US20070214575A1 - Method of constructing an inflatable support system having thermoplastic polyurethane constuction - Google Patents
Method of constructing an inflatable support system having thermoplastic polyurethane constuction Download PDFInfo
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- US20070214575A1 US20070214575A1 US11/800,930 US80093007A US2007214575A1 US 20070214575 A1 US20070214575 A1 US 20070214575A1 US 80093007 A US80093007 A US 80093007A US 2007214575 A1 US2007214575 A1 US 2007214575A1
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- layer
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- thermoplastic polyurethane
- welding
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- 239000004433 Thermoplastic polyurethane Substances 0.000 title claims abstract description 75
- 229920002803 thermoplastic polyurethane Polymers 0.000 title claims abstract description 75
- 238000000034 method Methods 0.000 title claims abstract description 35
- 239000000463 material Substances 0.000 claims description 23
- 238000003466 welding Methods 0.000 claims description 20
- 239000004744 fabric Substances 0.000 claims description 17
- 239000007788 liquid Substances 0.000 claims description 10
- 238000002844 melting Methods 0.000 claims description 3
- 230000008018 melting Effects 0.000 claims description 3
- 239000008188 pellet Substances 0.000 claims description 3
- 229920000728 polyester Polymers 0.000 claims description 2
- 238000010438 heat treatment Methods 0.000 claims 3
- 238000001816 cooling Methods 0.000 claims 2
- 238000005520 cutting process Methods 0.000 claims 2
- 238000010030 laminating Methods 0.000 claims 2
- 238000004519 manufacturing process Methods 0.000 claims 1
- 239000004800 polyvinyl chloride Substances 0.000 description 9
- 229920000915 polyvinyl chloride Polymers 0.000 description 9
- 238000010276 construction Methods 0.000 description 3
- 229920001971 elastomer Polymers 0.000 description 2
- 239000006260 foam Substances 0.000 description 2
- HGUFODBRKLSHSI-UHFFFAOYSA-N 2,3,7,8-tetrachloro-dibenzo-p-dioxin Chemical compound O1C2=CC(Cl)=C(Cl)C=C2OC2=C1C=C(Cl)C(Cl)=C2 HGUFODBRKLSHSI-UHFFFAOYSA-N 0.000 description 1
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
Images
Classifications
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/08—Fluid mattresses or cushions
- A47C27/087—Fluid mattresses or cushions with means for connecting opposite sides, e.g. internal ties or strips
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/08—Fluid mattresses or cushions
- A47C27/081—Fluid mattresses or cushions of pneumatic type
Definitions
- the present invention relates to the field of inflatable support systems, particularly to a method of constructing an inflatable support system at least in part from thermoplastic polyurethane material.
- Inflatable mattresses have been available for many years, and they are commonly used as both temporary and permanent sleeping arrangements. In addition, inflatable mattresses are often used outdoors on camping trips or other overnight trips. Because these mattresses are so often used while traveling, it is desirable to make them as light and portable as possible to minimize packing space and maximize convenience, while at the same time retaining the strength to resist punctures and leakage from the seams under normal use.
- new inflatable mattresses that more closely resemble conventional mattresses are often very large, sometimes even having multiple chambers.
- a king-size conventional inflatable mattress that inflates to a height of almost three feet can weigh nearly 125 pounds when deflated. This weight may severely limit its portability.
- thermoplastic polyurethane a recyclable material that is lighter than polyvinyl chloride (“PVC”) or rubber, materials that have been conventionally used to construct inflatable mattresses.
- PVC polyvinyl chloride
- TPU material has been used in self-inflating mattress pads, but such pads incorporated a foam internal structure that was glued to the TPU sheets.
- the foam structure while adding support to the pads, added a significant amount of weight.
- Such pads were much smaller than conventional inflatable mattresses, usually having a height of no more than two inches. Such a pad in the size of a conventional inflatable mattress would weigh ten pounds or more.
