U.S. patent application number 16/731271 was filed with the patent office on 2020-10-01 for sleeping pad with dual coated bottom sheet and central layer.
The applicant listed for this patent is NEMO EQUIPMENT, INC.. Invention is credited to Camon Brensinger.
Application Number | 20200305592 16/731271 |
Document ID | / |
Family ID | 1000004896751 |
Filed Date | 2020-10-01 |
United States Patent
Application |
20200305592 |
Kind Code |
A1 |
Brensinger; Camon |
October 1, 2020 |
SLEEPING PAD WITH DUAL COATED BOTTOM SHEET AND CENTRAL LAYER
Abstract
An inflatable sleeping pad or air mattress comprises an
inflatable pad having a top layer and a bottom layer. At least one
middle layer is disposed parallel to the top and bottom layers, and
supported between the top layer and the bottom layer by 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
further comprises an air inlet/outlet valve disposed on at least
one of the inflatable pad top or bottom layers.
Inventors: |
Brensinger; Camon;
(Stratham, NH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NEMO EQUIPMENT, INC. |
Dover |
NH |
US |
|
|
Family ID: |
1000004896751 |
Appl. No.: |
16/731271 |
Filed: |
December 31, 2019 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
15878989 |
Jan 24, 2018 |
10524563 |
|
|
16731271 |
|
|
|
|
62449818 |
Jan 24, 2017 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47B 3/002 20130101;
A47B 13/088 20130101; A47B 2200/001 20130101; A47B 3/06 20130101;
A47B 2003/0806 20130101; A47B 3/0803 20130101; F16B 12/44 20130101;
A47B 13/003 20130101; A47B 3/12 20130101; A47B 3/083 20130101; A47B
37/04 20130101; F16B 2012/446 20130101; A47B 2220/0072
20130101 |
International
Class: |
A47B 3/12 20060101
A47B003/12; A47B 3/083 20060101 A47B003/083; A47B 13/08 20060101
A47B013/08; A47B 3/08 20060101 A47B003/08; A47B 3/06 20060101
A47B003/06; F16B 12/44 20060101 F16B012/44; A47B 37/04 20060101
A47B037/04; A47B 13/00 20060101 A47B013/00; A47B 3/00 20060101
A47B003/00 |
Claims
1. (canceled)
2. An inflatable sleeping pad comprising: an inflatable pad having
a top layer and a bottom layer, said top and bottom layers disposed
parallel to one another and having a length and a width; at least
one middle layer constructed of a first material having a length
and a width and disposed parallel to said top and bottom layers,
and wherein said at least one middle layer is supported between the
top layer and the bottom layer; a plurality of support baffles, a
first plurality of support baffles disposed between the at least
one middle layer and the top layer, and a second plurality of
support baffles disposed between the at least one middle layer and
the bottom layer; and an air inlet/outlet valve disposed on at
least one of the inflatable pad top or bottom layers.
3. The inflatable sleeping pad according to claim 2, wherein the
first and second plurality of support baffles are truss support
baffles, attached at predetermined locations between the top layer,
the middle layer, and the bottom layer.
4. The inflatable sleeping pad according to claim 3, wherein said
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.
5. The inflatable sleeping pad according to claim 4, wherein said
top and bottom layers each include an interior facing surface, and
wherein each of said interior facing surfaces of said top and
bottom layers include at least a plurality of heat weldable
regions.
6. The inflatable sleeping pad according to claim 4, wherein said
at least one middle layer includes a plurality of openings.
7. The inflatable sleeping pad according to claim 6, wherein
predetermined regions of said first plurality of truss baffles are
welded at predetermined points directly to predetermined regions of
said second plurality of truss baffles through said plurality of
openings in said at least one middle layer.
8. The inflatable sleeping pad according to claim 7, wherein said
at least one middle layer is not heat weldable.
9. The inflatable sleeping pad according to claim 2, wherein the at
least one middle layer is constructed of a thermal energy
reflective material.
10. The inflatable sleeping pad according to claim 9, wherein the
middle layer is a mylar coated aluminum sheet.
11. The inflatable sleeping pad according to claim 2, wherein the
bottom layer is coated with polyurethane on at least predetermined
regions of an inner surface and generally entirely on an outer
surface thereof.
12. The inflatable sleeping pad according to claim 3, wherein said
at least one middle layer includes two middle layers, wherein said
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
said bottom layer and a first one of said two middle layers, a
second plurality of truss baffles are disposed between said first
one of said two middle layers and said second one of said two
middle layers, and wherein a third plurality of truss baffles are
disposed between said second one of said two middle layers and said
top layer.
13. the inflatable sleeping pad according to claim 12, wherein said
first, second and third plurality of truss baffles are made of a
heat or ultrasonic weldable material.
14. The inflatable sleeping pad according to claim 12, wherein each
of said first and second middle layers include a plurality of
openings.
15. The inflatable sleeping pad according to claim 14, wherein
predetermined regions of said first plurality of truss baffles are
welded at predetermined points directly to predetermined regions of
said second plurality of truss baffles through said plurality of
openings in said first middle layer, and wherein predetermined
regions of said second plurality of truss baffles are welded at
predetermined points directly to predetermined regions of said
third plurality of truss baffles through said plurality of openings
in said second middle layer.
16. The inflatable sleeping pad according to claim 12, wherein said
two middle layers are not heat weldable.
