AU2011101735A4 - A portable interface device and pump - Google Patents

Abstract

Abstract: An interface device comprising: an airtight receptacle, a movable filling within the airtight receptacle, a port attached to the airtight receptacle to allow the receptacle to be pressurised, evacuated or sealed, wherein the interface device is formed from multiple layers having varying flexible properties in different zones, and a hand pump comprising a main chamber with a piston arranged to cause air to flow in and out of the main chamber, a valve unit, and a rotatable mode control unit comprising a main port for attachment to a device that is to be inflated, the mode control unit operable with the valve -unit to switch the pump between one of three modes, wherein in a first mode reciprocal movement of the piston causes air to flow out Ni of the main port, in a second mode reciprocal movement of the piston causes air to flow in through the main port and in a third mode the main port is sealed. WO 2012/087155 PCT/NZ2011/000265

Description

WO 2012/087155 PCT/NZ2011/000265 1 A PORTABLE INTERFACE DEVICE AND PUMP FIELD OF THE INVENTION 5 The present invention relates to a portable interface device and method of manufacture, and a hand pump suitable for use with the portable interface device. BACKGROUND 10 Interface devices enable a user to fill a space between two objects. For example, back support devices attempt to fill a space between a user's lower back and the seat upon which the user is sitting. As a further example of an interface device, packing devices attempt to fill a space between the item being packed and the 15 container in which the item is being transported. Another example of an interface device includes padding or support elements that aim to provide additional padding or support between protection devices worn by a user and the user's body. A further example of an interface device includes padding or support elements that attempt to provide additional support or padding between a saddle 20 and an animal's body upon which the saddle is located. Prolonged sitting in seats and chairs or the like is known to lead to pain in the lower back. This pain may be alleviated if the user is able to lean back into the seat in such a way that the pelvis cannot slump backwards away from its natural 25 lumbar lordosis position, such as it is when the user is standing. Portable back supports are generally used to help provide users with additional back support when seated. Known back supports do not provide effective support, as they do not sufficiently fit the user's back, i.e. they do not sufficiently 30 fill the gap between the user's back and the seat upon which they are sitting. That is, empty spaces are still present between the user's back and the seat upon which they are sitting, thus providing transition zones or areas which can lead to back problems. Further, existing portable back supports are not arranged to fit a wide variety of chairs, i.e. they do not provide sufficient support when 35 transferred between differently formed chairs.

WO 2012/087155 PCT/NZ2011/000265 2 Known back supports also do not provide additional lumbar support without preventing the user from using any further support that the seat provides, such as shoulder and head support. Also, portable back supports used in vehicle seats do 5 not provide sufficient side support in order to effectively support the back. Existing back supports include fixedly formed supports that are shaped to fit against the profile of a person's back. Because people's backs are not all the same shape, these supports may be offered in a range of sizes. However, they 10 still do not sufficiently allow for different shapes of users, and may not provide the required support for the majority of users. Back supports are also available that have a non-fixed form and can be adjusted to fit different users. However, these types of support have limited adjustability 15 and may not provide the required support for the majority of users. Back supports are available with fixedly formed back surfaces, however these types of support can't be adjusted to fit different chairs. Back supports are available with malleable back surfaces that can mould to fit different chairs, 20 however these supports are not firm enough to provide effective back support for most users. A back support is described in US 2010/0140995 that provides side support. However, the angle and position of the side support is fixed and therefore will not 25 provide the required support for the majority of users. In order to address these problems, back supports have been developed that use vacuum set technology to enable the back support to be moulded into the exact shape of a user's back and then fixedly set into that form by evacuating the air 30 from the support. For example US patent US4114214 describes a super conforming seating system that is fixed into a particular form using a low pressure air differential mode. However, this back support has the same general problem of being non-transferable from seat to seat, as the vacuum set technology is incorporated into the seat.

WO 2012/087155 PCT/NZ2011/000265 3 Patent no US2006/0229541 describes an orthopaedic inlay or interface device for a body part having a vacuum mouldable cushion filled with a moveable filling and evacuated with a pump, However, this device has the limitation of being encased 5 in a supporting shell. This shell is of a predetermined shape and has the limitation that it can only work as interface device for body parts that can fit inside the supporting shell. In order to evacuate the air and depressurise these forms of back support, pumps 10 are generally required. Hand pumps generally have two modes of operation, a pressurising mode and a vacuum mode. In a first pressure mode, pumping the piston in and out of the pump cylinder causes air to be expelled out of the pump nozzle, where in a 15 vacuum mode, pumping the piston in and out of the pump cylinder causes air to be sucked into the nozzle. However, these types of pumps have a problem that occurs when the pump is being disconnected from the system being pumped or evacuated. That is, a loss of the pressure or vacuum in the system being pumped or evacuated occurs until a seal is manually fitted to the air connection. 20 US6059548 describes a hand pump that has a pump mode, a vent mode and a seal mode to seal the air connection. However, this form of pump does not have a vacuum mode to enable a vacuum to be created in the device connected to its outlet port. 25 An object of the present invention is to provide an improved form of interface device that has a reversibly mouldable front face that enables it to fill empty spaces in a wide variety of applications. 30 A further object of the present invention is to provide an improved pump system that has three modes; a vacuum mode, a pressure mode and a seal mode. Each object is to be read disjunctively with the object of at least providing the public with a useful choice.

