Optionally, the at least one insulating layer comprises an intermediate insulating layer arranged between the upper insulating layer and the lower insulating layer.

[0039] Advantageously, the provision of more than one insulating layer helps to enable additional capture and reflection of heat back to the user, thereby reducing the amount of thermal energy transferred through the inflatable mat and improving the thermal efficiency of the inflatable mat.

[0040] Optionally, the plurality of connecting elements each comprise a neck portion. Optionally, the intermediate insulation layer comprises an opening sized to be retained around the neck portion to position the intermediate insulation layer relative to the connecting element in a direction transverse to the upper and lower outer layers when the inflatable mat is in an inflated configuration.

[0041] Optionally, the opening defines a width and the minimum width of the neck section is substantially equal to the width of the opening.

[0042] Optionally, the connecting element essentially has an hourglass shape defining the neck section.

[0043] Providing an hourglass shape advantageously allows the neck portion to hold the insulation layer in the correct position when the inflatable mat is in its intended orientation and when the inflatable mat is upside down. Furthermore, an hourglass shape is easy to manufacture and install.

[0044] Optionally, the at least one insulating layer comprises a plurality of openings each configured to receive the neck portion of a respective connecting element.

[0045] Advantageously, the provision of a plurality of openings helps to distribute the insulating layer across its surface, which can help to improve the thermal performance of the inflatable mat.

[0046] Optionally, each of the plurality of connecting elements is formed from a single piece extending between the upper outer layer and the lower outer layer.

[0047] Optionally, each of the plurality of connecting elements is a beam element or a column element.

[0048] Beam or column elements advantageously represent a simple way to provide support and shape to the upper and lower outer layers and are easy to manufacture and install.

[0049] Optionally, the majority of connecting elements and / or belt elements are welded or heat sealed to the respective upper or lower outer layer.

[0050] Advantageously, such joining methods provide a strong and permanent connection and thereby a reliable structural integrity of the joints.

[0051] Optionally, the upper and lower outer layers and at least one insulating layer are made of different materials.

[0052] Advantageously, making the upper and lower outer layers and at least one insulating layer from different materials means that the layers can, in use, perform the dual function of increasing the thermal efficiency of the inflatable mat and providing support to the user during use.

[0053] Furthermore, because the upper and lower insulation layers are made of a different material than the upper and lower outer layers, the upper and lower insulation layers cannot be heat-sealed or welded to the respective upper or lower outer layers. Thus, the connecting elements and strap elements help overcome the problem of how to connect or position the insulation layer(s) to the upper and lower outer layers.

[0054] Optionally, the outer layers are made of a textile material, optionally a nylon or a polyester material.

[0055] Advantageously, these materials offer user comfort, durability and light weight.

[0056] Optionally, the at least one insulating layer is made of a material designed for heat reflection, optionally a metallic material, optionally a metallic foil, for example a woven or non-woven fabric or a gauze with a metallic coating.

[0057] Advantageously, such materials have high thermal reflectivity and are lightweight.

[0058] Another aspect of the present teachings provides an inflatable mat comprising: an upper outer layer and a lower outer layer defining a substantially enclosed interior space; and / or at least one valve in selectable fluid communication with the interior space; and / or at least one insulating layer disposed between the upper outer layer and the lower outer layer; and / or a plurality of connecting elements each extending between and directly connected to the upper outer layer and the lower outer layer, each of the plurality of connecting elements comprising a neck portion;and / or wherein the at least one intermediate insulating layer comprises an opening sized to be retained around the neck portion to position the insulating layer relative to the connecting member in a direction substantially transverse to the upper and lower outer layers when the inflatable mat is configured for use.;

[0059] Advantageously, the use of the connecting elements helps to support the upper outer layer against the lower outer layer when the inflatable mat is in an inflated configuration. Additionally, the connecting elements serve the secondary function of locating the insulation layer, thereby reducing the complexity of manufacturing the inflatable mat and the number of components.

[0060] Optionally, the neck portion defines a minimum width, and the minimum width is spaced from the top and bottom ends of the connecting element.

[0061] The provision of a minimum width spaced from the upper and lower ends of the connecting member advantageously enables the neck portion to maintain the insulation layer in the correct position when the inflatable mat is in the orientation of use and when the inflatable mat is upside down.

[0062] Optionally, the opening defines a width, with the minimum width of the neck portion being substantially equal to the width of the opening.

[0063] Optionally, the connecting element essentially has an hourglass shape defining the neck section.

[0064] Providing an hourglass shape advantageously allows the neck portion to hold the insulation layer in the correct position when the inflatable mat is in its intended orientation and when the inflatable mat is upside down. Furthermore, an hourglass shape is easy to manufacture and install.

[0065] Optionally, the at least one insulating layer comprises a plurality of openings each configured to receive the neck portion of a respective connecting element.

[0066] Advantageously, the provision of a plurality of openings helps to distribute the insulating layer across its surface, which can help to improve the thermal performance of the inflatable mat.

[0067] Optionally, each of the plurality of connecting elements is formed from a single piece that extends between the upper outer layer and the lower outer layer.

[0068] Optionally, the inflatable mat comprises a plurality of connecting elements, each extending between the upper outer layer and the lower outer layer and being directly connected thereto.

