U.S. patent application number 15/154194 was filed with the patent office on 2017-09-28 for inflatable mattress.
The applicant listed for this patent is Bestway Inflatables & Material Corp.. Invention is credited to Feng LIU.
Application Number | 20170273472 15/154194 |
Document ID | / |
Family ID | 56072260 |
Filed Date | 2017-09-28 |
United States Patent
Application |
20170273472 |
Kind Code |
A1 |
LIU; Feng |
September 28, 2017 |
INFLATABLE MATTRESS
Abstract
An inflatable mattress has an upper layer structure, an
inflatable middle layer and a bottom layer structure. The upper
layer structure includes a basic fabric layer and a covering layer.
The basic fabric layer is woven by a plurality of fabric fibers,
wherein the number of weft and warp fibers per square inch is
higher than 100. The covering layer and the basic fabric layer
stick to each other by glues, wherein the weight of the glues are
higher than 20 grams per square yard and lower than 80 grams per
square yard. The basic fabric layer orients toward the direction of
the coverage layer, pressing and embedding into the covering layer
and constituting a fabric surface laminating material.
Inventors: |
LIU; Feng; (Shanghai,
CN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Bestway Inflatables & Material Corp. |
Shanghai |
|
CN |
|
|
Family ID: |
56072260 |
Appl. No.: |
15/154194 |
Filed: |
May 13, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47C 27/087 20130101;
A47C 27/081 20130101; A47C 27/10 20130101; A47C 31/001
20130101 |
International
Class: |
A47C 27/10 20060101
A47C027/10; A47C 27/08 20060101 A47C027/08; A47C 31/00 20060101
A47C031/00 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 25, 2016 |
CN |
201610178686.2 |
Mar 25, 2016 |
CN |
201620239569.8 |
Claims
1. An inflatable mattress, comprising: an upper layer structure
comprising a basic fabric layer and a covering layer, the basic
fabric layer being woven by a plurality of fabric fibers, wherein
the number of weft and warp fibers per square inch is higher than
100, the covering layer and the basic fabric layer are stuck to
each other by glues, wherein the weight of the glues is higher than
20 grams per square yard and lower than 80 grams per square yard,
and the basic fabric layer faces toward the direction of the
covering layer, presses and embeds into the covering layer and
constitutes a first fabric surface laminating material; an
inflatable middle layer, a first surface of the inflatable middle
layer being fixedly connected to the upper layer structure, and the
inflatable middle layer comprising at least one air chamber
configured to provide a predetermined shape after expansion during
the inflation, and the outer side of the inflatable middle layer
comprising the second fabric surface laminating material; and a
bottom layer structure, wherein a second surface of the inflatable
middle layer is fixedly connected to the bottom layer structure,
and the bottom layer structure comprises the third fabric surface
laminating material.
2. The inflatable mattress as claim 1, wherein the portions of the
upper layer structure, the inflatable middle layer and the bottom
layer structure facing outwardly are all covered with the fabric
surface laminating material.
3. The inflatable mattress as claim 1, wherein the inflatable
middle layer has at least one drawstring, the drawstring connecting
respectively to the upper layer structure and the bottom layer
structure, so as to ensure the predetermined shape of the
inflatable mattress after expansion during the inflation.
4. The inflatable mattress as claim 3, wherein the upper layer
structure comprises a top surface portion comprising the basic
fabric layer, the top surface portion covering more than 70% of the
area of the upper layer structure facing up, and the top surface
portion connecting to the bottom layer structure by a plurality of
drawstrings, and the drawstrings being Y-type drawstrings.
5. The inflatable mattress as claim 3, wherein the upper layer
structure comprises a top surface portion comprising the basic
fabric layer, the top surface portion covering more than 70% of the
area of the upper layer structure facing up, and the top surface
portion connecting to the bottom layer structure by a plurality of
drawstrings, and the drawstrings are round hole drawstrings.
6. The inflatable mattress as claim 1, wherein the fabric fiber of
the basic fabric layer comprises polyester materials, and the
weight per unit length are different for the fabric fiber in weft
direction and the fabric fiber in warp direction.
7. The inflatable mattress as claim 1, wherein the fabric fiber of
the basic fabric layer has number of fibers of more than 50 and
less than 300 per square inch in weft direction and warp
directions.
8. The inflatable mattress as claim 1, wherein the materials of the
covering layer includes PVC material.
