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
  • A47C27/10—Fluid mattresses or cushions with two or more independently-fillable chambers
• • 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
  • A47C27/088—Fluid mattresses or cushions incorporating elastic bodies, e.g. foam

Definitions

• the invention described in PCT/US03/39259 relates to a novel film-based cellular matrix that creates a plurality of repeating geometric cells such that when placed on end, forms a suitable core to an inflatable body. While that invention pioneered the concept of commercially feasible film-based cellular matrices particularly for use in the arts of inflatable bodies, use of this technology caused a material loss of inherent thermal transfer resistance when compared to prior core configurations for such articles. And while use of radiant barriers as a component of a cell wall is disclosed, the only disclosed orientation of the open-ended cells is with the major axis of the cell being orthogonal to the opposing panels comprising the outer envelope of the inflatable body.
• This orientation results in an unimpeded fluid/gas conduit from one panel to an opposing panel, although this core orientation is considered advantageous from the perspective of self-inflation (once compressed, the material in this orientation provides a restorative force that facilitates self-inflation of the envelope surrounding the core). As noted in the referenced publication, the intrinsic restorative force would be insufficient if the core orientation was otherwise.
• the invention is characterized in part as an improvement of and to the innovations disclosed in PCT/US03/39259, which is incorporated herein by reference, and further is directed to inflatable bodies incorporating embodiments of the invention. More particularly, the present invention is directed towards a cellular matrix having integrated radiant and/or convection barriers, methods for making such matrices, articles of manufacture incorporating such matrices as a core thereof and methods for making such articles of manufacture.
• heat energy or thermal transfer takes place via three modes: conductive (direct transfer of molecular kinetics), convective (indirect transfer of molecular kinetics through a dynamic medium) and radiant (emission and absorption of electromagnetic radiation).
• conductive direct transfer of molecular kinetics
• convective indirect transfer of molecular kinetics through a dynamic medium
• radiant emission and absorption of electromagnetic radiation
• the cellular matrix of various invention embodiments is generally characterized as a plurality of generally identical cells (open-ended geometric prisms) arranged to form a repeating geometric form, and comprise radiant and/or convection barriers at each cell to mitigate undesired thermal transmission in a plurality of directions there through.
• the matrix is particularly suited for use as a core between two opposing panels, wherein the cellular axes of the matrix are parallel to at least one virtual panel plane and the panels are preferably sealed about a common perimeter to create a flexible, fluid impervious envelope, to which the core may or may not be bonded.
• at least some cells of the matrix may comprise or be defined by portions of the envelope panels.
• a plurality of substantially triangular prisms comprises the cellular matrix.
• the triangular prisms may be either registered or non-registered (the meaning of these terms being defined below), wherein each prism is defined by two portions of a corrugating film or other material, and one portion of a generally planar film or other material (the meaning of these terms also being defined below).
• a matrix “row” is characterized as laterally repeating geometric forms having perceptible, and generally spatially constant, upper and lower boundaries, as shown in the Figures herein; a “column” is defined as a direction orthogonal to the direction of a row, as shown in the Figures herein.
• registered is used where the shape and orientation of adjacent cells within a row are orthogonally consistent, (stated alternatively, the shape, relative position and orientation of the geometric forms in any given column are substantially the same in each row).
• non-registered or “offset” is used where every other row of cells are registered, i.e., the shape and orientation of the geometric form in adjacent rows for any given column are not the same, and are usually mirror images thereof.
• swipe and “corrugating” are used interchangeably and reference films or materials that form two of three sides of cells in a matrix embodiment of the invention when the matrix is in an expanded state;
• planar references a film or material that forms one of three sides of such cells and assumes a generally planar geometry also when the matrix is in an expanded state.
• the orientation of a matrix functioning as a core in an inflatable body can be changed so that the prism's longitudinal axis (or height direction in a geometric sense) is parallel to a virtual plane defined by a major surface of an upper/lower outer panel of an inflatable body (i.e., not orthogonal to such plane(s)).
• the various invention embodiments described herein comprise a non-film sheet material, preferably but not exclusively a non-woven (e.g., spun) or batting-type sheet material as well as a foam sheet material, that may be substituted for some or all of the conventional strips of film disclosed in PCT/USO/39259 to provide enhanced thermal convection mitigation means, and/or integration of a thermally reflective film or coating into the matrix and/or enveloping panels of an inflatable body to provide enhanced thermal radiation mitigation means.
• a non-film sheet material preferably but not exclusively a non-woven (e.g., spun) or batting-type sheet material as well as a foam sheet material, that may be substituted for some or all of the conventional strips of film disclosed in PCT/USO/39259 to provide enhanced thermal convection mitigation means, and/or integration of a thermally reflective film or coating into the matrix and/or enveloping panels of an inflatable body to provide enhanced thermal radiation mitigation means.
• non-film sheet materials such as non-woven or batting-type sheet material as well as foam sheet material may be substituted for the serpentine or corrugating film sheets and/or the planar film sheet(s) in a cellular matrix arrangement.