[0069] Advantageously, the plurality of connecting elements contribute to maintaining a desired distance between the upper outer layer and the lower outer layer when the inflatable mat is in an inflated configuration to maintain its generally planar shape with a desired thickness. The strap elements contribute to holding the insulating layers relative to the upper and lower outer layers, thereby maintaining the insulating layers in suitable positions where they effectively prevent heat loss when the mat is in an inflated configuration.

[0070] The provision of connecting and strapping elements to perform the aforementioned functions can help to improve ease of manufacture while maintaining the desired shape and arrangement of the insulating layer of the inflatable mat in the inflated configuration.

[0071] Optionally, the plurality of connecting elements are each discrete from one another. Optionally, the plurality of belt elements are each discrete from the plurality of connecting elements and from one another.

[0072] Advantageously, the provision of a plurality of discrete connecting elements and / or discrete strap elements improves ease of manufacture of the inflatable mat - for example, compared to a continuous arrangement of connecting elements and / or strap elements.

[0073] Optionally, the connecting elements are aligned essentially transversely to the belt elements.

[0074] Advantageously, the provision of the connecting elements transverse to the strap elements helps to provide support and shape to the inflatable mat in more than one direction.

[0075] Optionally, the plurality of connecting elements are aligned substantially transversely to the upper outer layer and the lower outer layer when the inflatable mat is in an inflated configuration.

[0076] Advantageously, the transverse connecting elements connect the upper outer layer to the lower outer layer and provide support and shape in the direction transverse to the upper outer layer and the lower outer layer.

[0077] Optionally, each of the plurality of belt elements extends from the respective upper or lower outer layer through the at least one insulating layer and back to the same respective upper or lower layer to connect the at least one insulating layer to the respective upper or lower outer layer.

[0078] Advantageously, the provision of strap members extending through the at least one insulating layer and back upon themselves connects the upper or lower outer layer to the at least one insulating layer, thereby providing support and shape to the inflatable mat.

[0079] Optionally, each of the plurality of connecting elements is connected to the upper outer layer at an upper connection point and to the lower outer layer at a lower connection point, and wherein the upper and lower connection points are transversely aligned with each other.

[0080] Advantageously, the provision of transversely aligned joints provides support and shape in the direction transverse to the upper outer layer and the lower outer layer, which helps to support the weight of a user.

[0081] Optionally, the plurality of strap elements are directly connected to the respective upper or lower outer layer at a first connection point and at a second connection point spaced apart from the first connection point. Optionally, the first connection point is longitudinally aligned with the second connection point.

[0082] Advantageously, the first and second connection points enable the connection of the at least one insulating layer to the upper or lower outer layer.

[0083] In addition, the provision of longitudinally aligned joints provides support and shape in the longitudinal direction.

[0084] Optionally, the plurality of connecting elements are arranged in an array of rows. Optionally, each row extends in a direction substantially perpendicular to the central longitudinal axis of the inflatable mat.

[0085] Advantageously, providing an array of rows provides uniform support and helps maintain the shape of the inflatable mat along each row. Furthermore, rows are easy to manufacture.

[0086] Optionally, adjacent rows of the plurality of connecting elements are arranged offset in the longitudinal direction.

[0087] Advantageously, the provision of longitudinally staggered rows contributes to supporting a larger area with a given number of connecting elements. Furthermore, the spacing created by the longitudinally staggered rows can be utilized for the belt elements.

[0088] Optionally, the plurality of strap elements are arranged in an array of rows. Optionally, each row extends in a direction substantially perpendicular to a central longitudinal axis of the inflatable mat.

[0089] Advantageously, providing an array of rows provides uniform support and helps maintain the shape of the inflatable mat along each row. Furthermore, rows are easy to manufacture.

[0090] Optionally, adjacent rows are arranged offset in the longitudinal direction.

[0091] Advantageously, the provision of longitudinally staggered rows contributes to supporting a larger surface area with a given number of connecting elements. Furthermore, the spacing created by the longitudinally staggered rows can be utilized for the belt elements.

[0092] Optionally, each of the plurality of belt elements is arranged between adjacent connecting elements.

[0093] Advantageously, the provision of belt elements arranged between the connecting elements helps to provide uniform support and uniform shape, and the spaces between the adjacent connecting elements are efficiently used for arranging the belt elements.

[0094] Optionally, the at least one insulating layer comprises a plurality of openings each adapted to receive a connecting element therethrough.

[0095] Advantageously, the openings in the at least one insulating layer are easy to produce and enable a connection and support between the upper outer layer and the lower outer layer.

[0096] Optionally, the at least one insulating layer comprises an upper insulating layer connected to the upper outer layer by a plurality of upper belt elements and a lower insulating layer connected to the lower outer layer by a plurality of lower belt elements.

[0097] Advantageously, the provision of more than one insulating layer helps to enable additional capture and reflection of heat back to the user, thereby reducing the amount of thermal energy transferred through the inflatable mat and improving the thermal efficiency of the inflatable mat.

[0098] Optionally, the first and second connection points of each of the plurality of upper belt elements are arranged between the upper outer layer and the upper insulating layer and / or the first and second connection points of each of the plurality of lower belt elements are arranged between the lower outer layer and the lower insulating layer.

[0099] Optionally, each of the plurality of connecting elements is a beam element or a column element.

[0100] Beam or column elements advantageously represent a simple way to provide support and shape to the upper and lower outer layers and are easy to manufacture and install.

