US20200305592A1 - Sleeping pad with dual coated bottom sheet and central layer - Google Patents
Sleeping pad with dual coated bottom sheet and central layer Download PDFInfo
- Publication number
- US20200305592A1 US20200305592A1 US16/731,271 US201916731271A US2020305592A1 US 20200305592 A1 US20200305592 A1 US 20200305592A1 US 201916731271 A US201916731271 A US 201916731271A US 2020305592 A1 US2020305592 A1 US 2020305592A1
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- layer
- baffles
- truss
- layers
- middle layer
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Links
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- 239000000463 material Substances 0.000 claims description 21
- 239000004814 polyurethane Substances 0.000 claims description 8
- 229920002635 polyurethane Polymers 0.000 claims description 8
- 239000004744 fabric Substances 0.000 claims description 6
- 229920002799 BoPET Polymers 0.000 claims description 5
- 239000005041 Mylar™ Substances 0.000 claims description 5
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 4
- 229910052782 aluminium Inorganic materials 0.000 claims description 4
- 239000011527 polyurethane coating Substances 0.000 claims description 3
- 230000008439 repair process Effects 0.000 description 10
- 238000003466 welding Methods 0.000 description 9
- 238000010276 construction Methods 0.000 description 5
- 230000000694 effects Effects 0.000 description 3
- 239000006260 foam Substances 0.000 description 3
- 230000007958 sleep Effects 0.000 description 3
- 239000000853 adhesive Substances 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 238000007664 blowing Methods 0.000 description 1
- 210000003746 feather Anatomy 0.000 description 1
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- 239000000126 substance Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
Images
Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
- E04H15/00—Tents or canopies, in general
- E04H15/32—Parts, components, construction details, accessories, interior equipment, specially adapted for tents, e.g. guy-line equipment, skirts, thresholds
- E04H15/54—Covers of tents or canopies
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47B—TABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
- A47B13/00—Details of tables or desks
- A47B13/003—Connecting table tops to underframes
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47B—TABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
- A47B13/00—Details of tables or desks
- A47B13/08—Table tops; Rims therefor
- A47B13/088—Sectional table tops
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47B—TABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
- A47B3/00—Folding or stowable tables
- A47B3/002—Folding or stowable tables with foldable underframe
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47B—TABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
- A47B3/00—Folding or stowable tables
- A47B3/06—Folding or stowable tables with separable parts
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47B—TABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
- A47B3/00—Folding or stowable tables
- A47B3/08—Folding or stowable tables with legs pivoted to top or underframe
- A47B3/0803—Folding or stowable tables with legs pivoted to top or underframe the legs rotating around a vertical axis
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47B—TABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
- A47B3/00—Folding or stowable tables
- A47B3/08—Folding or stowable tables with legs pivoted to top or underframe
- A47B3/083—Folding or stowable tables with legs pivoted to top or underframe with foldable top leaves
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47B—TABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
- A47B3/00—Folding or stowable tables
- A47B3/12—Stowable tables with detachable top leaves
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47B—TABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
- A47B37/00—Tables adapted for other particular purposes
- A47B37/04—Tables specially adapted for use in the garden or otherwise in the open air, e.g. with means for holding umbrellas or umbrella-like sunshades
-
- 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
- A47C27/04—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays
- A47C27/05—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with spring inlays with padding material, e.g. foamed material, in top, bottom, or side layers
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- 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
- A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47G—HOUSEHOLD OR TABLE EQUIPMENT
- A47G9/00—Bed-covers; Counterpanes; Travelling rugs; Sleeping rugs; Sleeping bags; Pillows
- A47G9/06—Travelling rugs; Sleeping rugs
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47G—HOUSEHOLD OR TABLE EQUIPMENT
- A47G9/00—Bed-covers; Counterpanes; Travelling rugs; Sleeping rugs; Sleeping bags; Pillows
- A47G9/08—Sleeping bags
- A47G9/086—Sleeping bags for outdoor sleeping
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
- E04H15/00—Tents or canopies, in general
- E04H15/32—Parts, components, construction details, accessories, interior equipment, specially adapted for tents, e.g. guy-line equipment, skirts, thresholds
- E04H15/34—Supporting means, e.g. frames