9. The inflatable mattress as claim 1, wherein the glues withstands
drawing forces larger than 20 newtons per 3 centimeters.
10. The inflatable mattress as claim 1, wherein the glues
withstands drawing forces of more than 10 newtons and less than 50
newtons per 3 centimeters.
11. The inflatable mattress as claim 1, wherein the material of the
glues is PU glues with viscosity between 350000 CPS to 100000
CPS.
12. The inflatable mattress as claim 1, wherein the thickness of
the covering layer is between 0.15 mm to 0.9 mm, and the thickness
of embedment of the basic fabric layer into the covering layer is
between 0.06 mm to 0.1 mm.
13. The inflatable mattress as claim 1, wherein an affordability
for tensile strength of the fabric surface laminating material is
larger than 200 newtons per 2.54 centimeters, an affordability for
tear strength of the fabric surface laminating material is larger
than 4 newtons, and an affordability for peel strength of the
fabric surface laminating material is larger than 40 newtons per 3
centimeters.
14. The inflatable mattress as claim 1, wherein the covering layer
is doped with an flame retardant material, so that an ignition
point for the fabric surface laminating material is larger than 350
degrees Celsius.
15. The inflatable mattress as claim 1, wherein the covering layer
comprises a plurality of embossed patterns.
16. The inflatable mattress as claim 15, wherein the embossed
patterns of the covering layer have a plurality of protruding
embossed stripes cross-distributed on the surface of the covering
layer.
17. The inflatable mattress as claim 16, wherein the plurality of
protruding embossed stripes constitute a plurality of hexagonal
honeycomb structures.
18. The inflatable mattress as claim 16, further comprising a
plurality of protruding embossed blocks being distributed on
interspace areas separated out by the protruding embossed
stripes.
19. The inflatable mattress as claim 15, wherein the embossed
patterns are distributed on one side or two sides of the covering
layer.
20. The inflatable mattress as claim 15, wherein the inflatable
middle layer comprises at least one surrounding sheet and a
plurality of surrounding side drawstrings, and the surrounding side
drawstrings are welded with the surrounding sheet to configured to
a multi-layer structure in the inflatable middle layer.
21. A method for manufacturing an inflatable mattress, wherein the
inflatable mattress has an upper layer structure, an inflatable
middle layer and a bottom layer, and the upper layer structure, the
inflatable middle layer and the bottom layer have fabric surface
laminating materials, the method comprising: flattening a fabric
surface material; gluing on, drying, and cooling the heated
flat-lying fabric surface material; flattening a PVC material to
conduct the preheating; pressing and forming the fabric surface
material and the preheated PVC material into the fabric surface
laminating materials by a double-fitting roller; manufacturing the
outer surfaces of the upper layer, the inflatable middle layer and
the bottom layer by using the fabric surface laminating materials;
and using drawstrings to connect the upper layer structure and the
bottom layer structure.
Description
FIELD OF THE INVENTION
[0001] The present invention is related to a mattress, and more
particularly related to an inflatable mattress.
BACKGROUND
[0002] The human history of invention of beds is long,
nevertheless, new techniques have still been constantly in
development. After all, the ratio of time spent on sleeping for
human beings is very large. In addition, there are many different
kinds of mattresses, such as spring beds, memory mattresses,
tatamis, etc. Another different kind of mattresses further includes
water beds, and inflatable mattresses.
[0003] For inflatable mattresses, by inflation in interior
inflatable spaces, certain predetermined shapes can be maintained
for mattresses, so as to to provide experiences similar to using
mattresses for users. Since inflatable mattresses can reduce
volumes greatly by deflating, thus, one can have considerable
conveniences on storages or deliveries. In addition, since
relatively less materials are required for inflatable mattresses,
there are stronger advantages with respect to conventional
mattresses on manufacturing costs.
[0004] Nevertheless, conventional inflatable mattresses still pay
more attention conveniences, there are still considerable room for
improvements required for overall experiences of using.
SUMMARY OF THE INVENTION
[0005] According to the first embodiment of the invention, there is
an inflatable mattress. The inflatable mattress has an upper layer
structure, a inflatable middle layer structure and a bottom layer
structure.