[0101] Optionally, the majority of connecting elements and / or belt elements are welded or heat sealed to the respective upper or lower outer layer.

[0102] Advantageously, such joining methods provide a strong and permanent connection and thereby a reliable structural integrity of the joints.

[0103] Optionally, the upper and lower outer layers and at least one insulating layer are made of different materials.

[0104] Advantageously, making the upper and lower outer layers and at least one insulating layer from different materials means that the layers can, in use, perform the dual function of increasing the thermal efficiency of the inflatable mat and providing support to the user during use.

[0105] Furthermore, because the upper and lower insulation layers are made of a different material than the upper and lower outer layers, the upper and lower insulation layers cannot be heat-sealed or welded to the respective upper or lower outer layers. Thus, the connecting elements and strap elements help overcome the problem of how to connect or position the insulation layer(s) to the upper and lower outer layers.

[0106] Optionally, the outer layers are made of a textile material, optionally a nylon or a polyester material.

[0107] Advantageously, these materials offer user comfort, durability and light weight.

[0108] Optionally, the at least one insulating layer is made of a material designed for heat reflection, optionally a metallic material, optionally a metallic foil.

[0109] Advantageously, such materials - for example, a woven or non-woven fabric or a gauze with a metallic coating - have high thermal reflectivity and are lightweight.

[0110] Another aspect of the present teaching relates to a method for producing an inflatable mat, the method comprising the following steps: providing an upper outer layer and a lower outer layer; providing at least one insulating layer; providing a plurality of connecting elements and / or a plurality of strap elements; optionally connecting the insulating layer to the upper outer layer or the lower outer layer via the plurality of strap elements; optionally connecting each of the connecting elements to the upper outer layer or the lower outer layer such that each of the connecting elements optionally extends between the upper outer layer and the lower outer layer and the insulating layer is optionally arranged between the upper outer layer and the lower outer layer. BRIEF DESCRIPTION OF THE DRAWINGS

[0111] Exemplary embodiments are described below with reference to the accompanying drawings, in which: the Fig. 1 is a plan view of an inflatable mat according to the present teachings; the Fig. 2 is an exploded view of a portion of the inflatable mat of the Fig. 1 is; the Fig. 3 a schematic view of a cross-section of the inflatable mat of the Fig. 1 is; the Fig. 4 a plan view of the connecting elements and the strap elements of the inflatable mat of the Fig. 1; and the Fig. 5A to 5C are exploded views showing alternative embodiments of inflatable mats according to the present teachings. DETAILED DESCRIPTION OF THE EMBODIMENT(S)

[0112] First of all, Fig. 1, an inflatable mat according to the present teachings is generally designated by the reference numeral 10. The term "top" is understood to mean a side of the inflatable mat that is intended to face away from the ground (i.e., substantially upward) when the inflatable mat 10 is in an orientation intended for use by a user. The term "bottom" is understood to mean a side of the inflatable mat that is intended to face away from the ground (i.e., substantially downward) when the inflatable mat 10 is in an orientation intended for use by a user. For ease of understanding, the inflatable mat 10 will be described below in its inflated state. It will be understood that the relative positions of the components described below may change when deflated for storage or transport.

[0113] The inflatable mat 10 comprises an upper outer layer 12a and a lower outer layer 12b defining a substantially enclosed interior space, at least one valve 14 in selectable fluid communication with the interior space, at least one insulating layer 16a-c disposed between the upper outer layer 12a and the lower outer layer 12b, a plurality of connecting elements 18 extending between and directly connected to the upper outer layer 12a and the lower outer layer 12b, and / or a plurality of strap elements 20a, 20b each configured to connect the at least one insulating layer 16a, 16c to one of the upper and lower outer layers 12a, 12b. It should be understood that in some embodiments, the strap elements 20a, 20b may be omitted, as further described below.

[0114] The inflatable mat 10 is inflated to an inflated configuration by supplying air into the enclosed interior space via the valve 14. The valve 14 can be connected to a compressed air supply, such as a pump, or the valve 14 can be supplied with air by a user manually inflating the inflatable mat 10. In the embodiment of the Fig. 1, the valve 14 is disposed on the upper outer layer 12a near its periphery; however, in alternative embodiments, the valve 14 may be disposed on the lower outer layer 12b or at a seam between the upper outer layer 12a and the lower outer layer 12b. It is understood that the valve 14 may be any suitable valve 14, such as a Boston valve or a pinch valve, or that the valve 14 may be any form of closable opening.

[0115] The upper and lower outer layers 12a, 12b are made of an outermost composite material consisting of a flexible textile sheet material—for example, a nylon or polyester material—and an innermost flexible and air-impermeable plastic film—for example, a thermoplastic urethane (TPU) material. These materials provide user comfort while being durable and lightweight. The upper and lower outer layers 12a, 12b can be bonded together using any suitable manufacturing method, for example, by ultrasonic welding, heat sealing, or using an adhesive. It is understood that in other embodiments, the upper and lower outer layers 12a, 12b can be made of any suitable material known in the art.

[0116] The upper outer layer 12a forms a substantially flat surface that directly supports the weight of the user when lying on the inflatable mat. The lower outer layer 12b forms a substantially flat surface that comes into contact with a ground surface during use. The upper outer layer 12a and the lower outer layer 12b are substantially parallel when the inflatable mat 10 is in the inflated configuration.

