Method of making a self-inflating air mattress

Claim 1

A method of making a self-inflating air mattress comprising an envelope of upper and lower sheets bonded to one another, and a foam core having upper and lower surfaces securely bonded over substantially their entire surface areas to the upper and lower sheets, said method comprising: a. placing a planar piece of open cell foam core material between upper and lower sheets to form a pre-bonded assembly, said sheets being air impermeable and having an inner bonding layer of a thermo-plastic material, b. simultaneously heating and compressing said assembly to compress the foam core between the sheets and soften the layers of thermo-plastic material to permit propr interengagement thereof with said foam, and to bring said assembly to an elevated temperature, c. cooling said sheets and foam core portions immediately adjacent thereto only for a period of time necessary to cause a secure bonding of the foam to the upper and lower sheets to form a bonded assembly, and d. pressurizing the foam core to a pressure above ambient pressure by introduction of pressurized fluid therein immediately after cooling to apply an expanding force between the upper and lower sheets to break undesired weak foam filament bonds to said sheet and to enhance loft of said foam core.

Claim 2

A method of making a self-inflating air mattress comprising an envelope of upper and lower sheets bonded to one another, and a foam core having upper and lower surfaces securely bonded over substantially their entire surface areas to the upper and lower sheets, said method comprising: a. placing a planar piece of open cell foam core material between upper and lower sheets to form a pre-bonded assembly, said sheets being air impermeable and having an inner bonding layer of a thermo-plastic material, b. simultaneously heating and compressing said assembly to compress the foam core between the sheets and soften the layers of thermo-plastic material to permit propr interengagement thereof with said foam, and to bring said assembly to an elevated temperature, c. cooling said sheets and foam core portions immediately adjacent thereto only for a period of time necessary to cause a secure bonding of the foam to the upper and lower sheets to form a bonded assembly, and d. pressurizing the foam core to a pressure above ambient pressure by introduction of pressurized fluid therein immediately after cooling to apply an expanding force between the upper and lower sheets to break undesired weak foam filament bonds to said sheet and to enhance loft of said foam core.

Claim 8

A method of making a self-inflating air mattress comprising an envelope of upper and lower sheets bonded to one another, and a foam core having upper and lower surfaces securely bonded over substantially their entire surface areas to the upper and lower sheets, said method comprising: a. placing a planar piece of open cell foam core material between upper and lower sheets to form a pre-bonding assembly, said sheets being air impermeable and having an inner bonding layer of a thermo-plastic material, with perimeter portions of said sheets extending moderately beyond the perimeter of the core, b. simultaneously heating and compressing said assembly to compress the foam core between the sheets and soften the layer of thermo-plastic material to permit proper interengagement thereof with said foam, and to compress the perimeter portions of said sheets against one another to form a perimeter "T" joint so as to form an impervious envelope, c. applying a vacuum to the interior of said envelope so as to unload said sheets from the compressive force applied thereto and cause greater pressure engagement of the perimeter portions of the sheets, d. cooling said sheets and foam core portions immediately adjacent thereto only for a period of time necessary to cause a secure bonding of the upper and lower sheets to the foam core and to each other to form a bonded assembly, e. pressurizing the foam core to a pressure above ambient pressure by introduction of pressurized fluid therein immediately after cooling to apply an expanding force between the upper and lower sheets to break undesired weak foam filament bonds to said sheet and to enhance loft of said foam core.

Claim 9

A method of making a self-inflating air mattress comprising an envelope of upper and lower sheets bonded to one another, and a foam core having upper and lower surfaces securely bonded over substantially their entire surface areas to the upper and lower sheets, said method comprising: a. placing a planar piece of open cell foam core material between upper and lower sheets to form a pre-bonding assembly, said sheets being air impermeable and having an inner bonding layer of a thermo-plastic material, with perimeter portions of said sheets extending moderately beyond the perimeter of the core, b. simultaneously heating and compressing said assembly to compress the foam core between the sheets and soften the layer of thermo-plastic material to permit proper interengagement thereof with said foam, and to compress the perimeter portions of said sheets against one another to form a perimeter "T" joint so as to form an impervious envelope, c. applying a vacuum to the interior of said envelope so as to unload said sheets from the compressive force applied thereto and cause greater pressure engagement of the perimeter portions of the sheets, d. cooling said sheets and foam core portions immediately adjacent thereto only for a period of time necessary to cause a secure bonding of the upper and lower sheets to the foam core and to each other to form a bonded assembly, e. pressurizing the foam core to a pressure above ambient pressure by introduction of pressurized fluid therein immediately after cooling to apply an expanding force between the upper and lower sheets to break undesired weak foam filament bonds to said sheet and to enhance loft of said foam core.