- E04H15/42—Supporting means, e.g. frames external type, e.g. frame outside cover
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
- F16B12/00—Jointing of furniture or the like, e.g. hidden from exterior
- F16B12/44—Leg joints; Corner joints
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47B—TABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
- A47B3/00—Folding or stowable tables
- A47B3/08—Folding or stowable tables with legs pivoted to top or underframe
- A47B3/0803—Folding or stowable tables with legs pivoted to top or underframe the legs rotating around a vertical axis
- A47B2003/0806—Folding or stowable tables with legs pivoted to top or underframe the legs rotating around a vertical axis and the table top rotating around a horizontal axis
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47B—TABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
- A47B2200/00—General construction of tables or desks
- A47B2200/0001—Tops
- A47B2200/001—Manufacture of table tops
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47B—TABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
- A47B2220/00—General furniture construction, e.g. fittings
- A47B2220/0061—Accessories
- A47B2220/0069—Hinges
- A47B2220/0072—Hinges for furniture
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
- F16B12/00—Jointing of furniture or the like, e.g. hidden from exterior
- F16B12/44—Leg joints; Corner joints
- F16B2012/446—Leg joints; Corner joints with three-dimensional corner element, the legs thereof being inserted in hollow frame members
Definitions
- the present invention relates to outdoor equipment, outdoor furniture, outdoor camping equipment and parts and fittings therefore, and more particularly, relates to the construction of an inflatable sleeping pad or mattress that provides an additional layer at the center of the pad to join the top and bottom baffle fabric and in which the bottom fabric layer is coated on both sides for ease of welding and repair.
- Sleeping pads are widely used in the camping and outdoor arenas. Although foam sleeping pads are well-known, hikers and other remote campers are concerned with the weight they must carry and also the volume they must carry. Accordingly, some sleeping pads (such as foam sleeping pads) are much too large and bulky and not usable by hikers.
- Air filled (i.e. inflatable) sleeping pads are also widely known. Although air filled sleeping pads are generally lightweight and collapsible, they are often difficult to repair and are not tear and puncture resistant.
- an inflatable sleeping pad or mattress with a dual coated bottom sheet allowing electronic “welding” to the interior of the bottom sheet while also facilitating ease of repair in the field given the coating on the bottom or exterior of the bottom sheet, thus providing significant tear and puncture resistance and ease of repair.
- the present invention features an inflatable sleeping pad.
- the sleeping pad comprises an inflatable pad having a top layer and a bottom layer, wherein the top and bottom layers are disposed parallel to one another and have a length and a width.
- the bottom layer includes an inside facing surface as well as an outside facing surface. Both the inside and outside facing surfaces of the bottom layer are coated with polyurethane either entirely or at least in some predetermined locations to allow spot welding of the bottom layer to one or more interior trusses or baffles.
- the inside facing surface is coated with polyurethane to facilitate the welding between the inside surface of the bottom layer and the baffles or trusses as will be explained in greater detail below in connection with a second embodiment.
- the outside facing surface is coated to facilitate field repair of punctures with a self-adhesive patch that can cure to 80% or more a full strength in just minutes, making the inflatable sleeping pad usable immediately in the case of a care or puncture.
- the top layer also includes an inside facing surface and an outside facing surface.
- the inside facing surface of the top layer is also coated either entirely or in selected predetermined areas with polyurethane to facilitate the welding of the inside surface of the top layer to baffles or trusses as will be explained in greater detail below.
- the sleeping pad further comprises at least one middle layer constructed of a first material having a length and a width and disposed parallel to the top and bottom layers, and wherein the at least one middle layer is supported between the top layer and the bottom layer.
- the sleeping pad further comprises a plurality of support baffles, wherein a first plurality of support baffles is disposed between the at least one middle layer and the top layer, and a second plurality of support baffles disposed between the at least middle one layer and the bottom layer.
- the sleeping pad in all embodiments includes an air inlet/outlet valve disposed on at least one of the inflatable pad top or bottom layers.
- the first and second plurality of support baffles may be truss support baffles, attached at predetermined locations between the top layer, the middle layer, and the middle layer and the bottom layer.
- first and second plurality of truss support baffles are made of a heat weldable material and are spot welded at predetermined locations between the top layer, the middle layer, and the bottom layer.