• film sheet substitute material(s) include(s) recognition of the interface requirements between materials (between native film(s) and substitute material(s), or between a first substitute material and second substitute material), as well as between the film/substitute material(s) and the internal surfaces of the opposing panels comprising the fluid impervious envelope if applicable.
• the selection of appropriate film sheet substitute material(s) or treatment of conventional film(s)/material(s) includes recognition of the interface requirements between materials (between native film(s) and substitute material(s) or treated film(s)/material(s), or between a first substitute material or treated film(s)/material(s) and a second substitute material or treated film(s)/material(s)), as well as between the film/substitute/treated materials and the internal surfaces of the opposing panels comprising the fluid impervious envelope if applicable.
• suitable candidate materials for such film sheet include, but are not limited to, nylon, polyester and polyurethane.
• suitable candidate thin film substitute sheet materials for mitigating convection heat loss include, but are not limited to, nylon, polyester and polyurethane.
• open cell polyurethane foam, polyester foam or polyester batting also provide measurable levels of loft in a core when compressed and then permitted to restore, and therefore are considered desirable candidate materials for self- inflating body cores.
• Suitable candidate thin film sheet substitute materials for mitigating radiant heat loss include, but are not limited to, aluminized nylon, polyester and polyurethane films.
• preferred convention mitigating substitute materials include open cell polyurethane foam, polyester foam or polyester batting while preferred radiation mitigating substitute materials include aluminized polyurethane or polyester film.
• each cell in the cellular matrix comprises at least two discrete films (e.g., a corrugating film and a substantially planar film), at least one film can utilize convection mitigating substitute materials and at least one film can utilize radiation mitigating substitute materials. In this manner, the advantages of a core constructed with a cellular matrix can be achieved, and the attendant thermal deficiencies significantly mitigated.
• Fig. 1 is a perspective view of an inflatable body comprising a cellular matrix core according to the invention
• Fig. 2 is a detailed perspective view with cross section of the inflatable body of Fig. 1 wherein the core is representative of a first invention embodiment
• Fig. 3 is a cross section of the inflatable body of Fig. 2;
• Fig. 4 is a cross section of an inflatable body having a core representative of a second invention embodiment
• Fig. 5 is a cross section of an inflatable body having a core representative of a third invention embodiment
• Fig. 6 is a cross section of an inflatable body having a core representative of a fourth invention embodiment
• Fig. 7 is a cross section of an inflatable body having a core representative of a fifth invention embodiment
• Fig. 8 is a cross section of an inflatable body having a core representative of a sixth invention embodiment
• Core 20 which in this embodiment is comprised only of thin urethane films in the form of film sheets, includes planar sheet 22 to which is bonded first corrugating or serpentine sheet 24a and second corrugating or serpentine sheet 24b (collectively or generally referred to as corrugating or serpentine sheet(s) 24).
• Each corrugating or serpentine sheet 24 comprises proximal apexes 26 and distal apexes 28, which are preferably heat or RF bonded to the adjacent material; the material between the two apexes constituting one side of two adjacent cells 21.
• proximal apexes 26 of corrugating or serpentine sheets 24a and 24b are bonded to planar sheet 22 in general opposition to each other such that tension stress induced in sheet 24a, for example, transfers nearly directly to sheet 24b, and vice versa.
• this effective transference of tension forces beneficially provides the necessary tensile elements in certain article embodiments of the invention, and permits the use of relatively low tensile strength substitute materials in planar sheet 22.
• Matrix core 20 is shown disposed in, and partially bonded to, inflatable body 30.
• Inflatable body 30 comprises first and second panels 32a and 32b, each having inner and outer surfaces 34 and 36 respectively, and which are joined at their opposing perimeters to form an enveloping structure, and which form cell walls for roughly half of the cells that comprise core 20 through the bonding of distal apexes 28 of corrugating or serpentine sheets 24 there to.
• valve 38 is disposed in one of the panels (here shown disposed in panel 32a). Presuming that the ends of cells 21 are not sealed and/or at least one wall in each cell is fluid/gas permeable, any fluid/gas within the chamber defined by first and second panels 32a and 32b will pass through valve 38 upon complete compression of body 30.
• Each cell 21 in core 20 defines a longitudinal direction coincident with the cell axis or geometric "height" of the prism, and comprises for purposes of identification two leg walls and a base wall.
• any given cell 21 comprises base wall 23 and leg walls 25', 25" (note that the leg walls are visually discrete but are formed from a single instance of corrugating or serpentine sheet 24a or 24b).
• Leg walls 25" and 25" form an angle ⁇ there between, the value of which is proportional to the lateral length of base wall 23.
• the value of ⁇ is a factor in core 20's restorative bias as well as the load capacity of inflatable body 30.
• Inflatable body embodiments of the invention need not only provide for a single chamber in which a core is disposed.
• core 20 being longitudinally oriented and having planar sheet 22 essentially parallel to panels 32a and 32b as shown in Fig. 3, outward extension thereof to be included in the perimeter bond between panels 32a and 32b bifurcates the chamber, as best illustrated in Fig. 4.
• inclusion of one or both corrugating or serpentine sheets 24a and 24b in the peripheral bond may be desired, which is specifically illustrated in Fig. 4.
• chamber bifurcation can be achieved if only one or both corrugating or serpentine sheets 24a and 24b extend into the peripheral portion of panels 32a and 32b.
• any portion of core 20 extending outwardly there from and included in the peripheral bond between panels 32a and 32b is referred to as plenum portion 140.