- a method for constructing an inflatable support system by forming a first layer comprised of thermoplastic polyurethane and a second layer comprised of thermoplastic polyurethane. At least one coil is formed from thermoplastic polyurethane and a first end of the coil is attached to the first layer. A second end of the coil is attached to the second layer.
- FIG. 1 is a perspective view of an inflatable mattress produced utilizing the present method
- FIG. 2 is an external view of a flange produced utilizing the present method
- FIG. 3 is an internal view of the flange of FIG. 2 ;
- FIG. 4 is an external view of the flange of FIG. 2 with a valve attached;
- FIG. 5 is a cross-sectional view of the mattress of FIG. 1 showing the internal coils
- FIG. 6 is an enlarged view of the coils of FIG. 5 ;
- FIG. 7 is a cross-sectional view of a coil of FIG. 5 showing the fabric layer and the TPU layer.
- TPU 10 Thermoplastic polyurethane
- PVC polyvinyl chloride
- a mattress constructed from TPU will not leach harmful chemicals such as chloride and dioxin into the environment upon disposal.
- any shape or size mattress or inflatable object can be formed using TPU, the embodiment shown is a double-size inflatable mattress.
- Other sizes are envisioned, as well as thicker mattresses that incorporate more than one inflatable chamber, such as the raised mattress shown in U.S. Pat. No. 6,704,559.
- the present method includes a series of steps to form an inflatable mattress.
- First 14 and second 16 layers of TPU 10 are cut from a TPU sheet.
- a side gusset 18 is also cut from a TPU sheet.
- a layer of fabric 32 is laminated to one side of the TPU sheets 14 , 16 .
- TPU coil structures 24 are then formed from TPU material 10 , and these coil structures 24 are welded via sonic or heat welding to the sides 22 of the top 14 and bottom 16 TPU sheets opposite the fabric covered sides.
- the side gusset 18 is then welded to the outside edges 20 of the top 14 and bottom 16 sheets in a manner such that TPU is welded to TPU.
- An additional step of forming a flange 24 from TPU may also be included in the present method.
- a flange mold is supplied and TPU pellets are heated until a liquid is formed. This liquid is poured or injected into the flange mold and the mold may be heated to set the material. Alternatively, the TPU may simply be allowed to cool in the mold until it sets. The fully-formed TPU flange 26 is then removed from the mold. An opening is formed in the side gusset 18 , top sheet 14 or bottom sheet 16 to accept the flange 26 .
- the flange 26 is then welded via sonic or heat welding in the opening of the side gusset 18 of the inflatable mattress, or to the opening in the top 14 or bottom 16 layer of the inflatable mattress 12 if a side gusset 18 is not provided.
- the flange 26 is welded to the internal wall 30 of the side gusset 18 or the internal wall 22 of the top 14 or bottom 16 sheet of TPU such that TPU is welded to TPU, creating a substantially airtight weld.
- a valve 28 such as the valve 28 shown in FIG. 4 can then be attached to the flange 26 .
- a mattress produced utilizing the present method has at least one inflatable substantially airtight chamber 12 .
- This inflatable chamber 12 has a top 14 and a bottom 16 layer, each layer 14 , 16 being formed from a thin sheet of TPU material 10 .
- the TPU material 10 preferably has a thickness of no more than 0.2 mm, and is cut to form the desired mattress size. Greater thicknesses of TPU could also be used if increased strength is needed, but this would also increase the weight of the mattress 12 .
- Another piece of TPU material is cut to form a side gusset 18 for the mattress 12 .
- the side gusset 18 is welded via sonic or heat welding to the outside edges 20 of the top 14 and the bottom 16 layers.
- the top 14 and bottom 16 layers can be welded to each other at their outer edges 20 , thereby eliminating the need for a separate side gusset 18 .
- FIGS. 5-7 support structures in the form of internal coils, shown in FIGS. 5-7 , are provided.