[0117] The upper and lower outer layers 12a, 12b are elongated along a longitudinal axis aa of the inflatable mat 10. This approximately corresponds to the proportions / shape of the user, i.e., a human, thereby providing the user with a comfortably shaped inflatable mat 10 to sleep on. It is understood that in some embodiments, the upper and lower outer layers 12a, 12b may each be formed from more than one upper and one lower outer layer. For example, the upper and / or lower outer layers 12a, 12b may each be formed from more than two upper or lower outer layers 12a, 12b, for example, from more than three upper or lower outer layers 12a, 12b.

[0118] The at least one insulating layer 16a-c is made of a different material than the upper and lower outer layers 12a, 12b for insulation against radiated heat. The insulating layer can also contribute to reducing heat loss by convection. In the embodiment of the Fig. 1 to 4, the at least one insulating layer is made of a material that reflects radiated heat, for example, a thin scrim or gauze substrate made of woven or nonwoven fabric coated with a metallic material, such as aluminum or titanium, such as the proprietary "TILT" (Thermo Ionic Lining Technology) material. In alternative embodiments, the at least one insulating layer 16a-c may be made of any suitable sheet of insulating material—for example, a foam sheet—if a less compact mat is acceptable in the deflated state.

[0119] Such insulating layers 16a, 16c are made of materials that cannot be heat-sealed or welded to the respective upper or lower outer layers 12a, 12b. For example, metallic coatings typically impede the fusion of layers, even if the substrate could be heat-sealed. Therefore, the connecting elements 18 and the strap elements 20a, 20b contribute to properly locating the upper, lower, and intermediate insulating layers 16a-c relative to the upper and lower outer layers 12a, 12b.

[0120] In the Fig. In the embodiment shown in Figures 1 to 4, the at least one insulating layer 16a-c comprises an upper insulating layer 16a held in position adjacent the upper outer layer 12a by a plurality of upper strap members 20a, a lower insulating layer 16c held in position adjacent the lower outer layer 12b by a plurality of lower strap members 20b, and an intermediate insulating layer 16b disposed between the upper insulating layer 16a and the lower insulating layer 16c. The provision of more than one insulating layer 16a-c helps to enable additional reflection of heat back to the user and a reduction in heat loss via convection, thereby reducing the amount of heat energy transferred through the inflatable mat 10 and improving the thermal efficiency of the inflatable mat 10.In this embodiment, the insulating layers 16a-c each consist of substantially the same material, although this may not be the case in other embodiments.

[0121] It is understood that in alternative embodiments, any suitable number of insulating layers 16a-c may be used, for example, one, two, or four insulating layers 16a-c. The number of insulating layers 16a-c may depend on the season in which the inflatable mat 10 is to be used. Inflatable mats 10 for summer use may have fewer insulating layers 16a-c, for example, one insulating layer 16a-c, and inflatable mats 10 for winter use may have a greater number of insulating layers 16a-c, for example, three or four insulating layers 16a-c.

[0122] The insulating layers 16a-c extend over a large part of the area of ​​the inflatable mat 10, for example, over substantially the entire inflatable mat 10. This helps to improve the uniformity of insulation of the inflatable mat 10. As will be explained in more detail below, when the inflatable mat 10 is in the inflated configuration, the intermediate layer 16b is arranged approximately equidistant from the upper and lower outer layers 12a, 12b.

[0123] As in the Fig. 2 and Fig. 3, the upper and lower insulating layers 16a, 16c each comprise a plurality of connection openings 22, each adapted to receive a connecting element 18 therethrough. In the embodiment of Fig. 1 to 4, 5A and 5B, the upper and lower insulating layers 16a, 16c each comprise a plurality of belt openings 24 configured to receive a respective belt element 20a, 20b therethrough. The intermediate insulating layer 16b comprises a plurality of openings 26, each configured to receive a connecting element 18 therethrough. In this embodiment, the connecting openings 22 of the upper and lower insulating layers 16a, 16c are each arranged transversely aligned with one another, and each of the openings 26 in the intermediate insulating layer 16b is arranged transversely aligned with a respective connecting opening 22 of the upper and lower insulating layers 16a, 16c, respectively, to receive a vertically arranged connecting element 18. In further embodiments, the connecting elements 18 may be angled, in which case the openings 22, 26 may not be aligned with one another.The arrangement of the connecting elements 18 and the belt elements 20a, 20b through the openings is described in more detail below.

[0124] The plurality of connecting elements 18 are each discrete from one another. The plurality of strap elements 20a, 20b are each discrete from one another and from each of the plurality of connecting elements 18. In other words, each of the plurality of connecting elements 18 and each of the plurality of strap elements 20a, 20b is a separate body. The provision of a plurality of discrete connecting elements 18 and / or discrete strap elements 20a, 20b contributes to improving the ease of manufacture of the inflatable mat 10—for example, compared to a continuous arrangement of connecting elements 18 and / or strap elements 20a, 20b. This arrangement can also, for example, improve the flexibility of the design to vary the number and position of the insulating layers 16a-c.