• inflatable body 130 includes two valves 138a and 138b, one for each sub- chamber. Again, suitable fluid/gas paths should exist to provide communication between cells 121 and the environment, at least within each sub-chamber. By establishing two sub-chambers in a stacked relationship, modulation of body 130's compression characteristics can be carried out. Just as inclusion of a box spring with a mattress provides benefit to a user over use of only a mattress, the ability to provide distinct degrees of compression resistance finds great utility to users of inflatable bodies.
• Inflatable bodies having a bifurcated chamber of the type illustrated in Fig. 4 provide a user in one possible respect with the ability to provide a firm basic supporting base providing maximum displacement from the inflatable body supporting surface, yet retain a comparatively compliant body interface.
• having the more compliant sub-chamber acting as a basic supporting base permits the inflatable body to conform to irregular supporting surfaces without negatively impacting performance or comfort.
• core 520 comprises four (4) rows of cells 521, and three (3) planar sheets 522a-c wherein sheet 522b extends from core 520 to form plenum portion 540.
• inflatable body 530 is equivalent to inflatable body 130 in Fig. 4.
• inflatable body 230 is shown with core 220.
• Core 220 differs from core 20 in that corrugating or serpentine sheet 24a is not comprised of a single film material, but instead is comprised of a fluid/gas permeable material such as polyester or nylon batting, open cell foam (preferably urethane foam) and/or a laminate comprising foraminous urethane film; the last example being particularly useful in embodiments wherein the corrugating or serpentine sheets are in tension during use of the inflatable body given the poor tensile performance of thin foam material.
• a fluid/gas permeable material such as polyester or nylon batting, open cell foam (preferably urethane foam) and/or a laminate comprising foraminous urethane film
• each row may intentionally have distinct thermal and other performance properties: pure film material, which is lighter in weight than batting material, can be used in one row to reduce overall core weight, yet the thermal performance benefit of batting material can still be exploited in another row.
• each of the identified candidate corrugating or serpentine substitute sheet materials intrinsically has greater macro resiliency over thin urethane film material (as used herein, macro resiliency refers to large scale crumpling or crushing wherein large portions of the material or subject to compression as opposed to traditional point load deformation of a section of material).
• macro resiliency in part mitigates the loss of restorative bias previously provided by cellular matrix cores of the prior art.
• the greater density of welds to panels 32a and 32b also create longitudinal stiffness in the inflatable body. This longitudinal stiffness creates a bias in the body to return to the generally planar if "rolled up", such as what is done when compressing the body to remove air entrapped therein.
• plural chamber inflatable body embodiments are particularly amenable to the use of a fluid/gas permeable material such as polyester or nylon batting, open cell foam (preferably urethane foam) and/or a laminate comprising foraminous urethane film as a substitute for non-permeable corrugating or serpentine sheets.
• a fluid/gas permeable material such as polyester or nylon batting, open cell foam (preferably urethane foam) and/or a laminate comprising foraminous urethane film as a substitute for non-permeable corrugating or serpentine sheets.
• each leg wall 25 is mechanically and nearly directly linked to a congruent, opposing leg wall 25 in an adjacent row (for ease of reference, the leg walls in the several drawings have been labeled such that leg wall 25' in one row mechanically links to a congruent leg wall 25' in an adjacent row so that the reader can better trace the preferred vector of tension force transmission between opposing panels 32a and 32b when the inflatable body is subjected to compression loading, which increases internal fluid/gas pressure and therefore results in panel displacement and induces tension in tensile elements in areas not subjected to the compression loading).
• planar sheet 22 is generally not subjected to any tension forces; only the bond interfaces between opposing leg walls presents a realistic location for failure. Because planar sheet 22 is therefore not considered a structural element in this sense, material selection opportunities are greatly increased.
• planar sheet 422 illustrates the use of a thin foam material, such as open cell urethane foam, as planar sheet 422.
• Thin foam material is generally not appropriate for applications wherein it is subject to localized tension forces, as tearing will likely occur, but it is a very good thermal insulator and is fluid/gas permeable.
• planar sheet 422 is appropriate in many embodiments of the invention due to its optional presence. In other words, a core not comprising a planar sheet or equivalent could perform as an effective tensile structure.
• planar sheet 422 includes plenum portion 440, thereby forming two sub-chambers, fluid communication there between is possible due to its fluid/gas permeability, as shown by the arrows.
• intelligent selection of substitute material for corrugating or serpentine sheets 24a and 24b resulted in increased shape restoration bias, e.g., Fig. 5.
• shape restoration bias e.g., Fig. 5.
• intelligent selection of a substitute material for planar sheet 22 can also impart a restorative bias to the body.
• selection of a relative stiff planar sheet material such as found in a closed cell foam, will create a bias towards the planar form, thereby assisting a rolled up inflatable body to unroll.
• the combination provides for a reasonably self-inflating inflatable body.
• radiant mitigation means can be employed with respect to any film or sheet material.
• substitution of aluminized MYLAR for urethane films would retain the benefits associated with the use of film material but provide enhanced resistance to heat transfer via radiation.
• various film substitute sheet materials can be vapor coated with aluminum or other radiant reflective substance to enhance such material's resistance to heat transfer via radiation.
• a preferred embodiment of the invention comprises a foam planar sheet to which is selectively bonded at least one non-woven or batting-type material as a serpentine or corrugating sheet, and at least one envelope panel having a radiant heat transfer mitigation treatment thereon, preferably on an interior surface thereof.