[0006] The upper layer structure comprises a basic fabric layer and
a covering layer. The basic fabric layer is woven by a plurality of
fabric fibers. the number of weft and warp fibers per square inch
are higher than 100. The covering layer and the basic fabric layer
stick to each other by glues, wherein the weight of the glues are
higher than 20 grams per square yard and lower than 80 grams per
square yard. The basic fabric layer orients toward the direction of
the coverage layer, pressing and embedding into the covering layer
and constituting a fabric surface laminating material.
[0007] The so-called pressing and embedding the basic fabric layer
into the covering layer is, by pressing the basic fabric layer and
the covering layer, the uneven surface of the basic fabric layer
having fibers directly or indirectly pressing the covering layer
via glues, so that the surface of the covering layer generating a
certain degree of concavity, and thus composing a more stable
pressing result.
[0008] A first surface of the inflatable middle layer is fixedly
connected to the upper layer structure. Also, the inflatable middle
layer comprises at least one air chamber configured to provide a
predetermined shape after expansion during the inflation. The outer
side of the inflatable middle layer comprises the fabric surface
laminating materials.
[0009] A second surface of the inflatable middle layer is fixedly
connected to the bottom layer structure, and the bottom layer
structure comprises the fabric surface laminating materials.
[0010] The portions orienting outward of the upper layer structure,
the inflatable middle layer and the bottom layer structure are all
covered with the fabric surface laminating materials.
[0011] In one condition, the outer surfaces of the upper layer
structure, the inflatable middle layer and the bottom layer
structure are all covered with the fabric surface laminating
materials.
[0012] The inflatable middle layer can have at least one
drawstring. the drawstring connects respectively to the upper layer
structure and the bottom layer structure, so as to ensure the
predetermined shape of the inflatable mattress after expansion
during the inflation.
[0013] The upper layer structure can comprise a top surface
portion. The top surface portion covers more than 70% of the area
of the upper layer structure facing up, and the top surface portion
can connect to the bottom layer structure by a plurality of
drawstrings, and the drawstrings are Y-type drawstrings or round
hole drawstrings.
[0014] The fabric fiber of the basic fabric layer can comprise
polyester materials, and the weight per unit length is different
for the fabric fiber in weft direction and the fabric fiber in warp
direction.
[0015] The fabric fiber of the basic fabric layer has number of
fibers of more than 50 and less than 300 per square inch in weft
direction and warp directions. For example, the basic fabric layer
can be constituted by polyester fibers of 75D.times.75D or
110D.times.80D. The "D" means the standard unit of the wire
diameter of 1 gram per 9 kilometers used in the industry.
[0016] The materials of the covering layer can include PVC
material. The glues can withstand drawing forces larger than 20
newtons per 3 centimeters. Alternatively, the glues can withstand
drawing forces of more than 10 newtons and less than 50 newtons per
3 centimeters. The material of the glues can be PU glues with
viscosity between 350000 CPS to 100000 CPS.
[0017] The thickness of the covering layer can be between 0.15 mm
to 0.9 mm. The thickness of embedment of the basic fabric layer
into the covering layer can be between 0.06 mm to 0.1 mm.
[0018] The affordability for tensile strength of the fabric surface
laminating materials is larger than 200 newtons per 2.54
centimeters, the affordability for tear strength of the fabric
surface laminating material is larger than 4 newtons, and the
affordability for peel strength is larger than 40 newtons per 3
centimeters.
[0019] The covering layer is doped with an flame retardant
material, so that an ignition point for the fabric surface
laminating materials can be larger than 350 degrees Celsius.
[0020] The covering layer can have embossments. The embossments not
only increase strengths of materials and reduce the manufacturing
costs, but also cause the covering layer to expand easier during
treating processes.
[0021] The embossments of the covering layer can have a plurality
of protruding embossment stripes cross-distributed on the surface
of the covering layer. For example, the plurality of protruding
embossment stripes constitute a plurality of hexagonal honeycomb
structure. In addition, a plurality of protruding embossment blocks
can also be distributed on interspace areas separated out by the
protruding embossment stripes.
[0022] The embossments can be distributed on one side or two sides
of the covering layer.
[0023] The inflatable middle layer has a surrounding sheet and a
plurality of surrounding side drawstrings. The surrounding side
drawstrings are welded with the surrounding sheet to configured to
a multi-layer structure in the inflatable middle layer.