WO 2012/087155 PCT/NZ2011/000265 4 The present invention aims to overcome, or at least alleviate, some or all of the afore-mentioned problems. 5 SUMMARY OF THE INVENTION It is acknowledged that the terms "comprise", "comprises" and "comprising" may, under varying jurisdictions, be attributed with either an exclusive or an inclusive meaning. For the purpose of this specification, and unless otherwise noted, 10 these terms are intended to have an inclusive meaning - i.e. they will be taken to mean an inclusion of the listed components that the use directly references, but optionally also the inclusion of other non-specified components or elements. According to one aspect, the present invention provides an interface device 15 comprising: an airtight receptacle, a movable filling within the airtight receptacle, a port attached to the airtight receptacle to allow the receptacle to be pressurised, evacuated or sealed, wherein the interface device is formed from multiple layers having varying flexible properties in different zones. 20 According to a further aspect, the present invention provides an interface device comprising: an airtight receptacle, a movable filling within the airtight receptacle, a port attached to the airtight receptacle to allow the receptacle to be pressurised, vacuumed or sealed, wherein the interface device is formed having a shaped profile that fits between two objects substantially without creating a transition area. 25 According to yet a further aspect, the present invention provides a method of manufacturing an interface device comprising the steps of: forming a plastic receptacle with a port to allow the receptacle to be pressurised, vacuumed or sealed, filling the receptacle with a movable filling, sealing the receptacle, 30 attaching a plastic sheet to the receptacle partially around an outer circumference of the receptacle, wherein the plastic sheet comprises one or more flexible zones. According to yet a further aspect, the present invention provides a hand pump comprising a main chamber with a piston arranged to cause air to flow in and out WO 2012/087155 PCT/NZ2011/000265 5 of the main chamber, a valve unit, and a rotatable mode control unit comprising a main port for attachment to a device that is to be inflated, the mode control unit operable with the valve unit to switch the pump between one of three modes, wherein in a first mode reciprocal movement of the piston causes air to flow out of 5 the main port, in a second mode reciprocal movement of the piston causes air to flow in through the main port and in a third mode the main port is sealed. According to yet a further aspect, the present invention provides a hand pump comprising a main chamber having an internal piston arranged to cause air to flow 10 in and out of the main chamber, a valve chamber comprising at least three ports, a valve assembly located within the valve chamber, a rotatable mode control unit comprising a main port and an opposing secondary port, wherein the main port is for attachment to a device that is to be inflated, the rotatable mode control unit arranged to configure the flow of air between the three valve chamber ports , the 15 main port and the secondary port dependent upon the rotational position of the mode control unit relative to the valve chamber so that a first valve chamber port is in fluid communication with the main chamber, and second and third valve chamber ports are either i) in fluid communication with the main port, ii) in fluid communication with the secondary port or iii) sealed from the main port and the 20 secondary port. According to yet a further aspect, the present invention provides a hand pump comprising: a main chamber having an internal piston arranged to cause air to flow in and out of the main chamber, a valve assembly located within a valve 25 chamber, wherein the valve chamber comprises a first port in fluid communication with the main chamber, a rotatable mode control unit comprising a main port and an opposing secondary port, wherein the main port is for attachment to a device that is to be inflated, the valve chamber further comprising a second and third port, wherein the main port is in fluid communication with one of the second and 30 third ports dependent on the rotational position of the mode control unit relative to the valve chamber, wherein the position of the mode control unit relative to the valve chamber causes the valve assembly to move within the valve chamber due to the air flow between the main port and the main chamber, and switches the pump between one of a vacuum mode, a pressure mode and a lock mode.

WO 2012/087155 PCT/NZ2011/000265 6 BRIEF DESCRIPTION OF THE DRAWINGS Embodiments of the present invention will now be described, by way of example 5 only, with reference to the accompanying drawings, in which: Figure 1 shows a front view of a portable back support according to an embodiment of the present invention; Figure 2 shows a reverse view of a portable back support according to an 10 embodiment of the present invention; Figure 3 shows a front view of a portable back support with a cover according to an embodiment of the present invention; Figure 4 shows a reverse view of a portable back support with a cover according to an embodiment of the present invention; 15 Figure 5 shows a side view of a portable back support according to an embodiment of the present invention; Figure 6 shows a first perspective view of a hand pump according to an embodiment of the present invention; Figure 7 shows a second perspective view of a hand pump according to an 20 embodiment of the present invention; Figure 8 shows a cross sectional side view of a hand pump in a pressure mode according to an embodiment of the present invention; Figure 9 shows a close up cross sectional view of a valve chamber according to an embodiment of the present invention; 25 Figure 10 shows a close up cross sectional view of valve components of the pump according to an embodiment of the present invention; Figure 11 shows a further close up cross sectional view of valve components of the pump according to an embodiment of the present invention; Figure 12 shows a cross sectional side view of a hand pump in a vacuum mode 30 according to an embodiment of the present invention; Figure 13 shows a close up cross sectional view of valve components of the pump according to an embodiment of the present invention; Figure 14 shows a further close up cross sectional view of valve components of the pump according to an embodiment of the present invention; WO 2012/087155 PCT/NZ2011/000265 7 Figure 15 shows a cross sectional side view of a hand pump in a seal mode according to an embodiment of the present invention; Figure 16 shows a close up cross sectional view of valve components of the pump according to an embodiment of the present invention; 5 Figure 17 shows a schematic diagram of a further embodiment of the present invention; and Figure 18 shows a schematic diagram of yet a further embodiment of the present invention. 10 DETAILED DESCRIPTION OF THE INVENTION First Embodiment According to this first embodiment, an interface device in the form of a portable 15 back support is described. Figure 1 shows a front view of a portable back support according to this embodiment. Various different layers of the back support are represented in figure 1. 20 The back support 101 is made up of several layers of various materials. An airtight bag 103 made from any suitable plastic film that may be welded. According to this embodiment, the plastic film is TPU (Thermoplastic Polyurethane). The airtight bag is formed into a flat three dimensional shape, i.e. 25 it is substantially two dimensional when not inflated, but becomes three dimensional when inflated. The shaped profile of the bag is such that it fits into a seat or chair substantially without creating a transition area or zone, i.e. there are no points of pressure and substantially all non-contact areas are removed thus providing increased support. That is, the back support provides a smooth 30 transition between the chair and the back support to create a firm support for the back without any gaps. This enables the posterior aspect of the user's buttocks to remain as far back in the seat as possible, while the support prevents the upper pelvis from falling backwards to hold the lumbar spine in its neutral lumbar lordosis.

