Patent Application
20250099314
This application claims the priority to Chinese Patent Application No. 202322577987.0, filed Sep. 21, 2023, entitled “A multi chamber inflatable mattress.” This application is hereby incorporated herein by reference in its entirety and for all purposes.
It should be noted that the figures are not drawn to scale and that elements of similar structures or functions are generally represented by like reference numerals for illustrative purposes throughout the figures. It also should be noted that the figures are only intended to facilitate the description of the preferred embodiments. The figures do not illustrate every aspect of the described embodiments and do not limit the scope of the present disclosure.
Inflatable pads can have strong flexibility and elasticity, and after inflation, their expansion volume increases. Inflatable pads can include advantages such as non-deformability, comfortable body feel, and easy portability. Some inflatable pads can be used for family and travel, and in some examples, only have one inflatable chamber and the mattress can be inflated through one inflation port. Such a structure can be designed to be convenient to carry.
Some inflatable pads used in medical care can divide the mattress into two compartments: front and rear. By filling and releasing gas from the compartments, the patient can be raised in the upper part of the body and lowered in the lower part of the body, and vice versa, which can facilitate the patient's sitting posture and can facilitate care. Another type of inflatable pad can include two inflatable chambers on the left and right sides of the pad, which can be filled with gas to achieve left high, right low, or right high, left low for patients to roll over in some examples.
For patients who have been bedridden for a long time, an inflatable pad can leak, and the pad can collapse. For patients with bedsores or prone to bedsores, when an inflatable pad collapses, patients can touch the bed board, causing damage to patient's existing bedsores and/or causing bedsores to form.
For patients with bedsores or prone to bedsores, in various embodiments it can be desirable to provide an alternating pressure pad system that provides varying contact with body of the patient while also providing a stable bed for the patient. Additionally, it can be desirable to provide a pad that provides characteristics such as a high-friction top surface that prevents slipping and sliding of the patient on the top of the pad while also providing a surface that is comfortable to the touch and reduces excess moisture by managing the heat and humidity of the skin of the patient. Additionally, given that bedridden patients may rest on an inflatable pad for long periods of time (e.g., days, weeks, months or years), it can be desirable to provide a pad that is durable and configured for constant use, including constant inflation and deflation and constant pressure of the patient on the pad. An alternating pressure pad as discussed herein can provide relief and comfort to patients by providing alternating pressure on skin surfaces and bony prominences. The slow inflation and deflation in some embodiments can increase circulation and reduce the need of exhausting, yet otherwise necessary, constant turning or moving of the patient to prevent discomfort, bedsores, blood clots, and the like.
Various embodiments disclosed herein provide a flocked multi chamber alternating pressure pad that comprises a first layer and a second layer. In some embodiments, the first layer is a flocked PVC (Polyvinyl Chloride) sheet ranging from 0.50 mm-0.70 mm in thickness that is welded to the second layer, which is a PVC sheet ranging from 0.29-0.40 mm in thickness.
In some embodiments, the multi chamber inflatable pad includes a lining layer arranged at the edge of the first layer, wherein the contour of the lining layer complements the contours of the first and second chambers to provide an overall rectangular pad. For example, such a pad can be generally rectangularity-sized for a single human adult or child user, for a twin bed, for a queen-sized bed, for a king-sized bed, and the like. In some embodiments, the lining layer can comprise, consist essentially of or consist of a flocking layer. Flocking technology in various embodiments can integrate various velvet materials onto one or more layers of PVC material and can be beneficial to the user experience.
Flocking on PVC sheets can include a manufacturing process for achieving a textured or velvety surface finish on a PVC sheet. Flocking can be desirable in various applications where a soft feel, enhanced aesthetic appearance, or improved grip is desired. In an example, a manufacturing process begins with the preparation of a PVC substrate such as a sheet of PVC, which can be cleaned and pre-treated to ensure optimal adhesion of the flocking material. An adhesive (e.g., in liquid form) can be uniformly applied to a face of the PVC sheet. The choice of adhesive in some examples can depend on factors such as the type of flocking material being used and the desired properties of the final flocked product. A flocking material in various examples can be composed of tiny fibers (flock).
In some embodiments, such flocking fibers or flock can include microfibers, with diameters typically between 0.5 and 2 deniers (a “denier” is a unit of measurement used to quantify the thickness of threads and fibers in textiles; it is defined as the mass in grams per 9000 meters of the fiber. In other words, if a 9000-meter length of a specific fiber weighs 1 gram, that fiber is 1 denier).