[0024] According to another embodiment of the invention, the
embodiment provides a method for manufacturing an inflatable
mattress. The inflatable mattress has an upper layer structure, an
inflatable middle layer and a bottom layer, and the upper layer
structure, the inflatable middle layer and the bottom layer have
fabric surface laminating materials. The method includes steps as
follows. Flatten a fabric surface material. Glue on, dry, and cool
the heated flat-lying fabric surface material. Flatten a PVC
material to conduct the preheating. Press and form the fabric
surface material and the preheated PVC material into the fabric
surface laminating materials by a double-fitting roller.
Manufacture the outer surfaces of the upper layer, the inflatable
middle layer and the bottom layer by using the fabric surface
laminating materials. Use drawstrings to connect the upper layer
structure and the bottom layer structure.
[0025] In one embodiment, the basic fabric layer conducts a
waterproof treatment. The fabric layer can also be dope with silver
materials to prevent the occurrence of stink smell.
[0026] In one embodiment, the inflatable mattress can further
include a buckling structure, configured to settle and fix a
removable upper layer mattress above the upper layer structure. The
removable upper layer mattress is transparent materials, and the
removable mattress has a buckle-in structure corresponding to the
buckling structures.
[0027] In one embodiment, wherein the removable upper layer
mattress can be a thin pad constituted by a nature material.
[0028] In one embodiment, wherein the upper layer structure further
comprises a memory buffer layer. The buffer layer is set below the
basic fabric layer, configured to memorize the stature of a user,
in order to provide a surface shape more consistent with the
stature of a user.
[0029] By combinations of above mentioned embodiments and
corresponding characteristics, and according to a plurality of and
repeated experiments and tests, the manufacturing method and
related techniques herein can manufacture an inflatable mattress
which can reduce the costs and at the same time having comfort,
thus bringing substantial technical effects.
BRIEF DESCRIPTIONS OF THE DRAWINGS
[0030] FIG. 1a is a schematic drawing of an inflatable mattress
according to the first embodiment of the invention.
[0031] FIG. 1b is a schematic drawing of an inflatable mattress
according to the second embodiment of the invention.
[0032] FIG. 2a is an embodiment of fabric surface laminating
materials according to the invention.
[0033] FIG. 2b is an embodiment of fabric surface laminating
materials according to the invention.
[0034] FIG. 3a is an embodiment of a first kind of embossments of
the PVC layer according to the invention.
[0035] FIG. 3b is an embodiment of a second kind of embossments of
the PVC layer according to the invention.
[0036] FIG. 3c is an embodiment of a third embossments of the PVC
layer according to the invention.
[0037] FIG. 4 is a flow diagram of manufacturing the fabric surface
laminating materials according to the invention.
[0038] FIG. 5a is a schematic drawing of a drawstring of the
inflatable mattress according to the invention.
[0039] FIG. 5b is a schematic drawing of an embodiment of a
drawstring of the inflatable mattress according to the
invention.
[0040] FIG. 6 is a schematic drawing of another embodiment of the
inflatable mattress according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0041] Refer to FIG. 1a. FIG. 1a exemplifies an embodiment of an
inflatable mattress 10 according to the invention.
[0042] In FIG. 1a, the inflatable mattress 10 has an upper layer
structure 101, an inflatable middle layer 105 and a bottom layer
structure 102. The upper layer structure 101 has a top surface
portion, that is the inner rectangular region of the upper layer
structure 101 in the FIG. 1a. The top surface portion covers more
than 70% of the area of the upper layer structure facing up, and
the top surface portion can connect to the bottom layer structure
102 by a plurality of Y-type drawstrings
[0043] The upper layer structure 101 can include a basic fabric
layer and a covering layer. The basic fabric layer is woven by a
plurality of fabric fibers. the number of weft and warp fibers per
square inch are higher than 100. The covering layer and the basic
fabric layer stick to each other by glues, wherein the weight of
the glues are higher than 20 grams per square yard and lower than
80 grams per square yard. The basic fabric layer orients toward the
direction of the coverage layer, pressing and embedding into the
covering layer and constituting a fabric surface laminating
material.
[0044] The so-called pressing and embedding the basic fabric layer
into the covering layer is, by pressing the basic fabric layer and
the covering layer, the uneven surface of the basic fabric layer
having fibers directly or indirectly pressing the covering layer
via glues, so that the surface of the covering layer generating a
certain degree of concavity, and thus composing a more stable
pressing result.
[0045] The inflatable middle layer 105 can be fixedly connected to
the upper layer structure 101 on a first surface of the inflatable
middle layer by the drawstrings 106, and fixedly connected to the
bottom layer structure 102 on a second surface of the inflatable
middle layer.