WO 2012/087155 PCT/NZ2011/000265 8 The bag 103 is connected to an airline 105 that is used to pump up, evacuate and seal the airtight bag using a pump, as will be explained in more detail below. 5 Before the airtight bag 103 is sealed (by welding) to form an airtight receptacle, it is filled with a pourable (i.e. movable) filling 107. The movable filling is made up of multiple particles that are able to form an interlocked structure under vacuum pressure. In this embodiment the filling consists of expanded polystyrene beads (EPS). It will be understood that other types of filling may be used, such as other 10 forms of plastic balls or the like. The air tight bag 103 is attached to a flexible plastic sheet 109. According to this embodiment, the plastic sheet is stitched to the airtight bag, however it will be understood that the plastic sheet may be attached in any other suitable manner, 15 such as gluing or welding, for example. The airtight bag is only attached to the plastic sheet 109 along the two upper sides of the triangular front profile of the bag 103, thus leaving the lower edge of the bag free to move away from the lower edge of the plastic sheet. The lower edge of the bag rests against the back of the seat or chair as the user settles into the interface device. 20 Also, formed on the reverse side of the back support is an extra flexible zone 111. The flexible zone is formed by cutting away or removing a portion of the flexible plastic sheet 109. The extra flexible zone 111 shown in figure 1 is positioned to one side of the back support in a lower corner of the triangular front 25 profile, wherein the strip of area 111 stretches from the lower portion of the back support up to a first side portion of the back support. A further strip of extra flexible material is also formed on the opposing lower corner of the back support, as shown in figure 2. These extra flexible zones provide an area of additional flexibility between the lower corners of the back support and the central portion of 30 the back support. It will be understood that the areas or zones of extra flexibility may be created using other forms for the cut out regions. For example, each zone 111 may be created by cutting out a single area of the plastic sheet 109 (as shown in figures WO 2012/087155 PCT/NZ2011/000265 9 1 & 2) in any suitable form or shape. Alternatively, each zone may be created by cutting out multiple sections or areas of the plastic sheet. For example, in each zone, there may be two cut out portions, where a first cut out portion extends from an upper edge of the triangular front profile and stops at a central side 5 portion of the profile, and a second cut out portion extends from a lower edge of the triangular front profile and stops at the central side portion of the profile leaving a gap between each cut out portion. This effectively provides a flexible side portion of the flexible plastic sheet that is connected to the main portion of the plastic sheet by a central tab. The upper part of the flexible side portion of 10 the flexible plastic sheet is attached to the airtight bag, whereas the lower part of the flexible side portion is not connected to the airtight bag. The flexible zones 111 of the flexible plastic sheet 109 allow the back support to wrap forwards at a point determined by the shape of the user and the shape of 15 the chair. The back support can wrap forwards over a broad range depending on the shape of the user and chair, or not at all if appropriate. It will be understood that, as an alternative, there may be one or more flexible zones created on the flexible plastic sheet depending on the desired use of the 20 interface device. That is, the number of flexible zones will vary depending on how many zones on the device are required to flex in order to provide additional support. The number of flexible zones and shape of the flexible zones may be dependent on the shape or form of the two objects between which the interface device is to be placed. 25 The two extra flexible zones 111 and the flexible plastic sheet 109 ensure the back support has multiple layers with varying flexible properties in different zones. This provides additional back support by causing the back support to grasp the user around the sides when used in a seat with a curved surface such 30 as a vehicle seat. That is, because vehicle seats are curved, the flexible back layer allows the back support to flex forwards around the user's sides to provide additional side support.

WO 2012/087155 PCT/NZ2011/000265 10 By causing the back support to grasp the user around the sides at a point determined by the shape of the user and the shape of the chair, effective support is provided against shear forces during activities where such movement is encountered, such as driving. The sides do not flex once they are set. The extra 5 flexi zones enable the back support to wrap forwards. Without them, the cover (as discussed below) would hold the sides back towards the seat, preventing the forwards wrap. Figure 2 shows a reverse view of a portable back support according to this 10 embodiment. In this figure can be seen the flexible plastic sheet 109 on the reverse side of the back support. Both the extra flexible areas 111 can also be seen positioned on the left and right side on the reverse of the back support. The flexible plastic sheet also provides support for the airtight bag. That is, the 15 flexible plastic sheet ensures the airtight bag maintains a defined shape as the bag is attached to the plastic sheet. Thus, when the airtight bag is fixed in form, it maintains its height and general shape due to it being fixedly attached to the plastic sheet. 20 An airline connector 201 connects the airline 105 to the internal cavity of the airtight bag 103. According to this embodiment, the airline connector is welded to the bag 103 at a central position to enable the device to be used on both left hand and right-hand drive cars. A fastening line 203 is shown around the top edge of the back support. That is, during manufacture, the flexible plastic sheet 25 109 is joined up around the top edge at the fastening line to the sealed bag 103. A weld line 205 is shown around the perimeter of the airtight zone of the inflatable component 103. The airtight bag takes on a substantially triangular shape when filled and held 30 vertically so the filling can run to the bottom. The lack of transition between the back support and seat is enabled by the ratio of filling to the size of the bag. When a person leans back into the back support and sits up straight, some filling remains in the lumbar area, and the rest moves up and out to the sides, tapering off to no filling at the top and bottom. The ratio of filling to the size of the inflatable WO 2012/087155 PCT/NZ2011/000265 11 bag has been calculated to allow the filling to taper off at the top and bottom. This allows the top and bottom to be very thin. Combined with the fact that the back support can mould to the shape of the seat, there is no transition area between the back support and seat. 5 Figure 3 shows a front view of a portable back support with a cover according to this embodiment. A removable cover is provided in which the airtight bag 103 is placed. The cover 10 provides protection to the airtight bag from punctures as well as allowing the back support to be easily cleaned without the need to clean the airtight bag. The cover is made from fabric and plastic. The cover also provides padding from the back support and, in this embodiment, includes attachment points for a fastening strap. The front side of the cover is made from a breathable material. 15 The front side 301 of the cover includes four distinct zones created by the stitching of the fabric material. These zones provide four separate areas 303A, 303B, 303C & 303D across the left side, central and right side portions and around the perimeter of the front face of the back support. 20 The stitching line is also functional and assists with the shaping of the inner airbag when in use. The stitching line along the bottom of the cover creates a tension zone that stops the filling in the airbag from completely sagging to the bottom. It also encourages most of the filling to sit in the lumbar area. The stitch 25 line also helps to remove transition zones between the back support and seat. The stitch line effectively provides a hinge along the line to encourage the bag to bend at that line when there is air within the bag and the filling is free to move. This causes the filling to locate itself at the bottom of the bag initially, and then as the user settles into the bag the filling is effectively pushed away from the bottom 30 of the bag to fill the interface area between the user's lower back and the back of the seat. Figure 4 shows a view of the reverse side of the cover 401 of a portable back support cover according to this embodiment.

