Inflatable support system having thermoplastic polyurethane construction

Abstract: An inflatable support system comprised of at least one inflatable chamber that is defined by at least a top and a bottom layer of material. At least one of these layers of material is comprised of thermoplastic polyurethane. The inflatable support system includes at least one support structure that is also comprised of thermoplastic polyurethane. This support structure is attached to at least one of the layers of material that define the inflatable chamber. (end of abstract)

Agent: Brinks Hofer Gilson & Lione - Chicago, IL, US
Inventors: Timothy F. Austen, Chai Swo Chung, Wen Ta Sen
USPTO Applicaton #: #20070033739 - Class: 005712000 (USPTO)
Related Patent Categories: Beds, Mattress (for Whole Body), Having Confined Gas (e.g., Air Mattress), Having Tie Or Internal Seal

Inflatable support system having thermoplastic polyurethane construction description/claims

The Patent Description & Claims data below is from USPTO Patent Application 20070033739, Inflatable support system having thermoplastic polyurethane construction.

Brief Patent Description - Full Patent Description - Patent Application Claims

BACKGROUND

[0001] 1. Field of the Invention

[0002] The present invention relates to the field of inflatable support systems, particularly to an inflatable support system being constructed at least in part from thermoplastic polyurethane material.

[0003] 2. Related Art

[0004] 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.

[0005] 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.

[0006] 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.

[0007] 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.

BRIEF SUMMARY

[0008] Disclosed herein is an inflatable support system comprised of at least one inflatable chamber that is defined by at least a top and a bottom layer of material. At least one of these layers of material is comprised of thermoplastic polyurethane. The inflatable support system includes at least one support structure that is also comprised of thermoplastic polyurethane. This support structure is attached to at least one of the layers of material that define the inflatable chamber.

[0009] Also 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.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 is a perspective view of an embodiment of the present invention;

[0011] FIG. 2 is an external view of the flange of the present invention;

[0012] FIG. 3 is an internal view of the flange of FIG. 2;

[0013] FIG. 4 is an external view of the flange of FIG. 2 with a valve attached;

[0014] FIG. 5 is a cross-sectional view of an embodiment of the present invention showing the internal coils;

[0015] FIG. 6 is an enlarged view of the coils of FIG. 5; and

[0016] FIG. 7 is a cross-sectional view of a coil of FIG. 5 showing the fabric layer and the TPU layer.

DETAILED DESCRIPTION OF THE DRAWINGS AND THE PRESENTLY PREFERRED EMBODIMENTS

[0017] Referring in combination to FIGS. 1-6, an embodiment of the present invention 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.

[0018] 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.

[0019] In the illustrated embodiment, the present invention 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 0.2mm, 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. Alternatively, 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.

[0020] 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 in FIGS. 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 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.

Brief Patent Description - Full Patent Description - Patent Application Claims
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