In some embodiments, such flocking fibers or flock can include microfibers having a length of less than or equal to 0.25 mm, 0.5 mm, 0.75 mm, 1 mm, 1.5 mm, 2.0 mm, 2.5 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, or the like, or a range between such example values.
In some embodiments, flocking fibers, can be characterized by deniers from 1 to 10 and lengths spanning 0.5 to 5 millimeters. In further embodiments, flocking fibers, can be characterized by being within the 10 to 40 denier range and lengths of 1 to 5 millimeters. In various embodiments, flocking fibers can be cylindrical or other suitable shape.
During manufacturing of a flocked sheet of PVC, the flocking material can be electrostatically charged, which in various examples can provide for the flocking material to adhere vertically to the adhesive-coated PVC surface, creating a directional orientation. The application of the charged flock can allow for control over the flock's alignment and density.
Once the electrostatically charged flocking materials can be applied to the adhesive-coated PVC sheet, the adhesive can be cured or dried, which can permanently affix the flock to the PVC surface. This can generate a durable and long-lasting flocking finish in various embodiments. Depending on the desired outcome, in some examples additional processes may be employed to align the flock in one or more specific directions, creating patterns or textures that enhance both the visual and tactile aspects of the flocked PVC sheet.
Throughout the manufacturing process, in various embodiments quality control measures can be implemented to ensure uniform flock distribution, optimal adhesion strength, and overall product consistency. The flocking process can provide customization options in some examples, including varying flock lengths, color choices, and the creation of intricate patterns, providing flexibility in design.
In various embodiments, resulting flocked or velvety surface not only enhances the aesthetic appeal of the PVC sheet but also adds a tactile dimension, making it suitable for applications where grip, touch, temperature control and humidity control are desirable. In various examples, a flocking manufacturing process can generate a finished product that withstands wear and tear, making it suitable for a wide range of applications including one or more embodiments discussed herein.
While examples of PVC sheets are discussed herein in various examples, in some embodiments any suitable material can be flocked and used to generate various embodiments. For example, such materials can include Thermoplastic Polyurethane (TPU), Ethylene-vinyl Acetate (EVA), Polyethylene (PE), rubber, and the like.
In some embodiments, a multi chamber inflatable pad further includes an extension portion connected to the ends of the first and second layers. The extension part can increase the coverage area of the inflatable pad and facilitate its fixation (e.g., it can be clamped or pressed tightly with the bed body through the extension block). In some embodiments, the extension portion is expandable and has a third inflation port. In some embodiments, the extension portion is a solid component, allowing for direct use. In some embodiments, the contour between the first bifurcation and the adjacent second bifurcation is linear, such as having a stepped cross-sectional contour. In some embodiments, the contour between the first bifurcation and the adjacent second bifurcation is curved, such as having a wavy cross-sectional contour.
Various embodiments of an alternating pressure pad can achieve different air pressures in different chambers by generating multiple chambers in a pad and configuring separate inflation ports in each chamber that can allow for the separate chambers to be selectively inflated and deflated separately to provide alternating pressure in the separate chambers in some examples. For example, different air pressures in the two chambers can cause the height of the upper surface of the two chambers to raise and lower separately, allowing for alternating or changing location of the upper surface of the alternating pressure pad that contacts the body of the user, which in various examples can avoid long-term contact of the alternating pressure pad in the same body area. In various embodiments, this can be desirable for the rehabilitation of patients with bedsores, to prevent bedsores from forming, or to increase patient comfort. As discussed herein, various embodiments include a flocking layer, which can make the alternating pressure pad more comfortable and softer for the patient.
Various embodiments include staggered chambers through separated parts of the alternating pressure pad, each of which chambers can provide support for the patient's body. A first and second chamber can be separate such that if one chamber leaks, the other chamber will not collapse or leak, and the support for the patient can remain effective, avoiding contact between the patient's bedsore position and a bed board or other surface that the alternating pressure pad is disposed on.
Turning to
In some embodiments, the first layer 1 comprises, consists essentially of or consists of a flocked planar sheet ranging from 0.5 mm-0.7 mm in thickness. In one preferred embodiment, the thickness of the flocking portion is 0.2 mm and the thickness of the sheet portion (e.g., PVC sheet) is 0.4 mm.
In some embodiments, a flocked planar sheet can have a thickness of 0.2 mm, 0.25 mm, 0.3 mm, 0.35 mm, 0.4 mm, 0.45 mm, 0.5 mm, 0.55 mm, 0.6 mm, 0.65 mm, 0.7 mm, 0.75 mm, 0.8 mm, 0.85 mm, 0.9 mm, 0.95 mm, 1.0 mm, or the like, or a range between such example values.