WO 2012/087155 PCT/NZ2011/000265 12 A reinforcing flexible plastic sheet layer 405 is sewn in to the reverse side of the cover 401. The plastic layer 405 is positioned centrally from top to bottom of the outer cover 401. The plastic layer 405 puts the cover under tension to enable it 5 to maintain shape and reduce deformation. According to this embodiment, the sheet 405 is formed in an hour glass shape. It will be understood that the sheet may take other suitable forms to provide reinforced flexible support. Behind the reverse side of the cover 401 the back 406 of the front side of the 10 cover 301 can be seen. A first plastic friction panel 403A is provided on the reverse side of the cover on a lower left side portion of the cover. A second plastic friction panel 403B is also provided on the reverse side of the cover on a lower right side of the cover. The 15 two friction panels provide additional friction when the cover (back support) is placed on a seat to aid in stopping the cover (back support) from moving around when in use. That is, the friction panels assist the user when settling into the back support when in use by reducing the movement of the back support. Further, they also keep the back support in position and reduce vertical and 20 lateral movement of the back support. The lack of movement between the back support and seat also assists in the effective moulding of the back support to the shape of both the seat and the user's back. According to this embodiment, the friction panels are made from chlorosulfonated polyethylene (CSPE) synthetic rubber (CSM), also known as Hypalon

TM

. 25 Therefore, the layers of the cover from front to back are the fabric front layer with stitching 301, reverse side of the fabric front layer 406, the two friction panels 403A and 403B, and the reverse-side cover 401 with an internal reinforcing plastic sheet 405. 30 Through the first and second friction panels are located apertures or attachment points for attaching a support strap assembly. The support strap assembly is used to attach the back support to the seat. That is, the support strap is attached to the back support at one set of strap attachment point on one side of the back WO 2012/087155 PCT/NZ2011/000265 13 support, and then passed around the seat to be attached to the other set of strap attachment points located on the other side of the back support. Figure 5 shows a side perspective view of a portable back support as it looks if it 5 were lying on its back according to this embodiment. The air line 105 attaches to the air bag 103 via the airline connector 201. A particle filter 501 is mounted inside the inflatable bag over the airline connector to prevent the moveable filling entering the air line. This enables the airbag to be 10 inflated and deflated using a suitable inflation deflation device. For example, the pump as described herein may be used to inflate and deflate the device. The portable back support may be manufactured by using any suitable combination of steps. For example, the back support may be assembled by 15 forming a plastic receptacle with a port to allow the receptacle to be pressurised, vacuumed or sealed, where the receptacle is the airtight bag. The airtight bag may then be filled with a movable filling such as those described herein using any suitable filling device. 20 A reinforcing flexible layer 109 may then be fastened to the airtight bag 103 at least partially around an outer circumference of a reverse portion of the back support. The reinforcing flexible layer may then be shaped or modified to produce flexible 25 zones. For example, the flexible zones may be created by removing at least a portion of the reinforcing flexible layer 109. It will be understood that the flexible zones may be created before or after attachment of the plastic sheet to the air tight bag. 30 The airtight bag and flexible layer 109 may then be inserted into a cover as described above.

WO 2012/087155 PCT/NZ2011/000265 14 Figure 6 shows a first perspective view of a hand pump according to this embodiment of the present invention. The herein described hand pump is designed to be operated with the herein 5 described back support. It will be understood that the pump described herein may also be used for other purposes besides the inflation and deflation of the described back support and may be used to inflate and deflate any other suitable device. 10 A hand pump 601 is provided with a pump handle 603, main chamber body 605, rotatable mode control unit 607 and a connection port 609. The pump handle 603 is arranged to move up and down to allow air to be pumped in and out of the connection port 609 as will be explained in more detail 15 below. The pump including the main chamber body, handle and rotatable mode control unit has a generally slim lined profile in order to allow the pump to be easily stored. The main chamber body 605 has a generally non-circular cross section. 20 It has a flat sided profile along the length with two rounded edges along its width. This shape is particularly useful in terms of its integral strength when handling vacuum states. The rotatable mode control unit 607 is used to switch the pump between different 25 pump modes. The unit 607 rotates with respect to the main chamber body 605 to switch between the different modes. The connection port 609 is arranged to connect to the airline 105 of the back support. Therefore, the connection port is the main port that connects to the 30 device being inflated or deflated. Figure 7 shows a second perspective view of the hand pump with the handle 603 slight raised showing the internal shaft that connects to the piston assembly WO 2012/087155 PCT/NZ2011/000265 15 within the chamber body. Also, this view shows the rotatable mode control unit moved to place the pump into a different mode. Figure 8 shows a cross sectional side view of the hand pump in a first mode 5 according to this embodiment. This first mode is a pressure mode that pressurises the air tight bag of the back support. That is, air is forced into the air tight bag to increase the air volume within the bag. This allows the beads to float more freely, and therefore mould more easily to the user's body. 10 The shaft 701 connects to a piston 801 that includes a seal recess 803 to hold a seal 805, such as an o-ring or the like. The piston 801 moves up and down in the main chamber 807 to cause air to flow into and out of the main chamber. In the pressure mode, when the piston starts at the top end of the main chamber 15 807 and is forced downwards by applying pressure to the handle 603 to drive the piston down into the main chamber, the seal 805 forces air in the chamber 807 to be expelled out of the chamber and out of the main port of the mode control unit as explained below. When the handle is pulled upwards, air is sucked into the chamber 807 via a secondary port 821 that opposes the main port of the mode 20 control unit (air feed port). At the lower end of the main chamber 805 is a chamber port 809 that connects to a first port 811 of a valve chamber. Inside the valve chamber is a valve assembly which includes a first valve component 813 and a second valve component 815. 25 The valve assembly in this embodiment is a 2 part poppet valve. On the rotatable mode control unit 607 is formed an outlet port 817 which on one side is in fluid communication with the connection port 609 that connects to the airline, and on the other side is in fluid communication with the valve chamber 30 (when either in the pressure mode or vacuum mode). Located in a recess on the rotatable mode control unit is an o-ring 823 that provides a seal between the rotating mode control unit and the outer surface of the valve chamber. When in the pressure mode, the seal 823 sits around the entrance to the valve chamber and around the outlet port next to the valve chamber.