- TPU is cut into belts, which are then welded via sonic or heat welding to the internal sides 22 of the top 14 and bottom 16 sheets of TPU 10 .
- the coils 24 in the illustrated embodiment are welded in a four-sided shape having slightly concave sides, but they could be welded to the top 14 and bottom 16 layers using a more conventional oval shape, or any other shape desired.
- the coils 24 are preferably aligned in parallel rows and have an elongated oval shape in cross-section. The overall effect of the coil shape and arrangement is to form a box-like construction, similar to a conventional mattress. This also adds support and strength to the inflatable mattress 12 .
- a mattress formed utilizing the present method includes a flange 26 constructed from TPU material designed to have a valve 28 attached to it for inflation and/or deflation of the inflatable mattress 12 .
- a flange would be formed from heavy PVC, thus adding more weight to the mattress.
- the flange 26 is preferably formed by melting TPU material, which can be in the form of TPU pellets, into a liquid form. This liquid is then poured into a flange-shaped mold to fill the entire mold cavity. The mold is then heated until the TPU material is set. At this point, the mold is opened and the TPU material is allowed to cool.
- An opening is defined in the side gusset 18 , and the finished flange 26 is attached via heat or sonic welding to the internal wall 30 of the side gusset 18 .
- the weld forms a substantially airtight seal around the flange 26 .
- the flange 26 can be welded to the internal wall 22 of the top 14 or bottom 16 layer of TPU.
- the present method may be adjusted such that the finished flange 26 can accept a valve 28 that allows both inflation and deflation of the inflatable mattress 12 such as that shown in U.S. Pat. Nos. 5,627,363; 5,367,726; and 6,237,621.
- a valve 28 that allows both inflation and deflation of the inflatable mattress 12
- other types of valves could be formed using the present method as well as different flange shapes adapted to the specific valves.
- the present method can be used to form a second flange from TPU. This second flange (not shown) can be defined on the side gusset 18 for receiving a pump.
- a fabric layer 32 is utilized to provide even more strength without significantly increasing the weight of the inflatable mattress 12 .
- a top layer 14 , bottom layer 16 , and a side gusset 18 are formed from TPU 10 .
- a thin layer of fabric or flocking is then laminated or applied to one side of the TPU sheets using polyurethane glue.
- the opposite side 34 of the TPU sheets is left bare, in order to allow welding of the TPU coils 24 to the internal sides 22 of the top 14 and bottom 16 layers.
- the fabric is 150 Denier polyester, but other types of thin fabric layers could also be utilized.
- FIGS. 2-4 and 7 An example of a TPU layer laminated to a fabric layer 32 and incorporating a TPU coil 24 support structure is most clearly shown in FIGS. 2-4 and 7 .
- the fabric layer 32 is shaded for clarity in these figures.
- FIG. 2 the internal wall 30 of the side gusset 18 is shown.
- a double bed formed from TPU including a fabric layer and a TPU flange weighs only about eight pounds, nearly 1 ⁇ 3 less than a conventional PVC inflatable double bed.
- a bed constructed utilizing the present method is also able to withstand a 650 pound dead weight test and a life roller test consisting of an octagon roller weighing 180 pounds rolled side to side over the mattress 12 30,000 times.
- the welding pattern could take different forms.
- the entire inflatable support system could also be constructed in any number of shapes and sizes.
- the flange could take any number of shapes, dependent on the type of valve that it is designed for.
- the coils could also be replaced by other structural supports formed from TPU, such as TPU strips that are attached to the top and bottom layers to prevent the top and bottom layers from ballooning out upon inflation. The order of the steps of the present method could also be adjusted if necessary.
- the TPU material used to form the top and bottom layers of the mattress and the flange can be any type of TPU known to one of skill in the art.
- the TPU can also be mixed with other materials, such as conventional PVC or rubber, before being formed into sheets.
- the TPU used to mold the flange can also contain other materials. Additional layers of material other than fabric could also be incorporated, such as PVC layers which could be laminated or otherwise attached to the TPU layers.