- the interior facing surfaces of the top and bottom layers include at least a plurality of heat weldable regions.
- the at least one middle layer preferably constructed of a non-heat weldable material, includes a plurality of openings such that the first plurality of truss baffles are welded at predetermined points directly to predetermined regions of the second plurality of truss baffles through the plurality of openings in the at least one middle layer.
- the at least one middle layer is preferably constructed of a thermal energy reflective material.
- the middle layer is a mylar coated aluminum sheet.
- the inflatable sleeping pad includes two middle layers, wherein the two middle layers are supported between the top and bottom layers in a spaced apart configuration, and wherein the plurality of truss baffles include a first plurality of truss baffles disposed between the bottom layer and a first one of the two middle layers, a second plurality of truss baffles are disposed between the first one of the two middle layers and the second one of the two middle layers, and wherein a third plurality of truss baffles are disposed between the second one of the two middle layers and the top layer.
- the first, second and third plurality of truss baffles are made of a heat or ultrasonic weldable material.
- the first and second middle layers preferably include a plurality of openings and predetermined regions of the first plurality of truss baffles are welded at predetermined points directly to predetermined regions of the second plurality of truss baffles through the plurality of openings in the first middle layer, and wherein predetermined regions of the second plurality of truss baffles are welded at predetermined points directly to predetermined regions of the third plurality of truss baffles through the plurality of openings in the second middle layer.
- the two middle layers are not heat weldable however this is not a limitation of the present invention as in any embodiment were in a middle layer is present, it may be made of a heat weldable material or include a coating making the surfaces of the middle layer heat weldable.
- FIG. 1 illustrates a double layer pad construction providing an additional weld at the center of the pad that joins the top and bottom baffle fabrics
- FIG. 2 illustrates an inflatable pad having a bottom sheet of fabric that is coated on both sides with polyurethane to facilitate field repairs and internal welding.
- an inflatable pad requires an external pressure source to inflate, typically in the form of a pump or by blowing orally. Convection of the air inside the mattress from a bottom surface typically against a cold and/or wet ground to the top surface against which a user sleeps reduces the amount of insulation the air mattress provides.
- One method of reducing convection is by partitioning the internal cavity between the top and bottom sheets or by filling the cavities with material to trap the air such as down feathers or synthetic insulation.
- Manually inflated pads have the advantage of offering good thickness and a great deal of comfort while being lightweight and able to pack to a small size.
- the feature of the present invention is a construction technique for inflatable sleeping pads 50 and the like which provides one or more additional sheet 26 at the center of the pad that joins the top 20 and bottom 22 sheets to a series of internal baffles 24 , 28 , see FIG. 1 , in order to stop or lessen convection that would tend to make the pad less effective at insulating the user from cold, damp surfaces on which the air mattress 50 is placed.
- the purpose of the center weld is to create a structure that can support an additional layer of material 26 in the center of the pad.
- One possible construction consist of 3 layers of coated mylar; a top layer 20 supported by baffles 28 ; a central layer 26 supported in the center of the pad or mattress 50 by both a top baffle layer 28 and a bottom baffle layer 24 ; and a bottom layer 22 of the pad held in place by bottom baffles 24 welded to the interior surface 30 of the bottom sheet 22 .
- the purpose of this construction is to create smaller air cells within the pad to reduce convective heat transfer and to add an additional layer of IR reflective material (central layer 26 ) to reduce radiant heat loss from the user to the surface on which the air mattress or pad is placed.
- An additional feature of this embodiment of the present invention features providing a bottom sheet of fabric 22 on an inflatable air pad or the like, that is coated on both sides (interior and exterior) with polyurethane, FIG. 2 .
- the inside facing surface 30 is coated with polyurethane either in its entirety or at least in selected predetermined areas to facilitate welding to the baffles 24 while the outside facing surface 32 is coated generally entirely to facilitate field repair of punctures with a quick curing self-adhesive patch.
- a repair of a standard vinyl air pad that is not coated with polyurethane or a similar substance takes about 24 hours to cure and be usable.
- a standard repair kits such as “tear-aid” brand patches reach 80% of their full strength in just minutes making the pad usable almost immediately and certainly that night.
- the sleeping pad 50 in accordance with an embodiment of the present invention, is described in more elaboration hereinafter with respect to FIGS. 1 and 2 .