[0046] The inflatable middle layer 105 can have one or more than
one inflation holes which conducting the inflation to the
inflatable middle layer 102 by an exterior inflation pump. Another
approach is to integrate the inflation pump and the inflatable
middle layer 105, providing an inflation power by plug-in or other
ways. The inflatable middle layer 105 comprises at least one air
chamber configured to provide a predetermined shape after expansion
during the inflation. In practical manufacturing, more than two air
chambers can be designed, these air chambers maintain certain
independence even by the corresponding mechanism (such as a
unidirectional valve), so that another air chamber still can
maintain a certain supporting force when an air chamber is under
leakage. In addition, if the mattress is designed to be used by two
people, the air chamber corresponding to the mattress can be
designed to have a buffer space between the two sets. By this way,
even a first user lying on one side turns over, a second user
sleeping on the other side will not be directly affected by
excessive vibrations. The buffer layer can be constituted by
vibration isolated materials in itself such as an air chamber with
lower pressure or sponges, etc. Or, the gases between the two sets
of air chambers do not connected with each other, so as to generate
an effect similar to the independent cylinder of the conventional
mattresses.
[0047] In addition, the periphery of the inflatable middle layer
105 has a surrounding side drawstring 103. The side surrounding
sheet outstretches a surrounding three-layer structure by at least
one side drawstring. The side drawstring can be plastic materials,
fabric fiber materials or other connection materials which can
provide a certain tension and supporting forces. by ways of high
frequency welding or paste . . . etc., the side surrounding sheet
103 is connected to other portions of the inflatable mattress 10,
so as to maintain the inflatable mattress 10 to keep a
predetermined shape during inflation.
[0048] Refer to FIG. 1b. FIG. 1b exemplifies an embodiment of the
inflatable mattress 10 according to the invention.
[0049] In FIG. 1b, the inflatable mattress 11 has an upper layer
structure 111, an inflatable middle layer 155, and a bottom layer
structure 112. The upper layer structure 111 has a top surface
portion, that is the inner rectangular region of the upper layer
structure 111 in FIG. 1b. The top surface portion covers more than
70% of the area of the upper layer structure facing up, and the top
surface portion connect to the bottom layer structure 112 by a
plurality of round hole drawstrings 116.
[0050] A first surface of the inflatable middle layer 115 is
fixedly connect to the upper layer structure 111. A second surface
of the inflatable middle layer 115 is fixedly connected to the
bottom layer structure 112.
[0051] In addition, the periphery of the inflatable middle layer
115 has a surrounding side drawstring 113. The side surrounding
sheet 113 outstretches a surrounding three-layer structure by at
least one side drawstring 114. The side drawstring can be plastic
materials, fabric fiber materials or other connection materials
which can provide a certain tension and supporting forces. by ways
of high frequency welding or paste, etc., the side surrounding
sheet 113 is connected to other portions of the inflatable mattress
11, so as to maintain the inflatable mattress 11 to keep a
predetermined shape during inflation.
[0052] In other words, the inflatable middle layers 105, 115 can be
constituted by various kinds of different structures. Besides,
since the top surface portion of the upper layer structures 105,
115 are main parts in touch with users, therefore, the top surface
portion can include structures constituted by the fabric surface
laminating materials, so that the fabric surface laminating
materials oriented toward users are constituted by fabric surfaces.
Of course, based on considerations of factors on designs and
convenience of manufacturing . . . etc., this kind of fabric
surface laminating materials can also extend to the whole upper
layer structures 101, 111, or even extend to the side surrounding
sheets 103, 113. If one hopes the mattresses can be designed to be
used on two side, the bottom layer structures 102, 112 can be
directly designed to be the same as the design of the upper layer
structures 101, 111.
[0053] Refer to FIG. 2a. FIG. 2a exemplifies a schematic drawing of
an embodied way of the fabric surface laminating materials
according to the invention. In FIG. 2a, this kind of fabric surface
laminating materials 20 has a basic fabric layer 201 and a covering
layer 203. The basic fabric layer 201 and the covering layer 203
are being fixedly connected by the glues 202.
[0054] The basic fabric layer 201 can be woven by a plurality of
fabric fibers via weft (or warp) or other geometrical structural
ways. By different materials and weaving methods, different surface
characteristics can be provided. For example, by different
materials and weaving methods, the basic fabric layer 201 of
colors, patterns, heat dissipations, heat preservations, and
different sense of touches can be conducted.
