US4261776A — Method of making self-inflating air mattress

Claim 1

Independent Claim 334 words

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 area to the upper and lower sheets, said method comprising: (a) placing a first air impermeable sheet which has an inner bonding layer of a thermoplastic material on a first frame member, (b) placing a planar piece of open-celled foam core on said first sheet, with perimeter portions of the sheet extending moderately beyond the perimeter of the core, (c) mounting a second air impermeable sheet which likewise has in inner bonding layer of a thermoplastic material in a second mounting frame and placing it over said open celled foam core, (d) locating said foam core on said first sheet by moving locating side straightening members into contact with said foam core, (e) moving said second frame member downwardly to place said second sheet into contact with said foam core so as to frictionally engage said foam core, (f) removing said locating side staightening members out of contact with the foam core, (g) clamping said first and second frames to one another to provide a frame assembly with the foam core being held in a predetermined location in the frame assembly by engagement with the upper and lower sheets, (h) placing the frame assembly at a bonding location and simultaneously heating and compressing said assembly to compress the foam core between the sheets and soften the layers of thermoplastic material to permit proper interengagement thereof with the foam and to compress the perimeter portions of the sheets against one another so as to form an air impervious envelope with a perimeter "T" joint, (i) cooling said sheets to cause a secure bonding of the foam to the sheets while maintaining a pressure differential such that pressure applied to the outside surfaces of said sheets is greater than the air pressure applied within to form a bonded assembly.

Claim 2

Independent Claim 334 words

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 area to the upper and lower sheets, said method comprising: (a) placing a first air impermeable sheet which has an inner bonding layer of a thermoplastic material on a first frame member, (b) placing a planar piece of open-celled foam core on said first sheet, with perimeter portions of the sheet extending moderately beyond the perimeter of the core, (c) mounting a second air impermeable sheet which likewise has in inner bonding layer of a thermoplastic material in a second mounting frame and placing it over said open celled foam core, (d) locating said foam core on said first sheet by moving locating side straightening members into contact with said foam core, (e) moving said second frame member downwardly to place said second sheet into contact with said foam core so as to frictionally engage said foam core, (f) removing said locating side staightening members out of contact with the foam core, (g) clamping said first and second frames to one another to provide a frame assembly with the foam core being held in a predetermined location in the frame assembly by engagement with the upper and lower sheets, (h) placing the frame assembly at a bonding location and simultaneously heating and compressing said assembly to compress the foam core between the sheets and soften the layers of thermoplastic material to permit proper interengagement thereof with the foam and to compress the perimeter portions of the sheets against one another so as to form an air impervious envelope with a perimeter "T" joint, (i) cooling said sheets to cause a secure bonding of the foam to the sheets while maintaining a pressure differential such that pressure applied to the outside surfaces of said sheets is greater than the air pressure applied within to form a bonded assembly.

Claim 3

Dependent Claim 108 words

The method as recited in claim 1, wherein: (a) said heating and compressing of said assembly is accomplished by applying heated platens against said first and second sheets, (b) a vacuum is applied to the area between said sheets to cause ambient pressure to press said sheets toward one another and to press edge portions of said sheets into contact with one another, (c) removing said assembly from between said platens while maintaining said vacuum, and (d) cooling said sheets while maintaining said vacuum to cause a secure bonding of the upper and lower sheets to the foam core and to each other to form a bonded assembly.

Claim 4

Dependent Claim 38 words

The method as recited in claim 1, further comprising placing a valve housing at a predetermined location between said sheets, and locating said valve assembly with respect to said sheets by locating means mounting in the frame assembly.

Claim 5

Dependent Claim 38 words

The method as recited in claim 3, wherein said valve housing is located in the frame assembly by means of a locating tube, and said vacuum is applied to the area between said sheets through said locating tube.