- the inflatable sleeping pad 50 comprises an inflatable pad having a top layer 20 and a bottom layer 22 , wherein the top and bottom layers 20 , 22 are disposed parallel to one another and have a length and a width.
- the sleeping pad 50 further comprises at least one middle layer 26 constructed of a first material having a length and a width and disposed parallel to the top and bottom layers 20 , 22 .
- the middle layer 26 is supported between the top layer and the bottom layer 20 , 22 .
- the sleeping pad further comprises a plurality of support baffles, wherein a first plurality of support baffles 28 is disposed between the at least one middle layer 26 and the top layer 20 , and a second plurality of support baffles 24 is disposed between the at least middle one layer 26 and the bottom layer 22 .
- the sleeping pad 50 further comprises an air inlet/outlet valve 34 disposed on at least one of the inflatable pad top or bottom layers.
- the first and second plurality of support baffles 24 , 28 are truss support baffles, attached at predetermined locations between the top layer 20 , the middle layer 26 , and the bottom layer 22 .
- the first and second plurality of truss support baffles are made of a heat weldable material and are spot welded at predetermined locations between the top layer 20 , the middle layer 26 , and the bottom layer 22 .
- the top and bottom layers 20 , 22 each include an interior facing surface, and wherein each of the interior facing surfaces of the top and bottom layers include at least a plurality of heat weldable regions.
- the at least one middle layer 26 includes a plurality of openings. Predetermined regions of the first plurality of truss baffles 28 are welded at predetermined points directly to predetermined regions of the second plurality of truss baffles 28 through the plurality of openings in the at least one middle layer 26 .
- the at least one middle layer 26 may be heat weldable and therefore may not include a plurality of openings.
- the at least one middle layer 26 is preferably constructed of a thermal energy reflective material.
- the middle layer 26 is a mylar coated aluminum sheet and thus not heat weldable and therefore the provision of a plurality of openings facilitates the welding of first and second trusses 24 , 28 directly to one another through the openings.
- the air mattress may include two (2) or more middle layers 26 , wherein the two middle layers are supported between the top and bottom layers in a spaced apart configuration by a plurality of truss baffles.
- the plurality of truss baffles include a first plurality of truss baffles disposed between the bottom layer 22 and a first one ( 26 a ) of the two middle layers, a second plurality of truss baffles 28 are disposed between the first one of the two middle layers 26 a and the second one of the two middle layers 26 b , and wherein a third plurality of truss baffles are disposed between the second one of the two middle layers 26 b and the top layer 20 .
- the first, second and third plurality of truss baffles are made of a heat or ultrasonic weldable material.
- the first and second middle layers may include a plurality of openings.
- predetermined regions of the first plurality of truss baffles are welded at predetermined points directly to predetermined regions of the second plurality of truss baffles through the plurality of openings in the first middle layer, and wherein predetermined regions of the second plurality of truss baffles are welded at predetermined points directly to predetermined regions of the third plurality of truss baffles through the plurality of openings in the second middle layer.
- the two middle layers are not heat weldable.
- the present invention provides a novel and nonobvious air mattress including the features of a bottom layer having polyurethane coating on both the interior and exterior surfaces to facilitate heat welding to the interior surface of the bottom layer and tear or puncture repair on the exterior surface of the bottom layer.
- One or more middle layers preferably heat reflective layer, is provided in the Central region of the air mattress and supported by first and second layers of trusses which suspend or support the middle layer between the bottom layer and the top layer, to reduce convective air currents within the interior of the air mattress thereby preventing heat from a user's body from escaping to the ground or other cold surface on which the air mattress is placed.
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- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Architecture (AREA)
- Mechanical Engineering (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Tables And Desks Characterized By Structural Shape (AREA)
- Mattresses And Other Support Structures For Chairs And Beds (AREA)
- Rigid Containers With Two Or More Constituent Elements (AREA)
- Hinges (AREA)
- Tents Or Canopies (AREA)
- Pivots And Pivotal Connections (AREA)
Abstract
Description
- This application is a Divisional Application of U.S. patent application Ser. No. 15/878,989 titled “SMALL TABLE FRAME”, which was filed on Jan. 24, 2018 and claims priority from U.S. Provisional Patent Application No. 62/449,818 filed on Jan. 24, 2017 and titled “OUTDOOR EQUIPMENT 2016”, which is incorporated fully herein by reference.