WO 2012/087155 PCT/NZ2011/000265 16 Figure 9 shows a close up cross sectional view of the valve chamber 901. The valve chamber has an effectively inverted T-shaped profile. 5 It can be seen in this figure that the main chamber 807 is in fluid communication with a main chamber port 809 that connects to the valve chamber via a first port 811 of the valve chamber 901. A second port 903 of the valve chamber is formed having a predefined aperture circumference (or bore). This second port 903 allows air to flow inwards into the valve chamber and into the main chamber of 10 the pump. A third port 905 of the valve chamber opposing the second port 903 is formed having a larger aperture circumference (or bore) than the second port. This third port 905 allows air to flow outwards from the main chamber through the valve chamber to the main port 609 (via the outlet port 817) of the pump. 15 During vacuum mode (i.e. when the mode control unit is positioned such that the main port 609 is in line with this second port 903) air flows in through the second port 903 and into the main chamber when the piston is pulled upwards, and air flows from the main chamber and out of the third port 905 when the piston is pressed downwards. During pressure mode (i.e. when the mode control unit is 20 positioned such that the main port 609 is in line with the third port 905) air flows in through the second port 903 and into the main chamber when the piston is pulled upwards, and air flows from the main chamber and out of the third port 905 when the piston is pressed downwards. Therefore, air always flows in the same direction through the second and third ports regardless of the mode of operation 25 in which the pump is configured. The second port 903 is formed by narrowing the valve chamber enclosure. This also provides a first sealing surface 907 that is used to seal against a first sealing face of the poppet valve. 30 The third port 905 is formed by opening up the valve chamber enclosure. This also provides a second sealing surface 909 that is used to seal against a second sealing face of the poppet valve.

WO 2012/087155 PCT/NZ2011/000265 17 If it is considered that the valve chamber is fixed in relative position when compared to the rotatable mode control unit, it can be visualised that the mode control unit outlet port 817 can be rotated so that is in fluid communication with either the second valve chamber port 903 or the third valve chamber port 905, or 5 indeed neither of the second and third valve chamber ports. Therefore, either one or none of the second and third valve chamber ports (903, 905) may be in fluid communication with the outlet port 817 (and so the connection port 609) at any one position of the mode control unit. 10 The mode control unit includes an elongated wall portion which has formed therein an internal circular recess in which the valve chamber is located. That is, the internal recess of the mode control unit encompasses the valve chamber and the valve chamber and mode control unit rotate relative to each other. The internal recess includes a continuous surface, a recess for the o-ring seal 823 15 and an air feed port 821. A sealing surface is formed between the o-ring 823 and an outer wall surface of the valve chamber. Within the recess for the o-ring seal 823 is located an aperture that is in fluid connection with the outlet port 817. The valve chamber has an outer wall surface that sits against the internal recess 20 of the mode control unit. The second and third valve chamber ports are apertures that are formed through the outer wall surface to enable fluid communication from the internal valve chamber to the mode control unit. This outer wall surface also acts as a sealing surface against the o-ring seal 823 within the mode control unit when the outlet port is not aligned with either of the 25 second and third valve chamber ports (903, 905) Therefore, as the mode control unit is rotated relative to the valve chamber, the outlet port comes into fluid contact with either the second or third valve chamber ports (903, 905), or is sealed against the outer wall surface of the valve chamber 30 by the o-ring seal 823. Therefore, the outlet port 817 may be in fluid communication with the second valve chamber port 903, the third valve chamber port 905 or sealed off depending on the relative position of the mode control unit.