In some embodiments, a flocked portion of the first layer 1 can have a thickness of 0.1 mm, 0.12 mm, 0.14 mm, 0.16 mm, 0.18 mm, 0.2 mm, 0.22 mm, 0.24 mm, 0.26 mm, 0.28 mm, 0.3 mm, or the like, or a range between such example values. In various examples, the thickness of the flocked portion can be defined by the thickness of flocking material coupled to a sheet portion of the first layer 1 while the flocking material is generally lying flat against the face of the sheet portion of the first layer 1.
In some embodiments, a sheet portion of the first layer 1 can have a thickness of 0.05 mm, 0.1 mm, 0.15 mm, 0.2 mm, 0.25 mm, 0.3 mm, 0.35 mm, 0.4 mm, 0.45 mm, 0.5 mm, 0.55 mm, 0.6 mm, 0.65 mm, 0.7 mm, 0.75 mm, 0.8 mm, 0.85 mm, 0.9 mm, 0.95 mm, 1.0 mm, or the like, or a range between such example values. In some embodiments, the sheet portion of the first layer 1 comprises, consists essentially of or consists of PVC. In one preferred embodiment, the thickness of the first layer 1 can be a total of 0.6 mm with 0.2 mm of a sheet portion (e.g., PVC) and 0.4 mm of a flocking portion.
It should be clear that in various embodiments the novel thicknesses or ranges of thicknesses of the first layer 1, the flocked portion of the first layer 1 and the sheet portion of the first layer 1 are specifically selected to provide an optimum durability, comfort and weight of the alternating pressure pad 100 and are not simply an obvious design choice or optimization. For example, the novel thicknesses or ranges of thicknesses of the first layer 1, the flocked portion of the first layer 1 and the sheet portion of the first layer 1 can be specifically selected to have at least a minimum thickness to provide suitable durability for use as an alternating pressure pad 100 for a bedridden human adult patient that will be laying on the alternating pressure pad 100 for an extended period of time such as days, weeks, months or years. However, the novel thicknesses or ranges of thicknesses of the first layer 1, the flocked portion of the first layer 1 and the sheet portion of the first layer 1 can be specifically selected to have a thickness that is no greater than necessary so as to minimize weight of the alternating pressure pad 100, provide suitable flexibility of the alternating pressure pad 100, and to provide for suitable manufacturing as discussed herein.
For example, in one embodiment, using a flocked or non-flocked PVC sheet that is greater than or equal to 0.60 mm for one or both sides of the alternating pressure pad 100 would be cost-prohibitive due to the weight of the product (e.g., shipping costs increase as do the costs of the material). Accordingly, arguing that novel thicknesses or ranges of thicknesses discussed herein are obvious design choices or obvious optimizations would be impermissibly relying on hindsight reasoning in view of the present disclosure.
In one preferred embodiment, the first and/or second layers 1, 2 can have a puncture resistance of less than 39 lbf and greater than 18.5 lbf. In some examples, such a range can provide a desirable balance between durability and weight for the application of providing a flocked alternating pressure pad for bedsore prevention.
In some embodiments, the first and/or second layers 1, 2 can have a puncture resistance of less than 26 lbf, 27 lbf, 28 lbf, 29 lbf, 30 lbf, 31 lbf, 32 lbf, 33 lbf, 34 lbf, 35 lbf, 36 lbf, 37 lbf, 38 lbf, 39 lbf, 40 lbf, 41 lbf, 42 lbf, or the like or a range between such example values.
In some embodiments, the first and/or second layers 1, 2 can have a puncture resistance of greater than 16 lbf, 17 lbf, 18 lbf, 19 lbf, 20 lbf, 21 lbf, 22 lbf, 23 lbf, 24 lbf, 25 lbf, 26 lbf, 27 lbf, 28 lbf, 29 lbf, or the like or a range between such example values.
In one preferred embodiment, a flocked first layer 1 can have a puncture resistance of between 29 lbf and 32 lbf and a non-flocked second layer 2 can have a puncture resistance of between 24 lbf and 26 lbf.
In some embodiments, a flocked first layer 1 can have a puncture resistance of 25 lbf, 26 lbf, 27 lbf, 28 lbf, 29 lbf, 30 lbf, 31 lbf, 32 lbf, 33 lbf, 34 lbf, 35 lbf, 36 lbf, 37 lbf, or the like or a range between such example values.
In some embodiments, a non-flocked second layer 2 can have a puncture resistance of 19 lbf, 20 lbf, 21 lbf, 22 lbf, 23 lbf, 24 lbf, 25 lbf, 26 lbf, 27 lbf, 28 lbf, 29 lbf, 30 lbf, 31 lbf, or the like or a range between such example values.