- The present invention relates to outdoor equipment, outdoor furniture, outdoor camping equipment and parts and fittings therefore, and more particularly, relates to the construction of an inflatable sleeping pad or mattress that provides an additional layer at the center of the pad to join the top and bottom baffle fabric and in which the bottom fabric layer is coated on both sides for ease of welding and repair.
- A large portion of the population enjoy camping and other outdoor activities. When engaged in these activities, however, many people enjoy some of the comforts of home. Although individuals engaged in the activities enjoy such comforts of home, weight, space and collapsibility is still an important feature.
- Campers and others who sleep away from a home or motel often desire to soften the ground or floor on which they sleep with a foam or air filled pad. Sleeping pads are widely used in the camping and outdoor arenas. Although foam sleeping pads are well-known, hikers and other remote campers are concerned with the weight they must carry and also the volume they must carry. Accordingly, some sleeping pads (such as foam sleeping pads) are much too large and bulky and not usable by hikers. Air filled (i.e. inflatable) sleeping pads are also widely known. Although air filled sleeping pads are generally lightweight and collapsible, they are often difficult to repair and are not tear and puncture resistant.
- Accordingly, what is needed is an inflatable sleeping pad or mattress with a dual coated bottom sheet allowing electronic “welding” to the interior of the bottom sheet while also facilitating ease of repair in the field given the coating on the bottom or exterior of the bottom sheet, thus providing significant tear and puncture resistance and ease of repair.
- The present invention features an inflatable sleeping pad. The sleeping pad comprises an inflatable pad having a top layer and a bottom layer, wherein the top and bottom layers are disposed parallel to one another and have a length and a width.
- The bottom layer includes an inside facing surface as well as an outside facing surface. Both the inside and outside facing surfaces of the bottom layer are coated with polyurethane either entirely or at least in some predetermined locations to allow spot welding of the bottom layer to one or more interior trusses or baffles. The inside facing surface is coated with polyurethane to facilitate the welding between the inside surface of the bottom layer and the baffles or trusses as will be explained in greater detail below in connection with a second embodiment. The outside facing surface is coated to facilitate field repair of punctures with a self-adhesive patch that can cure to 80% or more a full strength in just minutes, making the inflatable sleeping pad usable immediately in the case of a care or puncture.
- The top layer also includes an inside facing surface and an outside facing surface. The inside facing surface of the top layer is also coated either entirely or in selected predetermined areas with polyurethane to facilitate the welding of the inside surface of the top layer to baffles or trusses as will be explained in greater detail below.
- In a second embodiment, the sleeping pad further comprises at least one middle layer constructed of a first material having a length and a width and disposed parallel to the top and bottom layers, and wherein the at least one middle layer is supported between the top layer and the bottom layer. In yet another embodiment, the sleeping pad further comprises a plurality of support baffles, wherein a first plurality of support baffles is disposed between the at least one middle layer and the top layer, and a second plurality of support baffles disposed between the at least middle one layer and the bottom layer. The sleeping pad in all embodiments includes an air inlet/outlet valve disposed on at least one of the inflatable pad top or bottom layers.
- In one embodiment, the first and second plurality of support baffles may be truss support baffles, attached at predetermined locations between the top layer, the middle layer, and the middle layer and the bottom layer.
- In another embodiment, the first and second plurality of truss support baffles are made of a heat weldable material and are spot welded at predetermined locations between the top layer, the middle layer, and the bottom layer. In this embodiment, the interior facing surfaces of the top and bottom layers include at least a plurality of heat weldable regions.
- In one or more embodiments, the at least one middle layer, preferably constructed of a non-heat weldable material, includes a plurality of openings such that the first plurality of truss baffles are welded at predetermined points directly to predetermined regions of the second plurality of truss baffles through the plurality of openings in the at least one middle layer.
- The at least one middle layer is preferably constructed of a thermal energy reflective material. In one example, the middle layer is a mylar coated aluminum sheet.