WO 2012/087155 PCT/NZ2011/000265 18 When the outlet port 817 (and so the main port 609) is in fluid communication with the second valve chamber port 903, the pump is in vacuum mode. That is, the pump is configured so that air flows in through the main port 609 into the valve chamber and into the main chamber when the pump handle is pulled 5 upwards, and air flows out of the main chamber through the valve chamber and out of the secondary port 821 (air feed port) of the mode control unit when the handle of the pump is pushed downwards. This effectively creates a negative pressure state (vacuum) at the main port 609. 10 When the outlet port 817 (and so the main port 609) is in fluid communication with the third valve chamber port 905, the pump is in pump mode. That is, the pump is configured so that air flows in through the secondary port 821 (air feed port) of the mode control unit into the valve chamber and into the main chamber when the pump handle is pulled upwards, and air flows out of the main chamber 15 through the valve chamber and out of the main port 609 when the handle of the pump is pushed downwards. This effectively creates a positive pressure state at the main port 609. Figure 10 shows a close up cross sectional view of valve components of the 20 pump. The first valve component 813 of the valve assembly has a first extended (elongated) portion 1001 that sits inside a recess formed in the second valve component 815. The first valve component 813 also has a second extended 25 (elongated) portion 1003 that is positioned within or inside the second port 903 of the valve chamber 901. In between the first and second extended portions (1001, 1003) is formed a raised sealing surface 1005 that is arranged to seal against the first sealing face 907 in the valve chamber. 30 The second valve component 815 includes a circular member with a recess 1101 in which the first extended portion 1001 of the first valve component 813 is movably located. The component 815 also includes a raised sealing surface 1007 that is arranged to seal against the second sealing face 909 in the valve chamber. When air is being pumped into the valve chamber from the main WO 2012/087155 PCT/NZ2011/000265 19 chamber 807, the two valve components move away from each other, whereas when air is passing through the valve chamber into the main chamber 807, the two valve components move towards each other. As shown in Figure 10, when the pump handle is pulled up, air is sucked in through the air feed port 821 and 5 second port 903 of the valve chamber. That is, the suction of air into the main chamber 807 causes the first valve component 813 to move from right to left (as viewed in figure 10) allowing air to pass the first valve component into the main chamber. 10 The two valve components effectively open and close the second and third ports of the valve chamber depending on the direction of air flow past the valve components. The first port of the valve chamber is in fluid communication with the main pump chamber at all times 15 Figure 11 shows a further close up cross sectional view of the valve components of the pump when the pump is placed into a pressure mode. In this view, the handle of the pump has been pushed down and the first valve component 813 is sealed against sealing face 907/1005 (i.e. it has moved from left to right as viewed in Figure 11), thus the air can be expelled out of the chamber through the 20 outlet port 817 (past the second valve component 815). During the pressure mode, the piston in the chamber body is moved upwards to bring air into the main chamber through the secondary port 821 (air feed port) and then downwards to force air out of the main chamber through the valve 25 chamber ports and outlet port 817 to the main connection port 609. In this mode, the second valve component 815 of the poppet valve is in alignment with the outlet port 817 due to the rotational position of the mode control unit 607. When the piston is moved downwards the air passes from the main chamber 807 through the first port 811 of the valve chamber and causes the second valve 30 component 815 to move away from the main chamber, first port 811 and first valve component 813. The circular member of the second component slides over the first extended portion 1001 of the first valve component 813. This effectively opens up the seal between the second sealing face 909 and the sealing surface 1007 to enable the air to pass through the outlet port 817 and out of the WO 2012/087155 PCT/NZ2011/000265 20 connection port 609. The expelled air pressurises the air bag connected to the connection port via the air line. Figure 12 shows a cross sectional side view of a hand pump in second mode, 5 according to this embodiment. This second mode is a vacuum mode that evacuates air from the air tight bag of the back support. That is, air is extracted from the air tight bag to create a vacuum within the bag. In the vacuum mode, when the piston and seal 805 start at or close to the bottom 10 end of the main chamber 807 and are forced upwards by pulling the handle 603 away from the main body, the seal 805 forces air into the chamber 807 from the main connection port 609 and outlet port 817 via the valve chamber. When the handle is pushed downwards, air is pushed out of the chamber 807 and out through the secondary port of the mode control unit (air feed port) 821. 15 Figure 13 shows a close up cross sectional view of valve components of the pump during vacuum mode when the pump handle is being pulled upwards. It can be seen that the two valve components (813 & 815) are brought together due to the direction of air flow, i.e. a vacuum is effectively created in the main 20 chamber. That is, an outer end surface of the first extended portion of the first component 813 comes into contact with an inner end surface 1301 of the second valve component 815. With the valve components in this position, the second port 903 of the valve chamber is in fluid communication with the first port 811 of the valve chamber. 25 In the mode shown in figure 13, the pressure inside the pump chamber is less than the pressure on the connection port 609 (and outlet port 817). This therefore causes the second valve component 815 to be directed towards the main chamber (where the pressure is lower) and seal its sealing surface 1007 30 against the second sealing face 909. Figure 14 shows a further close up cross sectional view of valve components of the pump when in vacuum mode and the pump handle is being pushed downwards. During this stage, the air within the pump main chamber is forced WO 2012/087155 PCT/NZ2011/000265 21 through the valve chamber via the second valve component 815 and out through the air feed port 821. Figure 15 shows a cross sectional side view of a hand pump in a third mode 5 according to an embodiment of the present invention. In the third mode, the pump chamber and outlet port are sealed from each other by rotating the mode control unit so that neither of the second and third ports of the valve chamber are in fluid communication with the main connection port 609. That is, the outlet port 817 of the mode control unit is sealed against the outer wall of the valve chamber 10 by the o-ring seal 823. This seal mode ensures the airtight bag remains in its vacuum state and does not deflate. In this embodiment, the seal 823 moves around with the rotatable mode control unit due to it being located within a recess formed on the rotatable mode control 15 unit. However, it will be understood that, as an alternative, the seal may be fixed in position on the outside body of the valve chamber at a position that is substantially at right angles to the second and third ports (903, 905) in the valve chamber 901. This would then provide a sufficient seal when in seal mode to reduce the amount of air being allowed to pass through the connection port. 20 Figure 16 shows a close up cross sectional view of valve components of the pump when in a sealed mode. Here it can be seen that neither of the second and third ports (903, 905) of the valve chamber are connected to the outlet port 817. The outlet port 817 or main connection port 609 are therefore not in fluid 25 communication with the main chamber or valve chamber of the pump. In order to operate the pump with the back support, the back support is positioned in the desired seat or chair. The user sits in the chair and arranges the back support so it is in a suitable back supportive position and shape. The 30 user then places the pump in the vacuum mode to evacuate the air from the airtight back and cause the material therein to set in a particular position or form. The pump may then be switched to seal mode in order to lock the material in the bag in that form. If the user wishes to reset the form of the back support, they place the pump in pressure mode and pump air in to the airtight bag, which WO 2012/087155 PCT/NZ2011/000265 22 enables the material to be released from its set form. They may then reset the form using the above described steps. Further Embodiments 5 It will be understood that the embodiments of the present invention described herein are by way of example only, and that various changes and modifications may be made without departing from the scope of invention. 10 For example, it will be understood that the interface device may be formed to enable it to be fitted underneath a horse's saddle to provide additional support between the saddle and the horse's back. Further, it will be understood that the interface device may be formed as a 15 packing device, which fills the space between an item being packed and a container in which the item is being transported. Further, it will be understood that the interface device may be formed as a padding or support element that provides additional padding or support between 20 protection devices worn by a user and the user's body. Further, it will be understood that the form of the interface device may vary depending on the shape, size and/or form of the two objects between which the interface device is to be positioned. Further, the number of flexible zones 25 provided in the plastic layer attached to the airtight bag may vary in position and number depending on the shape of the two objects between which the interface device is to be located. Further, it will be understood that the airtight bag may be sealed while enabling 30 the pump to be fully detached from the airtight bag. That is, an additional seal mechanism may be applied to the valve on the airtight bag to enable a user to manually seal the bag and detach the pump from the bag, with or without the air line.