[0125] As in the Fig. 1 and Fig. 4, the plurality of connecting elements 18 and the plurality of strap elements 20a, 20b are arranged in an array of rows. In this embodiment, each row of connecting elements 18 extends in a direction substantially perpendicular to the central longitudinal axis aa of the inflatable mat 10, and the rows of strap elements 20a, 20b extend longitudinally along the inflatable mat 10 in an alternating pattern. Providing an array of rows provides uniform support and helps maintain the shape of the inflatable mat 10 along each of the rows. Furthermore, rows are a simple configuration to manufacture. In the embodiment of Fig. 1 to 4, 25 rows of connecting elements 18 and five rows of belt elements 20a, 20b are provided. However, it is understood that—depending, for example, on a length or a width of the inflatable mat 10—any suitable number of rows with any suitable number of connecting elements 18 and / or belt elements 20a, 20b in each row may be provided. Adjacent rows of the plurality of rows of connecting elements 18 are arranged offset longitudinally. Adjacent rows of the plurality of belt elements 20a, 20b are arranged offset transversely. This contributes to supporting a larger surface area of ​​the inflatable mat 10 with a given number of connecting elements 18 or belt elements 20a, 20b.

[0126] Each of the plurality of belt elements 20a, 20b is arranged between adjacent connecting elements 18. Some of the belt elements 20a, 20b are arranged between longitudinally adjacent connecting elements 18, and some of the belt elements 20a, 20b are arranged between laterally adjacent connecting elements 18.

[0127] It is understood that the arrangement of the connecting elements 18 and the belt elements 20a, 20b shown in the figures, for example the arrangement shown in the Fig. 1 and the Fig. 4 is exemplary. In alternative embodiments, each row of strap elements 20a, 20b and / or connecting elements 18 may extend in a direction substantially parallel to the longitudinal axis aa of the inflatable mat 10. It should be understood that in alternative embodiments, the connecting elements 18 and / or the strap elements 20a, 20b may be arranged in any suitable arrangement—for example, in diamonds of connecting elements 18 and / or strap elements 20a, 20b.

[0128] The connecting elements 18 contribute to supporting the upper outer layer 12a against the lower outer layer 12b when the inflatable mat 10 is in the inflated configuration. It is understood that the connecting elements 18 are arranged in the enclosed interior of the inflatable mat 10, i.e., are connected to an inner surface of the upper and lower outer layers 12a, 12b. When the inflatable mat 10 is inflated, the upper and lower outer layers 12a, 12b are forced apart by the pressure of the air in the enclosed space. The connecting elements 18 act in tension to maintain the upper outer layer 12a and the lower outer layer 12b at a desired distance from each other, thereby providing the user with a comfortable and consistently shaped inflatable mat 10 to lie upon. The connecting elements 18 are thus under tension when the inflatable mat 10 is in the inflated configuration.

[0129] The connecting elements 18 enable the substantially flat surfaces of the upper and lower outer layers 12a, 12b so that the user can sleep comfortably on the upper outer layer 12a and the lower outer layer 12b can be supported by the floor surface.

[0130] In this embodiment, the connecting elements 18 are provided as a one-piece film of flexible, heat-weldable material. This can be a plastic film—for example, a thermoplastic urethane material (TPU). The elements 18 extend between the upper outer layer 12a and the lower outer layer 12b. As shown in Fig. 2, the connecting elements 18 are oriented substantially transversely to the strap elements 20a, 20b. Furthermore, the connecting elements 18 are oriented substantially transversely to the upper outer layer and the lower outer layer 12a, 12b when the mat is in an inflated configuration. Orienting the connecting elements 18 transversely helps to provide support and shape to the inflatable mat 10 in a direction substantially transverse to the upper and lower outer layers 12a, 12b, i.e., opposite to a direction in which a load is exerted on the upper outer layer 12a during user use. The connecting elements 18 may be, for example, beam elements or column elements.

[0131] As in the Fig. As shown in Figure 3, each of the connecting elements 18 is connected directly to the upper outer layer 12a at an upper connection point 28a and directly to the lower outer layer 12b at a lower connection point 28b. The upper and lower connection points 28a, 28b are formed in a folded lip or flange 29a, 29b at the free ends of the connecting elements 18, which are brought into contact with an inner surface of the respective outer layer 12a, 12b.

[0132] In this way, the upper and lower connection points 28a, 28b connect the upper and lower ends of the connecting element 18, which are opposite one another, to the respective upper or lower outer layer 12a, 12b. The connecting elements 18 are heat-sealed or welded at the upper and lower connection points 28a, 28b. As shown in the figures, the upper and lower connection points 28a, 28b can be a strip or a linear connection point.

[0133] The upper connection point 28a and the lower connection point 28b are arranged in transverse alignment when the inflatable mat 10 is inflated. The upper and lower connection points 28a, 28b are aligned with the connection openings 22 of the upper and lower insulating layers 16a, 16c and with the opening 26 of the intermediate insulating layer 16b. Thus, each connection element 18 extends from the upper connection point 28a transversely through the connection opening 22 of the upper insulating layer 16a, through the opening 26 of the intermediate insulating layer 16b, and through the connection opening 22 of the lower insulating layer 16c to the second connection point 28b. The connection openings 22 are sized to provide suitable clearance for assembly around the lips 29a, but not so large as to impair the insulating qualities.

[0134] It will be appreciated that in embodiments where the upper and lower insulating layers 16a, 16c are omitted, each connecting element 18 may extend from the upper connection point 28a across the opening 26 of the intermediate insulating layer 16b and to the lower connection point 28b.