- In a further embodiment, the inflatable sleeping pad includes two middle layers, wherein the two middle layers are supported between the top and bottom layers in a spaced apart configuration, and wherein the plurality of truss baffles include a first plurality of truss baffles disposed between the bottom layer and a first one of the two middle layers, a second plurality of truss baffles are disposed between the first one of the two middle layers and the second one of the two middle layers, and wherein a third plurality of truss baffles are disposed between the second one of the two middle layers and the top layer. In this embodiment, the first, second and third plurality of truss baffles are made of a heat or ultrasonic weldable material.
- The first and second middle layers preferably include a plurality of openings and predetermined regions of the first plurality of truss baffles are welded at predetermined points directly to predetermined regions of the second plurality of truss baffles through the plurality of openings in the first middle layer, and wherein predetermined regions of the second plurality of truss baffles are welded at predetermined points directly to predetermined regions of the third plurality of truss baffles through the plurality of openings in the second middle layer.
- In one disclosed preferred embodiment, the two middle layers are not heat weldable however this is not a limitation of the present invention as in any embodiment were in a middle layer is present, it may be made of a heat weldable material or include a coating making the surfaces of the middle layer heat weldable.
- These and other features and advantages of the present invention will be better understood by reading the following detailed description, taken together with the drawings wherein:
-
FIG. 1 illustrates a double layer pad construction providing an additional weld at the center of the pad that joins the top and bottom baffle fabrics; and -
FIG. 2 illustrates an inflatable pad having a bottom sheet of fabric that is coated on both sides with polyurethane to facilitate field repairs and internal welding. - Closely related to an air mattress, an inflatable pad requires an external pressure source to inflate, typically in the form of a pump or by blowing orally. Convection of the air inside the mattress from a bottom surface typically against a cold and/or wet ground to the top surface against which a user sleeps reduces the amount of insulation the air mattress provides. One method of reducing convection is by partitioning the internal cavity between the top and bottom sheets or by filling the cavities with material to trap the air such as down feathers or synthetic insulation. Manually inflated pads have the advantage of offering good thickness and a great deal of comfort while being lightweight and able to pack to a small size.
- Accordingly, the feature of the present invention is a construction technique for
inflatable sleeping pads 50 and the like which provides one or moreadditional sheet 26 at the center of the pad that joins the top 20 andbottom 22 sheets to a series ofinternal baffles FIG. 1 , in order to stop or lessen convection that would tend to make the pad less effective at insulating the user from cold, damp surfaces on which theair mattress 50 is placed. The purpose of the center weld is to create a structure that can support an additional layer ofmaterial 26 in the center of the pad. One possible construction consist of 3 layers of coated mylar; atop layer 20 supported bybaffles 28; acentral layer 26 supported in the center of the pad ormattress 50 by both atop baffle layer 28 and abottom baffle layer 24; and abottom layer 22 of the pad held in place bybottom baffles 24 welded to theinterior surface 30 of thebottom sheet 22. The purpose of this construction is to create smaller air cells within the pad to reduce convective heat transfer and to add an additional layer of IR reflective material (central layer 26) to reduce radiant heat loss from the user to the surface on which the air mattress or pad is placed. - An additional feature of this embodiment of the present invention features providing a bottom sheet of
fabric 22 on an inflatable air pad or the like, that is coated on both sides (interior and exterior) with polyurethane,FIG. 2 . The inside facingsurface 30 is coated with polyurethane either in its entirety or at least in selected predetermined areas to facilitate welding to thebaffles 24 while the outside facingsurface 32 is coated generally entirely to facilitate field repair of punctures with a quick curing self-adhesive patch. A repair of a standard vinyl air pad that is not coated with polyurethane or a similar substance takes about 24 hours to cure and be usable. However, a standard repair kits such as “tear-aid” brand patches reach 80% of their full strength in just minutes making the pad usable almost immediately and certainly that night. - The