WO 2012/087155 PCT/NZ2011/000265 23 Further, as an alternative or in addition to the herein described embodiments, the interface device may further incorporate an in-line valve 1701 where a first port of the in-line valve is in fluid communication with the port of the airtight bag of the interface device 103 and a second port of the in-line valve is in fluid 5 communication with the pump 601. For example, the pump 601 may be directly connected to the in-line valve 1701 or may be connected to the in-line valve via a hose 105. Also, the in-line valve may be directly connected to the airtight bag of the interface device 103 or 10 connected to the interface device via a hose 105. The in-line valve may be manually operated to either open the valve or close the valve 1701. When the in line valve is open, fluid communication is provided between the first port and second port of the in-line valve. When the in-line valve is closed, there is no longer any fluid communication between the first and second port of the in-line 15 valve. This therefore allows the flow of air out of the hose 105 or the airtight bag of the interface device 103 to be shut off. Therefore, once the device has been set with the pump 601 using negative air pressure, the in-line valve 1701 may be closed and the pump may be removed from the rest of the device and stored elsewhere. 20 Further, as an alternative or in addition to the herein described embodiments, the interface device may further incorporate a spring loaded shut-off valve 1801 that is in fluid communication with the port of the interface device. The spring loaded shut-off valve may be arranged to cooperate with a corresponding portion (e.g. a 25 nozzle) attached to either the pump 601 or the hose 105. The corresponding portion is arranged to cooperate with and activate or deactivate the spring loaded shut-off valve 1801. For example, the spring loaded shut-off valve may be directly connected to the 30 airtight bag of the interface device and the corresponding portion may be attached to the hose. When the hose is not attached to the spring loaded shut-off valve, the spring loaded shut-off valve is closed ensuring that there is no fluid communication out of the interface device via the spring loaded shut-off valve. Therefore, when the hose is removed from the interface device the interface WO 2012/087155 PCT/NZ2011/000265 24 device remains sealed. When the hose is attached to the spring loaded shut-off valve via the corresponding portion, the spring loaded shut-off valve then opens providing fluid communication between the hose and the interface device to enable the interface device to be adjusted. Alternatively, the corresponding 5 portion (e.g. a nozzle) may be attached to the main port on the pump. As a further example, the spring loaded shut-off valve may be directly connected to the hose attached to the interface device. Further, the corresponding portion may be attached to a corresponding piece of hose which is attached to the pump. 10

Claims (60)

1. An interface device comprising: an airtight receptacle, 5 a movable filling within the airtight receptacle, a port attached to the airtight receptacle to allow the receptacle to be pressurised, evacuated or sealed, wherein the interface device is formed from multiple layers having varying flexible properties in different zones. 10

2. The interface device of claim 1 wherein a first layer is a flexible layer that is fastened to the airtight receptacle partially around an outer circumference of the airtight receptacle. 15

3. The interface device of claim 2 wherein the first layer comprises flexible zones which have a relatively higher flexibility than other zones on the first layer.

4. The interface device of claim 3, wherein the flexible zones are formed in two distinct areas on the first layer. 20

5. The interface device of claim 3, wherein the flexible zones extend from an upper portion of the flexible layer to a lower portion of the flexible layer.

6. The interface device of claim 1, further comprising a cover forming at least 25 some of the multiple layers, wherein the cover comprises a reinforcing flexible layer formed therein.

7. The interface device of claim 1, wherein at least one of the multiple layers are formed as a removable cover. 30

8. The interface device of claim 1, wherein one of the layers has one or more friction zones having a high friction co-efficient relative to the other zones on the layer. WO 2012/087155 PCT/NZ2011/000265 26

9. The interface device of claim 8, wherein the friction zones are formed on a reverse portion of the back support.

10. The interface device of claim 8, further comprising a cover formed from a 5 composite fabric.

11. The interface device of claim 8, wherein the cover comprises one or more flexi zones. 10

12. The interface device of claim 11, wherein the cover is formed from a breathable material.

13. The interface device of claim 1, wherein the movable filing is a pourable filing. 15

14. The interface device of claim 13, wherein the movable filling comprises multiple particles that are able to form an interlocked structure under vacuum pressure.

15. The interface device of claim 1, further comprising two or more attachment 20 points for attachment of a support strap.

16. The interface device of claim 15, wherein the interface device further comprises a strap assembly for attachment to the attachment points. 25

17. The interface device as claimed in claim 1 further comprising a pump adapted to be attached to the port of the interface device and arranged to operate in one of three modes, wherein the three modes are a pressure mode, vacuum mode and seal mode. 30

18. The interface device of claim I further comprising an in-line valve in fluid communication with the port, the in-line valve arranged to shut off the port from the pump when the in-line valve is operated. WO 2012/087155 PCT/NZ2011/000265 27

19. The interface device of claim 1 further comprising a spring loaded shut-off valve in fluid communication with the port, the spring loaded shut-off valve arranged to seal the port when the pump is disconnected from the spring loaded shut-off valve. 5

20. An interface device comprising: an airtight receptacle, a movable filling within the airtight receptacle, a port attached to the airtight receptacle to allow the receptacle to be 10 pressurised, vacuumed or sealed, wherein the interface device is formed having a shaped profile that fits between two objects substantially without creating a transition area.

21. The interface device of claim 1 or 20, wherein the interface device is a 15 portable back support for attachment to a seat.

22. The interface device of claim 1 or 20, wherein the interface device is a packing device. 20

23. The interface device of claim 1 or 20, wherein the interface device is a padding or support element.

24. A method of manufacturing an interface device comprising the steps of: forming a plastic receptacle with a port to allow the receptacle to be 25 pressurised, vacuumed or sealed, filling the receptacle with a movable filling, sealing the receptacle, attaching a plastic sheet to the receptacle partially around an outer circumference of the receptacle, wherein the plastic sheet comprises one or 30 more flexible zones.

