CROSS-REFERENCES TO RELATED APPLICATIONS

[0001] The present application claims the benefit of U.S. Provisional Application

No. 61/866,751, filed on August 16, 2013 and also claims the benefit of U.S. Provisional Application No. 61/936,415, filed February 6, 2014, the full disclosures of which are

incorporated herein by reference. BACKGROUND

[0002] inflatable mattresses (also called "air mattresses" or "airbeds") are generally large rectangular rubber or plastic (e.g. vinyl) bladders that are filled with air so that they may be used as beds. Airbeds are well known in the art and have proven themseleves to be very useful. On the one hand, an inflatable airbed may be deflated and folded to store the airbed in a closet or basement, out of sight and out of the way. On the other hand, when guests arrive or when the owner of the airbed takes a trip to a place where there is no bed, the airbed may be easily inflated and may be used as a bed.

[0003] A goal of an airbed is to provide the same (or as close as possible) comfort and support as a conventional spring mattress. Because inflatable mattresses are filled with air, it is difficult to attain the same support as a conventional spring mattress. Internal structural supports or beams are needed to assist in retaining the top surface of an air mattress in alignment with the surface to provide a stable and supportive resting surface. Several internal supports are known in the art. Because conventional airbeds utilize single channel welds, however, even the use of known internal supports can result in less than desired rigidity, uneven sleep surfaces and can allow for excessive stretching of the airbed bladder material.

[0004] A goal of the present invention is to provide an inflatable product that provides a stronger, more rigid structure over standard inflatable products. A mesh support beam is attached to the connecting structure internal of the inflatable product using more than a single weld, increasing the strength of the structure and reducing stretch. This structure also assists in reducing puffiness on the surface of the airbed between the supports so that the bed remains flat, thus providing a better sleeping surface.

BRIEF SUMMARY [0003] The following presents a simplified summary of some embodiments of the invention in order to provide a basic understanding of the invention. This summary is not an extensive overaew of the invention. It is not intended to identify key/critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some embodiments of the invention in a simplified form as a prelude to the more detailed description that is presented later.

[0004] An embodiment comprises an inflatable mattress having at least one inflatable bladder defined by an upper sheet, a lower sheet and at least one side wall and also having an internal support structure comprising a plurality of elongated beams, a first side of each beam comprising a first generally triangular shaped channel connected to an interior surface of said upper sheet and a second, opposing side of each beam comprising a second generally triangular shaped channel connected to an interior surface of said lower sheet. The elongated beams further comprising a mesh panel extending between said first beam side and said second beam side, wherein said mesh is secured between channel support members.

[0005] In embodiments described herein, an inflatable mattress in an inflated configuration comprises an upper sheet have minimal deformation over its surface such that said upper sheet surface may be characterized as flat with respect, to differences in planar height over its sleep surface.

[0006] For a fuller understanding of the nature and advantages of the present invention, reference should be made to the ensuing detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] FIG. 1 shows a perspective view of an inflatable mattress, in accordance with an embodiment.

[0008] FIG. 2 shows an internal view of the beam structure the mattress of FIG, 1. [0009] FIG. 3 shows a right side view of the mattress FIG. 1, showing the end of the internal beam, taken along line 3-3 of FIG. 1.

[0010] FIG. 4 shows an end view of the mattress of FIG, 1, showing the side of the internal beam, taken along line 4-4 of FIG. 1.

DETAILED DESCRIPTION

[0011] In the following description, various embodiments of the present invention will be described. For purposes of explanation, specific configurations and details are set forth in order to provide a thorough understanding of the embodiments, It will also be apparent to one skilled in the art, however, that the present invention may be practiced without the specific details. Furthermore, well-known features may be omitted or simplified in order not to obscure the embodiment being described.