- an inflatable mattress could be formed from conventional PVC material and incorporate a TPU flange.
Landscapes
- Laminated Bodies (AREA)
- Mattresses And Other Support Structures For Chairs And Beds (AREA)
Abstract
A method for constructing an inflatable support system by forming a first layer comprised of thermoplastic polyurethane and a second layer comprised of thermoplastic polyurethane. At least one coil is formed from thermoplastic polyurethane and a first end of the coil is attached to the first layer. A second end of the coil is attached to the second layer.
Description
- The present application is a division of and claims benefit under 35 U.S.C. §121 of Nonprovisional application Ser. No. 11/202,769, filed Aug. 12, 2005.
- 1. Field of the Invention
- The present invention relates to the field of inflatable support systems, particularly to a method of constructing an inflatable support system at least in part from thermoplastic polyurethane material.
- 2. Related Art
- Inflatable mattresses have been available for many years, and they are commonly used as both temporary and permanent sleeping arrangements. In addition, inflatable mattresses are often used outdoors on camping trips or other overnight trips. Because these mattresses are so often used while traveling, it is desirable to make them as light and portable as possible to minimize packing space and maximize convenience, while at the same time retaining the strength to resist punctures and leakage from the seams under normal use.
- Furthermore, new inflatable mattresses that more closely resemble conventional mattresses are often very large, sometimes even having multiple chambers. A king-size conventional inflatable mattress that inflates to a height of almost three feet can weigh nearly 125 pounds when deflated. This weight may severely limit its portability.
- These shortcomings are addressed by constructing a mattress from thermoplastic polyurethane (“TPU”), a recyclable material that is lighter than polyvinyl chloride (“PVC”) or rubber, materials that have been conventionally used to construct inflatable mattresses. In the past, it has been prohibitively expensive to work with TPU, and as it is very thin, it has been difficult to weld to form the material into inflatable objects that require a rigid structure.
- In the past, TPU material has been used in self-inflating mattress pads, but such pads incorporated a foam internal structure that was glued to the TPU sheets. The foam structure, while adding support to the pads, added a significant amount of weight. Such pads were much smaller than conventional inflatable mattresses, usually having a height of no more than two inches. Such a pad in the size of a conventional inflatable mattress would weigh ten pounds or more.
- Disclosed herein is a method for constructing an inflatable support system by forming a first layer comprised of thermoplastic polyurethane and a second layer comprised of thermoplastic polyurethane. At least one coil is formed from thermoplastic polyurethane and a first end of the coil is attached to the first layer. A second end of the coil is attached to the second layer.
-
FIG. 1 is a perspective view of an inflatable mattress produced utilizing the present method; -
FIG. 2 is an external view of a flange produced utilizing the present method; -
FIG. 3 is an internal view of the flange ofFIG. 2 ; -
FIG. 4 is an external view of the flange ofFIG. 2 with a valve attached; -
FIG. 5 is a cross-sectional view of the mattress ofFIG. 1 showing the internal coils; -
FIG. 6 is an enlarged view of the coils ofFIG. 5 ; and -
FIG. 7 is a cross-sectional view of a coil ofFIG. 5 showing the fabric layer and the TPU layer. - Referring in combination to
FIGS. 1-6 , an inflatable support system in the form of an inflatable mattress produced utilizing the present method is shown. Thermoplastic polyurethane (“TPU”) 10, is utilized to create a lighter inflatable mattress that still retains the strength of a heavier, conventional polyvinyl chloride (“PVC”) mattress. At the same time, a mattress constructed from TPU will not leach harmful chemicals such as chloride and dioxin into the environment upon disposal. - While any shape or size mattress or inflatable object can be formed using TPU, the embodiment shown is a double-size inflatable mattress. Other sizes are envisioned, as well as thicker mattresses that incorporate more than one inflatable chamber, such as the raised mattress shown in U.S. Pat. No. 6,704,559.