[0135] As in the Fig. 3, in this embodiment, each of the plurality of connecting elements 18 comprises a neck portion 30. The neck portion 30 defines a minimum width of the respective connecting element 18, and the minimum width is spaced apart from the upper and lower ends of the connecting element 18. In the embodiment of Fig. 3, the minimum width is located substantially transversely centrally on the connecting element 18. In other words, the minimum width is equidistant from the upper and lower ends of the connecting element 18 or equidistant from the upper and lower outer layers 12a, 12b. The connecting element 18 is substantially planar. In this embodiment, the connecting element 18 substantially has an hourglass shape defining the neck portion 30. In other words, the connecting element 18 tapers inwardly toward the neck portion 30 from both the upper end (or upper connection point 28a) and the lower end (or lower connection point 28b). The tapers are substantially linear.

[0136] It is understood that in alternative embodiments, the connecting element 18 may have any suitable shape defining a neck portion 30—for example, curved or stepped. In some embodiments, the connecting element 18 may have more than one neck portion 30 for transversely disposing more than one intermediate insulating layer 16b. The connecting element 18 may taper inwardly and outwardly to form more than one neck portion 30. It is understood that the connecting element 18 may be provided in more than one piece, for example, in two pieces. The two pieces may, for example, be heat-sealed or welded to the neck portion 30.

[0137] The opening 26 of the intermediate insulation layer 16b is sized to be retained around the neck portion 30 to position the intermediate insulation layer 16b relative to the connecting element 18 in a direction substantially transverse to the upper and lower outer layers 12a, 12b when the inflatable mat 10 is in the inflated configuration. It should be understood that in embodiments where only the intermediate insulation layer 16b is provided, the intermediate insulation layer 16b may rather be referred to as the insulation layer 16b. The opening 26 defines a width, and the minimum width of the neck portion 30 is substantially equal to the width of the opening 26. "Substantially" may be understood to mean that the width of the opening 26 is up to 20% greater than the minimum width of the neck portion 30, for example, up to 10% greater than the minimum width of the neck portion 30.Since the minimum width of the neck portion 30 is spaced from the upper and lower ends of the connecting member 18, the intermediate layer 16b is positioned relative to the connecting member 18 regardless of the orientation of the inflatable mat 10 (i.e., regardless of whether the upper and lower outer layers 12a, 12b are upside down).

[0138] It is understood that in embodiments in which the upper and / or lower insulating layers 16a, 16c are omitted, only the upper belt elements 20a, only the lower belt elements 20b, or both the upper and lower belt elements 20a, 20b may be omitted. Thus, there may be embodiments of the inflatable mat 10 in which only the connecting elements 18 are included. The upper and lower belt elements 20a, 20b are substantially identical. The term "belt elements" is therefore used hereinafter with reference to both the upper and lower belt elements 20a, 20b.

[0139] The strap elements 20a, 20b help support the upper and lower insulation layers 16a, 16c relative to the upper and lower outer layers 12a, 12b when the inflatable mat 10 is in the inflated configuration. It is understood that the strap elements 20a, 20b are disposed within the enclosed interior space of the inflatable mat 10, i.e., are connected to the inner surface of the upper and lower outer layers 12a, 12b. Each of the plurality of strap elements 20a, 20b extends from the respective upper or lower outer layer 12a, 12b through the at least one insulation layer 16a, 16c and back to the same respective upper or lower layer 16a, 16c to connect the upper or lower insulation layer 16a, 16c to the respective upper or lower outer layer 12a, 12b.It will be appreciated that when the inflatable mat 10 is in the inflated configuration, the strap members 20a, 20b extend generally in a shallow U-shape from the upper or lower outer layer 12a, 12b and through the upper or lower insulation layer 16a, 16c, thus holding the respective insulation layer in its desired position.

[0140] The plurality of strap elements 20a, 20b are each aligned substantially parallel to the central longitudinal axis aa of the inflatable mat 10 when the inflatable mat 10 is in the inflated configuration.

[0141] The plurality of belt elements 20a, 20b are each formed from a flexible film and define opposing planar surfaces. One of the planar surfaces faces the upper outer layer 12a, and one of the planar surfaces faces the lower outer layer 12b. As shown in the Fig. 4, each of the plurality of belt elements 20a, 20b is substantially linear in plan view.

[0142] The plurality of belt elements 20a, 20b are directly connected to the corresponding upper outer layer 12a or lower outer layer 12b at a first connection point 32a and at a second connection point 32b spaced from the first connection point 32a. As shown in the Fig. 4, the first connection point 32a may be axially aligned with the second connection point 32b when the inflatable mat 10 is configured for use. The first and second connection points 32a, 32b may be dots or dashes. In alternative embodiments, the first and second connection points 32a, 32b may be aligned in any suitable orientation, for example, laterally. The first and second connection points 32a, 32b are disposed at opposite ends of each of the strap members 20a, 20b. In other words, these are the ends of the strap members 20a, 20b that are connected to the upper and lower outer layers 12a, 12b.