[0012] Referring now to the drawings, in which like reference numerals represent like parts throughout the several views, FIG. 1 shows an inflatable mattress 10 that includes inflatable bladder 12, upper sheet 14, lower sheet 16 and side wall 18. Side wall 18 is preferably a single piece of material which extends around the perimeter of the upper sheet edges and lower sheet edges and connects the sheets to form an enclosed bladder. Side wall 18 could comprise more than a single piece of material provided an enclosed bladder is still formed. The general construction of the inflatable bladder exterior is well-known in the airbed art and preferably utilizes "edge welds." When two or more sheets of material for an airbed are welded, the welded juncture forms a seam. This seam includes excess flashing materia! that usually extends outward at the seam. This excess flashing material is also known as an "edge weld". In most conventional airbeds, such junctures are formed at the connection of a upper sheet 12 of an airbed to a side wall 18 for the airbed, and similarly, at a connection of a lower sheet. 14 to the side wall 18. Other types of welds known in the airbed industry may also be used and such weld may be located at other locations.

[0015] As shown in FIG. 2, the internal structure of airbed 10 comprises a plurality of support beams 20. Each support beam 20 includes upper connecting structure 21, mesh panel 22 and lower connecting structure 23. Upper connecting structure 21 includes upper channel supports 24a, 24b and lower connecting structure 23 includes lower channel supports 26a, 26b. Upper connecting structure 21 is connected to the underside of upper sheet 14 at welds 28. Lower connecting structure 23 is connected to the upper surface of lower sheet 16 at welds 28. While tear drop shaped welds 28 are shown, other welds would be acceptable. As channel supports, upper sheet, lower sheet and side wall are preferably made of PVC material, the welding method utilized is that commonly used in the airbed industry such as RF welding, although other types of welding known in the art would be acceptable as well. Similarly, other methods of attachment known in the industry other than welding would also be within the scope of the present.

invention.

[0016] As shown in FIG. 2 and FIG, 3, a first edge of upper channel supports 24a, 24b is welded to the underside of upper sheet 14, A second edge of upper channel support s 24a, 24b is welded on either side of the upper edge of mesh panel 22. Similarly, a first edge of lower channel supports 26a, 26b is welded to the upper surface of lower sheet 16 and a second edge of lower channel supports 26a, 26b is welded on either side of the lower edge of mesh panel 22 with one or more welds. Where the mesh panel 22 is captured between the channel supports, the welding method is slightly different than a standard RF weld. The mesh fabric is preferably made of polyester. Other materials such as nylon, vinyl, cotton or materials having similar characteristic that do not melt easily can also be utilized. As the mesh fabric does not melt in the same manner as the conventional PVC material, the mesh fabric is held in place and clamped by PVC channel support edges which melts through the mesh fabric apertures, resulting in the PVC channel support edges being welded together and securing the mesh panel therein.

[0017] As can be seen in FIG, 3, upper sheet 14 and upper channel supports 24a, 24b form a generally triangular shaped channel 25 which runs almost the entire width of airbed 10.

Similarly, lower sheet 16 and lower channel supports 26a, 26b form a generally triangular shape lower channel 27 which, runs almost the entire width of airbed 10. Although channels 25, 27 are shown as running the width of airbed 10, it would be within the scope of the present invention for channels 25, 27 (and consequently, the associated structural elements discussed above and below) to run lengthwise along the airbed 10 (not shown). [0018] In order to provide sufficient support for the airbed 10 and to provide a sufficiently smooth sleeping surface (i.e. upper sheet 14 or lower sheet 16), the distance x (as shown in FIG. 3) between the inside welds 28 for each channel 25, 27 can vary between approximately 1 and 5 inches. Preferably, the distance x is between approximately 1 ½ and 3 inches and most.