- The present method includes a series of steps to form an inflatable mattress. First 14 and second 16 layers of
TPU 10 are cut from a TPU sheet. If desired, aside gusset 18 is also cut from a TPU sheet. If desired, a layer offabric 32 is laminated to one side of theTPU sheets TPU coil structures 24 are then formed fromTPU material 10, and thesecoil structures 24 are welded via sonic or heat welding to thesides 22 of the top 14 and bottom 16 TPU sheets opposite the fabric covered sides. Theside gusset 18 is then welded to theoutside edges 20 of the top 14 and bottom 16 sheets in a manner such that TPU is welded to TPU. - An additional step of forming a
flange 24 from TPU may also be included in the present method. A flange mold is supplied and TPU pellets are heated until a liquid is formed. This liquid is poured or injected into the flange mold and the mold may be heated to set the material. Alternatively, the TPU may simply be allowed to cool in the mold until it sets. The fully-formedTPU flange 26 is then removed from the mold. An opening is formed in theside gusset 18,top sheet 14 orbottom sheet 16 to accept theflange 26. Theflange 26 is then welded via sonic or heat welding in the opening of theside gusset 18 of the inflatable mattress, or to the opening in the top 14 or bottom 16 layer of theinflatable mattress 12 if aside gusset 18 is not provided. Theflange 26 is welded to theinternal wall 30 of theside gusset 18 or theinternal wall 22 of the top 14 or bottom 16 sheet of TPU such that TPU is welded to TPU, creating a substantially airtight weld. Avalve 28 such as thevalve 28 shown inFIG. 4 can then be attached to theflange 26. - In the illustrated embodiment, a mattress produced utilizing the present method has at least one inflatable substantially
airtight chamber 12. Thisinflatable chamber 12 has a top 14 and a bottom 16 layer, eachlayer TPU material 10. TheTPU material 10 preferably has a thickness of no more than 0.2 mm, and is cut to form the desired mattress size. Greater thicknesses of TPU could also be used if increased strength is needed, but this would also increase the weight of themattress 12. Another piece of TPU material is cut to form aside gusset 18 for themattress 12. Theside gusset 18 is welded via sonic or heat welding to theoutside edges 20 of the top 14 and the bottom 16 layers. Alternatively, the top 14 and bottom 16 layers can be welded to each other at theirouter edges 20, thereby eliminating the need for aseparate side gusset 18. - In order to prevent the
inflatable mattress 12 from ballooning out on its top and bottom sides, support structures in the form of internal coils, shown inFIGS. 5-7 , are provided. To create the internal coil construction, TPU is cut into belts, which are then welded via sonic or heat welding to theinternal sides 22 of thetop 14 andbottom 16 sheets ofTPU 10. Thecoils 24 in the illustrated embodiment are welded in a four-sided shape having slightly concave sides, but they could be welded to the top 14 and bottom 16 layers using a more conventional oval shape, or any other shape desired. Thecoils 24 are preferably aligned in parallel rows and have an elongated oval shape in cross-section. The overall effect of the coil shape and arrangement is to form a box-like construction, similar to a conventional mattress. This also adds support and strength to theinflatable mattress 12. - Referring to
FIGS. 1-4 , a mattress formed utilizing the present method includes aflange 26 constructed from TPU material designed to have avalve 28 attached to it for inflation and/or deflation of theinflatable mattress 12. On conventional inflatable mattresses, such a flange would be formed from heavy PVC, thus adding more weight to the mattress. In the present method, theflange 26 is preferably formed by melting TPU material, which can be in the form of TPU pellets, into a liquid form. This liquid is then poured into a flange-shaped mold to fill the entire mold cavity. The mold is then heated until the TPU material is set. At this point, the mold is opened and the TPU material is allowed to cool. An opening is defined in theside gusset 18, and thefinished flange 26 is attached via heat or sonic welding to theinternal wall 30 of theside gusset 18. The weld forms a substantially airtight seal around theflange 26. Alternatively, if aside gusset 18 is not used, theflange 26 can be welded to theinternal wall 22 of the top 14 or bottom 16 layer of TPU. - The present method may be adjusted such that the