25. The method of claim 24 further comprising the step of forming the one or more flexible zones in the plastic sheet prior to attachment of the sheet to the receptacle. WO 2012/087155 PCT/NZ2011/000265 28

26. The method of claim 24 further comprising the step of forming the one or more flexible zones in the plastic sheet after the sheet is attached to the receptacle. 5

27. The method of claim 24 further comprising the steps of forming a cover having multiple layers wherein an outer reverse-side layer of the cover has one or more friction zones having a high friction co-efficient relative to the other zones on the cover. 10

28. The method of claim 27 further comprising the step of forming a front-side layer on the cover from a composite fabric.

29. The method of claim 28 further comprising the step of forming one or more padded zones on the front-side layer. 15

30. The method of claim 29 further comprising the step of forming the padded zones from a breathable material.

31. The method of claim 28 further comprising the step of forming a stitch line on 20 the front-side cover to create tension zones.

32. A hand pump comprising a main chamber with a piston arranged to cause air to flow in and out of the main chamber, a valve unit, and 25 a rotatable mode control unit comprising a main port for attachment to a device that is to be inflated, the mode control unit operable with the valve unit to switch the pump between one of three modes, wherein in a first mode reciprocal movement of the piston causes air to flow out of the main port, in a second mode reciprocal movement 30 of the piston causes air to flow in through the main port and in a third mode the main port is sealed.

33. A hand pump comprising WO 2012/087155 PCT/NZ2011/000265 29 a main chamber having an internal piston arranged to cause air to flow in and out of the main chamber, a valve chamber comprising at least three ports, a valve assembly located within the valve chamber, 5 a rotatable mode control unit comprising a main port and an opposing secondary port, wherein the main port is for attachment to a device that is to be inflated, the rotatable mode control unit arranged to configure the flow of air between the three valve chamber ports , the main port and the secondary port 10 dependent upon the rotational position of the mode control unit relative to the valve chamber so that a first valve chamber port is in fluid communication with the main chamber, and second and third valve chamber ports are either i) in fluid communication with the main port, ii) in fluid communication with the secondary port or iii) sealed from the main port and the secondary port. 15

34. A hand pump comprising: a main chamber having an internal piston arranged to cause air to flow in and out of the main chamber, a valve assembly located within a valve chamber, wherein the valve chamber 20 comprises a first port in fluid communication with the main chamber, a rotatable mode control unit comprising a main port and an opposing secondary port, wherein the main port is for attachment to a device that is to be inflated, the valve chamber further comprising a second and third port, wherein the 25 main port is in fluid communication with one of the second and third ports dependent on the rotational position of the mode control unit relative to the valve chamber, wherein the position of the mode control unit relative to the valve chamber causes the valve assembly to move within the valve chamber due to the air 30 flow between the main port and the main chamber, and switches the pump between one of a vacuum mode, a pressure mode and a lock mode.

35. The hand pump of claim 34, wherein the main chamber is formed with a non circular cross-section. WO 2012/087155 PCT/NZ2011/000265 30

36. The hand pump of claim 34, wherein the main chamber is formed with a flat profile. 5

37. The hand pump of claim 34, wherein the valve assembly comprises a single valve.

38. The hand pump of claim 34, wherein the valve assembly comprises a first valve component and a second valve component that move independently of 10 each other.

39. The hand pump of claim 38, wherein the first valve component is nested within at least a portion of the second valve component and is slidably engaged with the second valve component. 15

40. The hand pump of claim 38, wherein the valve chamber further comprises two sealing surfaces and the valve assembly comprises two sealing faces, wherein the position of the mode control unit and air flow causes one of the sealing surfaces to seal against one of the sealing faces. 20

41. The hand pump of claim 40, wherein a first sealing surface is located around the second port of the valve chamber and a second sealing surface is located around the third port of the valve chamber. 25

42. The hand pump of claim 40, wherein a first sealing face is located around the first component of the valve assembly and a second sealing face is located around the second component of the valve assembly.

43. The hand pump of claim 34, wherein the valve assembly comprises a two part 30 poppet valve.

44. The hand pump of claim 34, wherein in a vacuum mode, the mode control unit is aligned with its main port adjacent to the second port of the valve chamber. WO 2012/087155 PCT/NZ2011/000265 31

45. The hand pump of claim 34, wherein in a pressure mode, the mode control unit is aligned with its main port adjacent to the third port of the valve chamber. 5

46. The hand pump of claim 34, wherein in a lock mode, the mode control unit is aligned with its main port aligned with a sealing surface of the valve chamber.

47. The hand pump of claim 34, wherein in a vacuum mode, a first component of the valve assembly moves to open its sealing surface away from a first sealing 10 face of the valve chamber, whilst a second component of the valve assembly moves to close its sealing surface onto a second sealing face of the valve chamber.

48. The hand pump of claim 34, wherein in a pressure mode, a first component of 15 the valve assembly moves outward to close its sealing surface with a first sealing face of the valve chamber, whilst a second component of the valve assembly moves outward to open its sealing surface away from a second sealing face of the valve chamber. 20

49. The hand pump of claim 34, wherein in a lock mode, the position of the valve has no effect on the operation of the pump.

50. The hand pump of claim 34, further comprising a pump handle in connection with the internal piston. 25

51. The hand pump of claim 34, the mode control unit further comprising a detent to identify an operating mode of the pump.

52. The hand pump of claim 51, wherein the detent identifies the pump is in the 30 lock mode.

53. The hand pump of claim 34, wherein the mode control unit is arranged to rotate between two stop positions, wherein each of the stop positions places the pump in one of two modes. WO 2012/087155 PCT/NZ2011/000265 32

54. The hand pump of claim 53, wherein the first stop position places the pump in the vacuum mode. 5

55. The hand pump of claim 53, wherein the second stop position places the pump in the pressure mode.

56. The hand pump of claim 32 further comprising a nozzle attached to the main port, the nozzle arranged to co-operate with and activate/de-activate a spring 10 loaded shut off valve when in use.

57. The hand pump of claim 32 further comprising an in-line valve in fluid communication with the main port, the in-line valve arranged to shut off the port from the pump when the in-line valve is operated. 15

58. The interface device of claim 1 or claim 20 in combination with the hand pump of any one of claims 32, 33 and 34.

59. An interface device substantially as herein described with reference to the 20 accompanying drawings.

60. A hand pump substantially as herein described with reference to the accompanying drawings. 25