17. An inflatable sleeping pad comprising: an inflatable pad having
a top layer and a bottom layer, said top and bottom layers disposed
parallel to one another and having a length and a width, wherein
said top and bottom layers each include an interior facing surface,
and wherein each of said interior facing surfaces of said top and
bottom layers include at least a plurality of heat weldable
regions; at least one middle layer constructed of a thermal energy
reflective material having a length and a width and disposed
parallel to said top and bottom layers, and wherein said at least
one middle layer is supported between the top layer and the bottom
layer and comprises a plurality of openings; a plurality of truss
support baffles constructed of a heat weldable material, a first
plurality of truss support baffles disposed between the at least
one middle layer and the top layer, and a second plurality of truss
support baffles disposed between the at least one middle layer and
the bottom layer, wherein said first and second plurality of truss
support baffles are spot welded at predetermined locations between
the top layer, the middle layer, and the bottom layer, and wherein
predetermined regions of said first plurality of truss baffles are
welded at predetermined points directly to predetermined regions of
said second plurality of truss baffles through said plurality of
openings in said at least one middle layer; and an air inlet/outlet
valve disposed on at least one of the inflatable pad top or bottom
layers.
18. The inflatable sleeping pad according to claim 17, wherein the
middle layer is a mylar coated aluminum sheet
19. The inflatable sleeping pad according to claim 17, wherein the
first plurality of baffles is spot welded between the top layer and
the middle layer, and the second plurality of baffles is spot
welded between the middle layer and the bottom layer.
20. The inflatable sleeping pad according to claim 17, wherein the
bottom layer is coated with a polyurethane coating on an inner
surface and an outer surface thereof.
21. The inflatable sleeping pad according to claim 17, wherein said
at least one middle layer includes two middle layers, wherein said
two middle layers are supported between the top and bottom layers
in a spaced apart configuration and, and wherein the plurality of
truss baffles include a first plurality of truss baffles disposed
between said bottom layer and a first one of said two middle
layers, a second plurality of truss baffles are disposed between
said first one of said two middle layers and said second one of
said two middle layers, and wherein a third plurality of truss
baffles are disposed between said second one of said two middle
layers and said top layer.
22. The inflatable sleeping pad according to claim 21, wherein said
first and second middle layers include a plurality of openings.
23. The inflatable sleeping pad according to claim 22, wherein
predetermined regions of said first plurality of truss baffles are
welded at predetermined points directly to predetermined regions of
said second plurality of truss baffles through said plurality of
openings in said first middle layer, and wherein predetermined
regions of said second plurality of truss baffles are welded at
predetermined points directly to predetermined regions of said
third plurality of truss baffles through said plurality of openings
in said second middle layer.
24. The inflatable sleeping pad according to claim 17, wherein the
first plurality of baffles is spot welded between the top layer and
the middle layer, and the second plurality of baffles is spot
welded between the middle layer and the bottom layer.
25. An inflatable sleeping pad comprising: an inflatable pad having
a top layer and a bottom layer, said top and bottom layers disposed
parallel to one another and having a length and a width, wherein
said top and bottom layers each include an interior facing surface,
and wherein each of said interior facing surfaces of said top and
bottom layers include at least a plurality of heat weldable
regions, and wherein the bottom layer is coated with a polyurethane
coating on an inner surface and an outer surface thereof; at least
one middle layer constructed of a thermal energy reflective
material having a length and a width and disposed parallel to said
top and bottom layers, and wherein said at least one middle layer
is supported between the top layer and the bottom layer and
comprises a plurality of openings; a plurality of truss support
baffles constructed of a heat weldable material, a first plurality
of truss support baffles disposed between the at least one middle
layer and the top layer, and a second plurality of truss support
baffles disposed between the at least one middle layer and the
bottom layer, wherein said first and second plurality of truss
support baffles are spot welded at predetermined locations between
the top layer, the middle layer, and the bottom layer, and wherein
predetermined regions of said first plurality of truss baffles are
welded at predetermined points directly to predetermined regions of
said second plurality of truss baffles through said plurality of
openings in said at least one middle layer; and an air inlet/outlet
valve disposed on at least one of the inflatable pad top or bottom
layers.
26. The inflatable sleeping pad according to claim 25, wherein the
plurality of truss support baffles are constructed of die-cut low
stretch fabric.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] 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.
TECHNICAL FIELD
[0002] 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.
BACKGROUND INFORMATION
[0003] 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.
[0004] 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.
[0005] 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.
SUMMARY
[0006] 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.
[0007] 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.
[0008] 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.
[0009] 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.
[0010] 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.
[0011] 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.
[0012] 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.
[0013] 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.
[0014] 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.
[0015] 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.
[0016] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] 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:
[0018] 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
[0019] 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.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] 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.
[0021] Accordingly, 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.
[0022] 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. 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.
[0023] 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.
[0024] In one embodiment, 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. 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 the top layer 20,
the middle layer 26, and the bottom layer 22.
[0025] In a non-limiting embodiment, 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. Furthermore, 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.
[0026] 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 one middle layer 26 is preferably
constructed of a thermal energy reflective material. In one
example, 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.
[0027] 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 the
bottom layer 22 and a first one (26a) of the two middle layers, a
second plurality of truss baffles 28 are disposed between the first
one of the two middle layers 26a and the second one of the two
middle layers 26b, and wherein a third plurality of truss baffles
are disposed between the second one of the two middle layers 26b
and the top 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.
[0028] 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.
[0029] 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.
[0030] 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.
* * * * *