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• Laminated Bodies (AREA)
• Mattresses And Other Support Structures For Chairs And Beds (AREA)
• Thermotherapy And Cooling Therapy Devices (AREA)
• Saccharide Compounds (AREA)

Priority Applications (7)

Applications Claiming Priority (2)

Related Child Applications (1)

Publications (2)

Family

ID=40901587

Family Applications (1)

Country Status (8)

Cited By (4)

Families Citing this family (4)

Family Cites Families (23)

• 2009
  • 2009-01-22 CN CN200980109138.2A patent/CN101969819B/zh active Active
  • 2009-01-22 JP JP2010544353A patent/JP5551615B2/ja active Active
  • 2009-01-22 WO PCT/US2009/000474 patent/WO2009094208A2/en active Application Filing
  • 2009-01-22 AU AU2009206691A patent/AU2009206691A1/en not_active Abandoned
  • 2009-01-22 CA CA2712759A patent/CA2712759C/en active Active
  • 2009-01-22 RU RU2010134803/12A patent/RU2010134803A/ru not_active Application Discontinuation
  • 2009-01-22 EP EP09704123.0A patent/EP2249684B1/en active Active
• 2011
  • 2011-05-23 HK HK11105115.6A patent/HK1150945A1/xx unknown

Non-Patent Citations (1)

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