[0143] The belt elements 20a, 20b are heat-sealed or welded to the respective upper or lower outer layer 12a, 12b at the first and second connection points 32a, 32b. Thus, the first and second connection points 32a, 32b securely hold the upper and lower insulating layers 16a, 16c to the respective upper and lower outer layers 12a, 12b without the need to heat-seale or weld the upper or lower insulating layers 16a, 16c to the upper or lower outer layer 12a, 12b.

[0144] The first and second connection points 32a, 32b are at least partially aligned transversely to the belt opening 24 of the respective upper or lower insulating layer 16a, 16c. This contributes to improved manufacturing convenience, as the belt elements 20a, 20b can be heat-sealed or welded to the upper or lower outer layer 12a, 12b via the belt openings 24, thereby connecting the upper or lower insulating layer 16a, 16c to the respective upper or lower outer layer 12a, 12b via the belt elements 20a, 20b.

[0145] Each belt element 20a, 20b extends through more than one of the plurality of belt openings 24 of the respective upper or lower insulating layer 16a, 16c. For example, each belt element 20a, 20b may extend through adjacent belt openings 24. Thus, each belt element 20a, 20b extends from the first connection point 32a through a belt opening 24 and below the respective upper or lower insulating layer 16a, 16c back through an adjacent opening 24 of the upper or lower insulating layer 16a, 16c and to the second connection point 32b. It is understood that in some embodiments, the belt element 24 may extend through more than two belt openings 24. Each belt element 20a, 20b extends only through the upper or lower insulating layer 16a, 16b. This is different from the connecting elements 18, which can pass through more than one of the insulating layers 16a-c.

[0146] A method for manufacturing an inflatable mat 10 is described below. An upper outer layer 12a and a lower outer layer 12b are provided. As described above, the upper outer layer 12a and the lower outer layer 12b may be formed from more than one layer. At least one insulating layer 16a-c—for example, an upper insulating layer 16a, a lower insulating layer 16c, and an intermediate insulating layer 16b—is provided. A plurality of connecting elements 18 and a plurality of strap elements 20a, 20b—for example, upper and lower strap elements 20a, 20b—which, as described, are of substantially identical configuration, are provided.

[0147] The upper insulating layer 16a is held to the upper outer layer 12a by the plurality of upper strap elements 20a. The lower insulating layer 16b is held to the lower outer layer 12b by the lower strap elements 20b. The strap elements 20a, 20b are disposed in the strap openings 24, and the strap elements 20a, 20b are heat-sealed or welded to the upper or lower outer layer 12a, 12b at the first and second connection points 32a, 32b. The intermediate insulating layer 16b is disposed on the neck portion 30 such that the openings 26 receive a neck portion 30 of the connection elements 18.Each of the connecting elements 18 is connected to the upper outer layer 12a and the lower outer layer 12b such that each of the connecting elements 18 extends between the upper outer layer 12a and the lower outer layer 12b, and the insulating layer 16b is disposed between the upper outer layer 12a and the lower outer layer 12b. The connecting element 18 is heat-sealed or welded at the upper and lower connection points 28a, 28b. The upper outer layer 12a and the lower outer layer 12b can then be secured at their peripheral edges to form the inflatable mat 10, for example, using heat sealing, welding, or an adhesive.

[0148] In the Fig. 5A to 5C, an alternative embodiment of the inflatable mat 10 is shown with an alternative number of insulating layers 16a-c. In the embodiment of Fig. 5A, the upper insulating layer 16a and the lower insulating layer 16b are provided (ie, there are two insulating layers 16a, 16c). Therefore, in this embodiment, no insulating layer 16b is arranged around the neck portion 30. It is therefore conceivable that the neck portion 30 may be omitted.

[0149] In the embodiment of the Fig. 5B, an upper insulating layer 16a and an intermediate insulating layer 16b are provided. In this embodiment, "intermediate" is understood to mean that the insulating layer 16b is disposed at the neck portion 30 or does not include any belt elements 20a, 20b extending therethrough. Accordingly, in this embodiment, the lower belt elements 20b are omitted. It is understood that in a further alternative embodiment, only the intermediate insulating layer 16b and the lower insulating layer 16c may be provided, and the upper belt elements 20b may be omitted.

[0150] The Fig. Figure 5C shows an alternative embodiment in which only one insulating layer 16a is provided. As described above, this embodiment of the inflatable mat 10 can be used in summer or in climates with higher temperatures. The embodiment of the Fig. 5C comprises an upper outer layer 12a and a lower outer layer 12b defining a substantially enclosed interior space, at least one valve in selectable fluid communication with the interior space, at least one insulating layer 16b disposed between the upper outer layer 12a and the lower outer layer 12b, and a plurality of connecting elements 18 each extending between and directly connected to the upper outer layer 12a and the lower outer layer 12b, each of the plurality of connecting elements 18 including a neck portion 30, and the at least one intermediate insulating layer 16b including an opening 24 sized to be retained around the neck portion 30 to position the insulating layer 16b relative to the connecting element 18 in a direction substantially transverse to the upper and lower outer layers 12a, 12b.when the inflatable mat 10 is configured for use.

[0151] It is understood that the above in relation to the Fig. 1 to 4 described teaching to the embodiments of the Fig. 5A to 5C is applicable.