Claim 6

Independent Claim 199 words

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-celled resilient foam core between upper and lower sheets to form a pre-bonded assembly, said sheets being air impermeable and having an inner bonding layer of a thermoplastic material, (b) heating and compressing the sheets toward one another by applying to the sheets heated platens to compress the foam core between the sheets and soften the layers of the thermo-plastic material to permit proper interengagement thereof with said foam, (c) applying a vacuum to the area between said sheets so as to cause ambient pressure to maintain pressure after an initial application of pressure by said platens, so as to press said sheets against the foam core, (d) removing the assembly relative to the area of engagement with said platens while maintaining said vacuum, and cooling said sheets to cause a secure bonding of the foam to the upper and lower sheets to form a bonded assembly.

Claim 7

Independent Claim 199 words

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-celled resilient foam core between upper and lower sheets to form a pre-bonded assembly, said sheets being air impermeable and having an inner bonding layer of a thermoplastic material, (b) heating and compressing the sheets toward one another by applying to the sheets heated platens to compress the foam core between the sheets and soften the layers of the thermo-plastic material to permit proper interengagement thereof with said foam, (c) applying a vacuum to the area between said sheets so as to cause ambient pressure to maintain pressure after an initial application of pressure by said platens, so as to press said sheets against the foam core, (d) removing the assembly relative to the area of engagement with said platens while maintaining said vacuum, and cooling said sheets to cause a secure bonding of the foam to the upper and lower sheets to form a bonded assembly.

Claim 8

Dependent Claim 55 words

The method as recited in claim 5, wherein edge perimeter portions of the sheets of the prebonded assembly are clamped in a perimeter frame to form a frame assembly, said heating and compressing being accomplished by placing said frame assembly between the platens, said cooling being accomplished after disengaging said frame assembly from the platens.

Claim 9

Dependent Claim 53 words

The method as recited in claim 5, wherein at least one of said platens has a moderately raised perimeter shoulder portion and a moderately recessed planar portion enclosed within the shoulder portion, and said shoulder portion presses against perimeter portion of said sheets to cause said sheets to be bonded one to another.

Claim 10

Dependent Claim 30 words

The method as recited in claim 5, wherein said foam core is pressurized subsequent to said cooling so as to apply an expanding force between the upper and lower sheets.

Claim 11

Dependent Claim 44 words

The method as recited in claim 5, wherein said upper and lower sheet each comprise an outer fabric layer, an intermediate air impervious layer of a plastic material, and an innermost layer in which said foam material is imbedded to form a secure bond.

Claim 12

Dependent Claim 54 words

The method as recited in claim 9, wherein said innermost layer is a thermo-plastic material having a predetermined softening temperature, and said intermediate air impervious layer is of a plastic material selected from a group of materials which is either thermo-setting or thermo-plastic with a softening temperature higher than that of the innermost layer.

Claim 13

Dependent Claim 82 words

The method as recited in claim 9, wherein said intermediate air impervious layer and said innermost layer are made of a plastic material having a gradual softening characteristic with temperature increase, and the heating and compressing of the sheets toward one another is accomplished such that by properly controlling time and temperature to accommodate foam compression forces there is proper penetration and interengagement of the foam core with the innermost layer, while the air impervious character of the intermediate layer is preserved.

Claim 14

Independent Claim 321 words

A method of making a self-inflating air mattress comprising an envelope of upper and lower sheets having inner surfaces bonded to one another at edge portions thereof, and a foam core having upper and lower surfaces securely bonded over substantially their entire surface areas to the upper and lower sheets within the bonded edge portions of the sheets, said method comprising: (a) placing a planar piece of open celled resilient foam core between upper and lower sheets to form a prebonded assembly, said sheets being air impermiable and having a bonding layer of a thermoplastic material, (b) positioning said sheets, with said foam core therebetween in a perimeter frame to form a bonding assembly, said sheets each having an edge portion, with an outer part of the edge portion being clamped in said perimeter frame, and an inner part of said edge portion being positioned outside of said foam core and spaced inwardly from said perimeter frame, (c) heating and compressing the sheets toward one another by applying to the sheets heated platens to compress the foam core between the sheets and soften the layers of the thermoplastic material to permit proper interengagement thereof with said foam, and to soften the layers of thermoplastic material at the edge portions of the sheets, (d) applying a vacuum to the area between said sheets so as to cause ambient pressure to maintain pressure after an initial application of pressure by said platens, so as to press said sheets against the foam core, and to maintain pressure of the edge portions of the sheets against one another, (e) removing the assembly relative to the area of engagement with said platens while maintaining said vacuum, and cooling said sheets to cause a secure bonding of the foam to the upper and lower sheets to form a bonded assembly, and to bond the edge portions of the sheets to one another to form a T joint.