[0055] These fabric fibers can generate surfaces with different
flatness on the surfaces according to their characteristics. In
principle, during the process of pressing, the basic fabric layer
201 presses and embeds into the covering layer 203. Please be noted
that, even the covering layer 203 which looks like flat in FIG. 2a,
by the processes of sticking by the glues and pressing laminating
on the surface, even the tiny or invisible laminations are
belonging to the "embedment into the uneven surface of the surface
of the fabric layer" herein.
[0056] FIG. 2b exemplifies a more obvious squeezing and embedment
phenomenon. The surface of the basic fabric layer 201 of the fabric
laminating materials 21 has obvious uneven ups and downs. Likewise,
one conduct the lamination between the basic fabric layer 211 and
covering layer 213 by the glues. From FIG. 2b one can clearly see
the basic fabric layer 211 pressing and embedding into the surface
of the covering layer 213, so that the two (211, 213) join more
closely together.
[0057] In one embodiment, the covering layer can have a polarity,
and by this characteristic, the covering layer can be fixed to the
inflatable middle layer by way of high frequency welding. For
example, the covering layer can use PVC materials. Comparing to
similar materials (with respect PVC materials), PVCs are easily
being processed, capable of recycling for continuous use, high
strength, superior geometrical stability.
[0058] In one embodiment, the fabric fiber of the basic fabric
layer has number of fibers of more than 50 and less than 300 per
square inch in weft direction and warp direction. For example, the
basic fabric layer can be constituted by polyester fibers of
75D.times.75D or 110D.times.80D. Wherein the "D" means the standard
unit of the wire diameter of 1 gram per 9 kilometers used in the
industry.
[0059] In one embodiment, the glues can withstand drawing forces
larger than 20 newtons per 3 centimeters. In one embodiment, the
material of the glues is PU glue with viscosity between 350000 CPS
to 100000 CPS. For example, the PU glues can be adopted for the
glues with viscosity between 350000 CPS to 100000 CPS, or between
40000 CPS to 60000 CPS. The PU is the polyurethane material, and
the CPS is a measurement unit for viscosity in the industry.
[0060] Set different amount of glues according to different
standards of laminating firmness. The higher the standard of the
laminating firmness, the more the amount of glues, and the higher
the costs. Preferred approaches are such as between 20 N/3cm to 100
N/3cm, or between 10 N/3cm to 50 N/3cm, and the amount of glues is
10 g/Y2 to 100 g/Y2. The "N" represents the newton, and the g/Y2
represents the amount of glues per square yard.
[0061] In one embodiment, the thickness of the covering layer is
between 0.15 mm to 0.9 mm, the thickness of embedment of the basic
fabric layer into the covering layer is between 0.06 mm to 0.1 mm,
and the total thickness of the upper layer structure is between 0.2
mm to 1 mm. It is an option as long as the thickness of the
covering layer satisfies the high frequency welding and no leakage.
The second lamination can all be under processing.
[0062] In one embodiment, the affordability for tensile strength of
the basic fabric layer is larger than 200 newtons per 2.54
centimeters, an affordability for tensile strength of the fabric
surface laminating material is larger than 4 newtons, and an
affordability for peel of the fabric surface laminating material is
larger than 40 newtons per 3 centimeters. There can be different
settings according to different specifications, materials, and glue
formulas of the basic fabric layer. Also, the basic fabric layer
can be doped with flame retardant material. For example, by doping
flame retardant material or a fireproof treatment, the ignition
point of the basic fabric layer is larger than 300 degrees
Celsius.
[0063] In FIG. 3a, the covering layer can have embossed patterns.
The embossed patterns of the covering layer can be pressed out by
one side of an embossing roller or by conducting rolling pressing
on all two sides, thus generating the corresponding embossed
patterns. In FIG. 3a, one can press out horizontal and vertical
parallel embossed stripes 311 on the covering layer 31 manufactured
by materials of PVC, etc. by the roller. Comparing to other
portions 312, the embossed strips 311 can have a certain degree of
protrusions. By designs of the embossed stripes 311, one can not
only create higher stability and structural drawing forces, better
effects can also be generated with respect to the cement of the
basic fabric layer.