sleeping pad 50, in accordance with an embodiment of the present invention, is described in more elaboration hereinafter with respect toFIGS. 1 and 2 . Theinflatable sleeping pad 50 comprises an inflatable pad having atop layer 20 and abottom layer 22, wherein the top andbottom layers sleeping pad 50 further comprises at least onemiddle layer 26 constructed of a first material having a length and a width and disposed parallel to the top andbottom layers middle layer 26 is supported between the top layer and thebottom layer support baffles 28 is disposed between the at least onemiddle layer 26 and thetop layer 20, and a second plurality ofsupport baffles 24 is disposed between the at least middle onelayer 26 and thebottom layer 22. Thesleeping pad 50 further comprises an air inlet/outlet valve 34 disposed on at least one of the inflatable pad top or bottom layers. - In one embodiment, the first and second plurality of
support baffles top layer 20, themiddle layer 26, and thebottom layer 22. In one example, the first and second plurality of truss support baffles are made of a heat weldable material and are spot welded at predetermined locations between thetop layer 20, themiddle layer 26, and thebottom layer 22. - In a non-limiting embodiment, the top and
bottom layers middle layer 26 includes a plurality of openings. Predetermined regions of the first plurality of truss baffles 28 are welded at predetermined points directly to predetermined regions of the second plurality of truss baffles 28 through the plurality of openings in the at least onemiddle layer 26. - In an alternative embodiment, the at least one
middle layer 26 may be heat weldable and therefore may not include a plurality of openings. The at least onemiddle layer 26 is preferably constructed of a thermal energy reflective material. In one example, themiddle layer 26 is a mylar coated aluminum sheet and thus not heat weldable and therefore the provision of a plurality of openings facilitates the welding of first andsecond trusses - In another embodiment (not shown but within the ordinary skill of the art), the air mattress may include two (2) or more
middle layers 26, wherein the two middle layers are supported between the top and bottom layers in a spaced apart configuration by a plurality of truss baffles. The plurality of truss baffles include a first plurality of truss baffles disposed between thebottom layer 22 and a first one (26 a) of the two middle layers, a second plurality of truss baffles 28 are disposed between the first one of the two middle layers 26 a and the second one of the two middle layers 26 b, and wherein a third plurality of truss baffles are disposed between the second one of the two middle layers 26 b and thetop layer 20. In the preferred embodiment of this configuration, the first, second and third plurality of truss baffles are made of a heat or ultrasonic weldable material. Furthermore, the first and second middle layers may include a plurality of openings. - Similar to the previously explained embodiment, predetermined regions of the first plurality of truss baffles are welded at predetermined points directly to predetermined regions of the second plurality of truss baffles through the plurality of openings in the first middle layer, and wherein predetermined regions of the second plurality of truss baffles are welded at predetermined points directly to predetermined regions of the third plurality of truss baffles through the plurality of openings in the second middle layer. In one embodiment, the two middle layers are not heat weldable.
- Accordingly, the present invention provides a novel and nonobvious air mattress including the features of a bottom layer having polyurethane coating on both the interior and exterior surfaces to facilitate heat welding to the interior surface of the bottom layer and tear or puncture repair on the exterior surface of the bottom layer. One or more middle layers, preferably heat reflective layer, is provided in the Central region of the air mattress and supported by first and second layers of trusses which suspend or support the middle layer between the bottom layer and the top layer, to reduce convective air currents within the interior of the air mattress thereby preventing heat from a user's body from escaping to the ground or other cold surface on which the air mattress is placed.
- Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present invention, which is not to be limited except by the allowed claims and their legal equivalents.
Claims (26)
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2018
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2019
- 2019-08-20 US US16/545,743 patent/US10716392B2/en active Active
- 2019-12-23 US US16/725,666 patent/US10982467B2/en active Active
- 2019-12-23 US US16/724,952 patent/US11060318B2/en active Active
- 2019-12-26 US US16/727,255 patent/US20200253372A1/en not_active Abandoned
- 2019-12-31 US US16/731,271 patent/US20200305592A1/en not_active Abandoned
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2020
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2023
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Also Published As
Publication number | Publication date |
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US20200253372A1 (en) | 2020-08-13 |
US11401730B2 (en) | 2022-08-02 |
US20240026705A1 (en) | 2024-01-25 |
US10982467B2 (en) | 2021-04-20 |
US10390609B2 (en) | 2019-08-27 |
US10716392B2 (en) | 2020-07-21 |
US11060318B2 (en) | 2021-07-13 |
US20190098993A1 (en) | 2019-04-04 |
US20180213926A1 (en) | 2018-08-02 |
US20200196745A1 (en) | 2020-06-25 |
US20200305593A1 (en) | 2020-10-01 |
US20190374021A1 (en) | 2019-12-12 |
US20200196746A1 (en) | 2020-06-25 |
US10524563B2 (en) | 2020-01-07 |
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