finished flange 26 can accept avalve 28 that allows both inflation and deflation of theinflatable mattress 12 such as that shown in U.S. Pat. Nos. 5,627,363; 5,367,726; and 6,237,621. Alternatively, other types of valves could be formed using the present method as well as different flange shapes adapted to the specific valves. Furthermore, the present method can be used to form a second flange from TPU. This second flange (not shown) can be defined on theside gusset 18 for receiving a pump. - In another embodiment of the present method, a
fabric layer 32 is utilized to provide even more strength without significantly increasing the weight of theinflatable mattress 12. As in the previous embodiment, atop layer 14,bottom layer 16, and aside gusset 18, if desired, are formed fromTPU 10. A thin layer of fabric or flocking is then laminated or applied to one side of the TPU sheets using polyurethane glue. Theopposite side 34 of the TPU sheets is left bare, in order to allow welding of the TPU coils 24 to theinternal sides 22 of the top 14 and bottom 16 layers. In a preferred embodiment, the fabric is 150 Denier polyester, but other types of thin fabric layers could also be utilized. This allows the design of different colored beds, beds having soft coverings or beds having a silk screened design on them. If no fabric is used, the beds can even have a clear construction. An example of a TPU layer laminated to afabric layer 32 and incorporating aTPU coil 24 support structure is most clearly shown inFIGS. 2-4 and 7. Thefabric layer 32 is shaded for clarity in these figures. InFIG. 2 , theinternal wall 30 of theside gusset 18 is shown. - As a comparative example of the decreased weight of an inflatable mattress formed utilizing the present method, a double bed formed from TPU including a fabric layer and a TPU flange weighs only about eight pounds, nearly ⅓ less than a conventional PVC inflatable double bed. A bed constructed utilizing the present method is also able to withstand a 650 pound dead weight test and a life roller test consisting of an octagon roller weighing 180 pounds rolled side to side over the
mattress 12 30,000 times. - It should be noted that a wide range of changes could be made to the present method without departing from its scope. As noted, the welding pattern could take different forms. The entire inflatable support system could also be constructed in any number of shapes and sizes. Additionally, the flange could take any number of shapes, dependent on the type of valve that it is designed for. The coils could also be replaced by other structural supports formed from TPU, such as TPU strips that are attached to the top and bottom layers to prevent the top and bottom layers from ballooning out upon inflation. The order of the steps of the present method could also be adjusted if necessary.
- The TPU material used to form the top and bottom layers of the mattress and the flange can be any type of TPU known to one of skill in the art. The TPU can also be mixed with other materials, such as conventional PVC or rubber, before being formed into sheets. The TPU used to mold the flange can also contain other materials. Additional layers of material other than fabric could also be incorporated, such as PVC layers which could be laminated or otherwise attached to the TPU layers. If desired, an inflatable mattress could be formed from conventional PVC material and incorporate a TPU flange.
- It is therefore intended that the foregoing detailed description be regarded as illustrative rather than limiting, and that it be understood that it is the following claims, including all equivalents, that are intended to define the spirit and scope of this invention.
Claims (13)
1. A method for constructing an inflatable support system, said method comprising the steps of:
forming a first layer comprised of thermoplastic polyurethane;
forming a second layer comprised of thermoplastic polyurethane;
forming at least one coil comprised of thermoplastic polyurethane;
attaching a first end of said coil to said first layer; and
attaching a second end of said coil to said second layer.
2. The method of claim 1 , further comprising the step of forming a side gusset comprised of thermoplastic polyurethane and attaching said side gusset to said first layer and said second layer.