Claim 15

Independent Claim 321 words

A method of making a self-inflating air mattress comprising an envelope of upper and lower sheets having inner surfaces bonded to one another at edge portions thereof, and a foam core having upper and lower surfaces securely bonded over substantially their entire surface areas to the upper and lower sheets within the bonded edge portions of the sheets, said method comprising: (a) placing a planar piece of open celled resilient foam core between upper and lower sheets to form a prebonded assembly, said sheets being air impermiable and having a bonding layer of a thermoplastic material, (b) positioning said sheets, with said foam core therebetween in a perimeter frame to form a bonding assembly, said sheets each having an edge portion, with an outer part of the edge portion being clamped in said perimeter frame, and an inner part of said edge portion being positioned outside of said foam core and spaced inwardly from said perimeter frame, (c) heating and compressing the sheets toward one another by applying to the sheets heated platens to compress the foam core between the sheets and soften the layers of the thermoplastic material to permit proper interengagement thereof with said foam, and to soften the layers of thermoplastic material at the edge portions of the sheets, (d) applying a vacuum to the area between said sheets so as to cause ambient pressure to maintain pressure after an initial application of pressure by said platens, so as to press said sheets against the foam core, and to maintain pressure of the edge portions of the sheets against one another, (e) removing the assembly relative to the area of engagement with said platens while maintaining said vacuum, and cooling said sheets to cause a secure bonding of the foam to the upper and lower sheets to form a bonded assembly, and to bond the edge portions of the sheets to one another to form a T joint.

Claim 16

Dependent Claim 52 words

The method as recited in claim 11 wherein at least one of said platens has a moderately raised perimeter shoulder portion and a moderately recessed planar portion enclosed within the shoulder portion, and said shoulder portion presses against the edge portions of said sheets to cause said sheets to engage one another.

Claim 17

Dependent Claim 30 words

The method as recited in claim 12, wherein said foam core is pressurized subsequent to said cooling so as to apply an expanding force between the upper and lower sheets.

Claim 18

Dependent Claim 44 words

The method as recited in claim 12, wherein said upper and lower sheet each comprise an outer fabric layer, an intermediate air impervious layer of a plastic material, and an innermost layer in which said foam material is embedded to form a secure bond.

Claim 19

Dependent Claim 54 words

The method as recited in claim 15, wherein said innermost layer is a thermo-plastic material having a predetermined softening temperature, and said intermediate air impervious layer is of a plastic material selected from a group of materials which is either thermo-setting or thermo-plastic with a softening temperature higher than that of the innermost layer.

Claim 20

Dependent Claim 82 words

The method as recited in claim 15, wherein said intermediate air impervious layer and said innermost layer are made of a plastic material having a gradual softening characteristic with temperature increase, and the heating and compressing of the sheets toward one another is accomplished such that by properly controlling time and temperature to accommodate foam compression forces there is proper penetration and interengagement of the foam core with the innermost layer, while the air impervious character of the intermediate layer is preserved.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1984-04-13	1984-10-13	1985-04-14	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1988-04-13	1988-10-13	1989-04-14	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1992-04-13	1992-10-13	1993-04-14	$7700.00	Window Closed / Lapsed

Method of making self-inflating air mattress

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