preferably, the distance is about 2 inches. For purposes of the present invention, a "smooth" or "flat" sleep surface is defined by the average difference in planar height of the weld plane x at approximate center point x' and the beam plane y at approximate center ointy', taken also in the approximate center along the length of each individual channel (as shown in FIG, Ϊ), The weld plane x is the area located between the inside welds 28 for each individual channel 25, 27. The measure for determining height difference with respect to the beam plane is taken at the approximately center of distance x at x'. The beam plane y is the area located between the welds of adjacent channels. The measure for determining height difference with respect to the weld plane is taken at the approximate center of distance y at y Differences of less than about 20mm would be considered sufficiently "flat" or "smooth" to fall within the scope of the present invention. Preferably, the difference is less than about 18mm and most preferably, the difference is less than about 14mm. In the alternative, it is also within the scope of the invention to determine the difference in planar height of y' as compared to the weld 28 itself. In such case, the preferred difference is less than about 18mm, more preferably less than about 15mm and most preferably less than about 13mm. [0019] As shown in FIG. 3, channels 25, 27 are most preferably in the shape of an equilateral triangle although other geometric shapes such as isosceles triangles and scalene triangles are also within the scope of the invention. The specific number, length and height of channels 25, 27 will vary as will the specific spacing between the plurality of channels. These variables will directly impact the firmness of the bed, the smoothness of the bed surface and will vary with the size and height of the bed itself. The mesh fabric is not as elastic as traditional PVC material which increases the stability and smoothness of the airbed 10. Using a mesh wall on the interior of the airbed provides a higher tensile strength than traditional PVC alternatives. The added strength extends the life and durability over a traditional all-PVC airbed. [0020] As shown in FIG. 4, mesh panels 22 may extend to the end of each support beam 20 but it is also within the scope of the present invention for the mesh material to be slightly shorter in length such that it does not extend the entire length of support beam (not shown).

[0021] A closure valve (not shown) may fluidly connect the bladder to the external atmosphere. In gen eral, any configuration of valve or valves may be utilized that allows the bladder or bladders to be inflated. The airbed may include a built in pump or compressor in addition to or instead of the valve that inflates the bladder. Such built in pump may be incorporated into the bladder as is known in the industry.

[0022] As used herein, "upper sheet" may mean the "top sheet" or "top surface" of an airbed as shown in the accompanying figures depicting a single layer airbed, it is also within the scope of the invention, however, for airbed 10 to have more than a single layer within a single bladder, wherein each such layer would have independent structural support, the layers being in fluid communication with each other as is known in the industry, in the case of an airbed having 2 such layers, the bladder would likely contain 3 sheets -- an upper sheet, a middle sheet and a lower sheet. In such case, the "upper sheet" will be understood to refer to the "top sheet" with respect to the upper layer. When referring to the lower layer, "upper sheet" will refer to the "middle sheet" within the bladder. Similarly, "lower sheet" will be understood to refer to the "middle sheet" when referencing the top layer and "lower sheet" will be understood to refer to the "bottom sheet" when referring to the lower layer. The same relative terminology applies for triple layer beds which would have 4 different sheets, and so on. The "upper sheet" and "lower sheet" should always be understood to refer to the top-most and bottom-most sheets within each respective layer of the airbed. As such, the present invention may be utilized with an airbed of varying heights - single high, double high, or even triple or more.

[0023] Similarly, the internal support structure of the present invention may be utilized with an airbed of any size - e.g. twin, double, queen, king, or other. It is within the scope of the invention to use the internal support structure with a single layer upper sheet or lower sheet as described above or with multiple layered upper sheets and lower sheets, such as laminated or flocked layers, or the like. The internal support structure may be used in an airbed having multiple bladders which are located adjacent to each other or otherwise (whether it be side by side or stacked) provided the support structure is used within at least one of the bladders. Similarly, an airbed using the internal support structure disclosed can include any number of additional features such as a pillow top, a headboard, flocking, reading lights, pockets, cup holders and the like. The internal support structure may also be used in not. only airbeds used primarily for sleeping, but also in floating pool mattresses, inflatable chairs or any inflatable product needing structural support and which would benefit from a flatter, smoother surface.

[0013] Other variations are within the spirit of the present invention. Thus, while the invention is susceptible to various modifications and alternative constructions, certain illustrated embodiments thereof are shown in the drawings and have been described above in detail, it should be understood, however, that there is no intention to limit the invention to the specific form or forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention, as defined in the appended claims.

[0014] The use of the terms "a" and "an" and "the" and similar referents in the context of describing the Invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms "comprising," "having," "including," and "containing" are to be construed as open-ended terms (i.e., meaning "including, but not limited to,") unless otherwise noted. The term "connected" is to be construed as partly or wholly contained within, attached to, or joined together, even if there is something intervening. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., "such as") provided herein, is intended merely to better illuminate embodiments of the invention and does not pose a limitation on the scope of the invention unless othenvise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[0015] Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein, Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

[0016] All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.