[0064] In FIG. 3b, the covering layer 32 has protrusive embossed
patterns 321. Different from the design of the embossed stripes
with staggered arrangements in horizontal and vertical directions
in FIG. 3a, the embossed stripes in FIG. 3b constitute hexagonal
shapes similar to honeycomb shapes, bringing better structural
stability. In the point of view of manufacturing, it means one can
manufacture a thin layer having the same strength using thinner
materials. This approach can further reduce the manufacturing
costs.
[0065] In FIG. 3c, the covering layer 33 also has protrusive
embossed blocks 331 distributed between the embossed stripes
arranged in horizontal and vertical directions (i.e. the black
geometrical block patterns as marked). Please be noted that, the
manufacture of embossed patterns on all two sides or only one side
of these covering layers can be conducted. The embossed patterns
can be protrusive, concave, or local protrusive and local
concave.
[0066] Refer to FIG. 4. FIG. 4 exemplifies a method for
manufacturing the mentioned fabric surface laminating materials.
First, flatten the fabric surface material (step S1). Usually, for
the convenience of transportation, fabric surfaces are preserved by
way of rolling up.
[0067] Next, apply glue on the heated flat-lying fabric surface and
drying cooling (step S2). In addition, flatten the PVC material
acted as the covering layer (step S3). Next, press and form the
fabric surface material and the preheated PVC material into the
fabric surface laminating materials by a double-fitting roller
(step S4). In other words, by the pressure of the roller, the PVC
material of the covering layer is conducted to have closer fixing
with the fabric surface material acted as the basic fabric layer by
the glues.
[0068] Finally, one cools the fabric surface laminating materials
by a cooling wheel and conducts an accumulator winding (step S5).
The manufactured fabric surface laminating materials can conduct
welding or lamination later with other elements, so as to
constituted various kinds products of inflatable mattresses.
[0069] In addition, the covering layer at PVC can have embossed
patterns on all two sides, and the kinds of lines are not being
limited. Different patterns can be pressed out by different
sleeves. The purpose is to decrease the thickness of the material,
and easily to e flattened, smoother, and easily been processed.
[0070] In one embodiment, a waterproof treatment is conducted to
the basic fabric layer. In addition, the brush, waterproof
treatment can be conducted on the surface of the basic fabric
layer. The basic fabric layer can be doped with silver materials,
so as to avoid the occurrence of stink smell.
[0071] Refer to FIG. 5a. FIG. 5a exemplifies a schematic drawing of
fixing the connection of the upper layer structure of the
inflatable mattress by Y-type drawstrings 512. Since the Y-type
drawstrings 512 are divided into two branches on the portion of the
connection with the upper layer mechanism 511, and are looked like
a shape of an Y-type alphabet, so as to be named Y-type drawstrings
512. In fact, the number of branches of the drawstrings can be even
more than two, depending on designs for practical requirements.
[0072] In addition, refer to FIG. 5b. FIG. 5b exemplifies a
schematic drawing of fixing the upper layer structure 521 of the
inflatable mattress by round hole drawstrings 522. The round circle
drawstrings draw the upper layer structure 521 in a structure
similar to a way of a cylinder, generating a certain drawing force,
and then ensure the shape of the inflatable mattress, corresponding
to embodiments in FIG. 1a and FIG. 1b. Of course, it should be
noted that, technical staffs can also use other ways to ensure the
shape of the inflatable mattress.
[0073] Refer to FIG.6. In one embodiment, the inflatable mattress
62 can further include one or more than one buckling structures
622, 624, configured to settle and fix a removable upper layer
mattress above the upper layer structure 61. The removable upper
layer mattress 61 is transparent materials, and the removable
mattress has a buckle-in structure corresponding to the buckling
structures 612, 614.
[0074] In one embodiment, In one embodiment, wherein the removable
upper layer mattress can be a thin pad constituted by a nature
material such as using a straw mat, tatami materials.
[0075] In one embodiment, wherein the upper layer structure further
comprises a memory buffer layer, such as a memory buffer layer
constituted by memory sponges. The buffer layer is set below the
basic fabric layer, configured to memorize the stature of a user,
in order to provide a surface shape more consistent with the
stature of a user.
[0076] By combinations of above mentioned embodiments and
corresponding characteristics, and according to a plurality of and
repeated experiments and tests, the manufacturing method and
related techniques herein can manufacture an inflatable mattress
which can reduce the costs and at the same time having comfort,
thus bringing substantial technical effects.
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