[0152] Although the teachings above have been described with reference to one or more preferred embodiments, it should be understood that various changes or modifications may be made without departing from the scope of protection as defined in the appended claims. For example, the connecting elements may not be of equal length. For example, the connecting elements at the side edges may be longer than those in the center. This makes the sides of the mat thicker than the center and thus helps position the user on the mat while sleeping. While the construction described above is described with reference to a sleeping mat, it may also be used for other articles, such as pillows or cushions, which are intended to be encompassed by the term "inflatable mat."

Claims

[1] Inflatable mat, comprising: an upper outer layer and a lower outer layer defining a substantially enclosed interior space; at least one valve in selectable fluid communication with the interior; at least one insulating layer arranged between the upper outer layer and the lower outer layer; a plurality of connecting elements each extending between the upper outer layer and the lower outer layer and being directly connected thereto; and a plurality of belt elements each adapted to hold the insulating layer to one of the upper and lower outer layers, respectively. [2] The inflatable mat of claim 1, wherein the plurality of connecting elements are each discrete from one another, and / or wherein the plurality of strap elements are each discrete from the plurality of connecting elements and from one another. [3] An inflatable mat according to claim 1 or claim 2, wherein the connecting elements are aligned substantially transversely to the strap elements. [4] An inflatable mat according to any preceding claim, wherein the plurality of connecting elements are aligned substantially transversely to the upper outer layer and to the lower outer layer when the inflatable mat is in an inflated configuration. [5] An inflatable mat according to any one of the preceding claims, wherein each of the plurality of strap members extends from the respective upper or lower outer layer through the at least one insulating layer and back to the same respective upper or lower layer to connect the at least one insulating layer to the respective upper or lower outer layer. [6] An inflatable mat according to any one of the preceding claims, wherein each of the plurality of connecting elements is connected to the upper outer layer at an upper connection point and to the lower outer layer at a lower connection point, and wherein the upper and lower connection points are transversely aligned with each other. [7] An inflatable mat according to any one of the preceding claims, wherein the plurality of strap elements are directly connected to the respective upper or lower outer layer at a first connection point and at a second connection point spaced from the first connection point, the first connection point optionally being longitudinally aligned with the second connection point. [8] An inflatable mat according to any one of the preceding claims, wherein the plurality of connecting elements are arranged in an array of rows, each row optionally extending in a direction substantially perpendicular to the central longitudinal axis of the inflatable mat, adjacent rows of the plurality of connecting elements optionally being arranged longitudinally offset. [9] An inflatable mat according to any one of the preceding claims, wherein the plurality of strap members are arranged in an array of rows, each row optionally extending in a direction substantially perpendicular to a central longitudinal axis of the inflatable mat, adjacent rows optionally being longitudinally offset. [10] An inflatable mat according to any one of the preceding claims, wherein each of the plurality of strap members is disposed between adjacent connecting members. [11] An inflatable mat according to any one of the preceding claims, wherein the at least one insulating layer comprises a plurality of openings each adapted to receive a connecting element therethrough. [12] An inflatable mat according to any one of the preceding claims, wherein the at least one insulating layer comprises a plurality of openings, each opening being adapted to receive a respective strap member therethrough, optionally wherein each strap member extends through more than one of the plurality of openings of the at least one insulating layer. [13] An inflatable mat according to any one of the preceding claims, wherein the at least one insulating layer comprises an upper insulating layer connected to the upper outer layer by a plurality of upper strap elements and a lower insulating layer connected to the lower outer layer by a plurality of lower strap elements, wherein the at least one insulating layer optionally comprises an intermediate insulating layer arranged between the upper insulating layer and the lower insulating layer. [14] An inflatable mat according to claim 13 when dependent on claim 7, wherein the first and second connection points of each of the plurality of upper belt members are arranged between the upper outer layer and the upper insulating layer and / or wherein the first and second connection points of each of the plurality of lower belt members are arranged between the lower outer layer and the lower insulating layer. [15] An inflatable mat according to claim 13 or claim 14, wherein the plurality of connecting elements each comprise a neck portion, and wherein the intermediate insulating layer comprises an opening dimensioned to be retained around the neck portion to position the intermediate insulating layer with respect to the connecting element in a direction transverse to the upper and lower outer layers when the inflatable mat is in an inflated configuration. [16] The inflatable mat of claim 15, wherein the neck portion defines a minimum width, and wherein the minimum width is spaced from the upper and lower ends of the connecting member. [17] The inflatable mat of claim 16, wherein the opening defines a width and wherein the minimum width of the neck portion is substantially equal to the width of the opening. [18] An inflatable mat according to claim 16 or claim 17, wherein the connecting member has a substantially hourglass shape defining the neck portion. [19] Inflatable mat according to one of claims 15 to 18, wherein the at least one insulating layer comprises a plurality of openings each adapted to receive the neck portion of a respective connecting element. [20] An inflatable mat according to any one of claims 15 to 19, wherein each of the plurality of connecting elements is formed from a single piece extending between the upper outer layer and the lower outer layer. [21] An inflatable mat according to any one of the preceding claims, wherein the plurality of connecting elements and / or strap elements are welded or heat sealed to the respective upper or lower outer layer. [22] Inflatable mat according to one of the preceding claims, wherein the upper and lower outer layers and the at least one insulating layer are made of different materials. [23] Inflatable mat according to claim 22, wherein the outer layers are made of a textile material, optionally a nylon or a polyester material, and / or wherein the at least one insulating layer is made of a material adapted for heat reflection, optionally a metallic material, optionally a metallic foil.

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