3. The method of claim 2 , further comprising the steps of supplying a flange mold;
heating thermoplastic polyurethane pellets until they are in a liquid state;
injecting said liquid into said flange mold to form a flange;
removing said flange from said mold; and
welding said flange to said side gusset.
4. The method of claim 2 , further comprising the step of laminating a fabric layer to at least one side of at least one of said first and said second layers.
5. The method of claim 2 , further comprising the step of applying a layer of flocking to at least one side of at least one of said first and said second layers.
6. A method of constructing an inflatable support system, said method comprising the steps of:
laminating a fabric layer to a layer of thermoplastic polyurethane to form a sheet;
cutting said sheet to form at least a top and a bottom layer;
cutting said sheet to form a side gusset;
forming at least one coil from a sheet of thermoplastic polyurethane;
welding a first end of said coil to said top layer on a side opposite said fabric layer;
welding a second end of said coil to said bottom layer on a side opposite said fabric layer; and
welding one edge of said side gusset to said top sheet and welding the opposite edge of said side gusset to said bottom sheet to form an inflatable chamber.
7. The method of claim 6 , further comprising the steps of:
supplying a mold for a flange;
melting thermoplastic polyurethane material to form a liquid;
injecting said liquid into said mold;
heating said mold until said thermoplastic polyurethane is permanently set;
opening said mold and cooling said flange;
defining an opening in said side gusset; and
welding said flange to said side gusset at said opening.
8. The method of claim 7 , further comprising the step of attaching a valve to said flange.
9. The method of claim 6 , wherein said sheets of thermoplastic polyurethane are not thicker than 0.2 mm.
10. The method of claim 7 , wherein said welding steps are performed by sonic welding.
11. The method of claim 7 , wherein said welding steps are performed by heat welding.
12. The method of claim 6 , wherein said fabric is polyester.
13. A method of manufacturing an inflatable support system, said method comprising the steps of:
forming a top and a bottom layer from a flexible, substantially airtight material;
forming a side gusset from a flexible, substantially airtight material;
welding one edge of said side gusset to said top layer and welding the opposite edge of said side gusset to said bottom layer;
supplying a mold for a flange;
melting thermoplastic polyurethane material to form a liquid;
injecting said liquid into said mold;
heating said mold until said thermoplastic polyurethane is set;
opening said mold and cooling said flange;
defining an opening in said side gusset; and
welding said flange to said side gusset at said opening.
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US11/800,930 US20070214575A1 (en) | 2005-08-12 | 2007-05-08 | Method of constructing an inflatable support system having thermoplastic polyurethane constuction |
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US11/202,769 US20070033739A1 (en) | 2005-08-12 | 2005-08-12 | Inflatable support system having thermoplastic polyurethane construction |
US11/800,930 US20070214575A1 (en) | 2005-08-12 | 2007-05-08 | Method of constructing an inflatable support system having thermoplastic polyurethane constuction |
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US11/202,769 Division US20070033739A1 (en) | 2005-08-12 | 2005-08-12 | Inflatable support system having thermoplastic polyurethane construction |
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US11/800,930 Abandoned US20070214575A1 (en) | 2005-08-12 | 2007-05-08 | Method of constructing an inflatable support system having thermoplastic polyurethane constuction |
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Cited By (1)
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US20100125951A1 (en) * | 2008-11-26 | 2010-05-27 | Sandra Stefano | Bedpan system |
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US20070056114A1 (en) * | 2005-09-09 | 2007-03-15 | Corey Lewison | Multi-zone coil construction airbed |
CN105615393A (en) * | 2016-02-23 | 2016-06-01 | 浙江大自然旅游用品有限公司 | Air inflation product and air inflation product welding process |
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US20100125951A1 (en) * | 2008-11-26 | 2010-05-27 | Sandra Stefano | Bedpan system |
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Also Published As
Publication number | Publication date |
---|---|
US20070033739A1 (en) | 2007-02-15 |
WO2007021739A1 (en) | 2007-02-22 |
EP1924171A1 (en) | 2008-05-28 |
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