In some embodiments, the second layer 2 comprises, consists essentially of or consists of a planar sheet ranging from 0.29-0.40 mm in thickness. In one preferred embodiment, the second layer 2 has a thickness of 0.35 mm. In some embodiments, a sheet portion of the first layer 2 can have a thickness of 0.05 mm, 0.1 mm, 0.15 mm, 0.2 mm, 0.25 mm, 0.3 mm, 0.35 mm, 0.4 mm, 0.45 mm, 0.5 mm, 0.55 mm, 0.6 mm, 0.65 mm, 0.7 mm, 0.75 mm, 0.8 mm, 0.85 mm, 0.9 mm, 0.95 mm, 1.0 mm, or the like, or a range between such example values. In some embodiments, the second layer 2 comprises, consists essentially of or consists of PVC.
The alternating pressure pad 100 can define two independent and staggered chambers 110 based at least on one or more couplings 115 between the first layer 1 and the second layer 2. Each chamber 110 can be equipped with a separate inflation port, which can provide for different air pressures/volumes to be generated in the different chambers 110 and allowing for alternating pressure in the respective chambers 110. For example, a generated difference in air pressure between the two chambers 110 can result in differences in the height of the top surfaces of the two chambers 110 opposing bottom surfaces that engage a bed or other surface that the alternating pressure pad 100 is disposed on. By alternating the height of the chambers 110 the portions of the alternating pressure pad 100 that contact the patient can be varied or the pressure on different portions of the patient's body can be varied based on the changing height of the chambers 110. Such configurations can include first chamber 110A being high and second chamber 110B being low; first chamber 110A being low and second chamber 110B being high; both first and second chambers 110 being low; and both first and second chambers 110 being high. Varied pressure and contact on the body of the patient through inflation and/or deflation of the chambers 110 can be desirable for preventing bedsores and expediting healing of existing bedsores where present. In various embodiments, the lining layer 3 (e.g., flocking layer) can make the alternating pressure pad 100 more comfortable and softer for the user, prevent slipping on the alternating pressure pad 100, provide for heat and/or moisture control, and the like.
In some embodiments, the alternating pressure pad 100 includes a first layer 1 and a second layer 2, wherein the second layer 2 is connected to the first layer 1 at the outer edge. In some embodiments, the one or more couplings 115 between the first and second layers can be a direct coupling between the first and second layers 1, 2 (e.g., via welding, an adhesive or the like).
However, in some embodiments, the first and second layers 1, 2 can be separated by a partition 4 (see e.g.,
In various embodiments, the first chamber 110A can be inflated and/or deflated via a first air charging port 6, that can be coupled to the first or second layer 1, 2 to define a passage through which air (or other suitable fluid) can be introduced into the first chamber 110A. In various embodiments, the second chamber 110B can be inflated and/or deflated via a second air charging port 7, that can be coupled to the first or second layer 1, 2 to define a passage through which air (or other suitable fluid) can be introduced into the second chamber 110B.
In various embodiments, the first and second chambers 110A, 110B can respectively define a plurality of first forks 21 and second forks 31 (see e.g.,
Such a staggered chamber configuration can be desirable to provide support along the length of the body of a patient laying on the alternating pressure pad 100 (e.g., with the transverse axis of the patient generally along the length axis of the alternating pressure pad 100), even if one of the first and second chambers 110A, 110B is deflated due to alternating inflation or structural failure of a chamber 110.
In various embodiments, the alternating pressure pad 100 can comprise an extension member 5, which in some examples increases the overall length of the alternating pressure pad 100. The extension member 5 in some examples can be configured to increase the coverage area of the alternating pressure pad 100, provide for a head or foot rest for a user, facilitate fixation of the alternating pressure pad 100 (e.g., to a bed, mattress or other surface or object that the alternating pressure pad 100 is disposed on).
In various embodiments, the extension member 5 can comprise an inflation port 8 that can be used to inflate and/or deflate the extension member. Accordingly, in some embodiments the extension member 5 cavity that can be filled with air or other suitable fluid. In some embodiments, the extension member 5 can be a solid component without such an inflatable cavity. In various embodiments, the extension member 5 can be defined by one or more planar sheets (e.g., PVC, flocked PVC, or the like).
The thickness of the extension member 5 in one preferred embodiment can be 0.18 mm. In some embodiments, the extension member 5 can have a thickness of 0.05 mm, 0.1 mm, 0.15 mm, 0.2 mm, 0.25 mm, 0.3 mm, 0.35 mm, 0.4 mm, 0.45 mm, 0.5 mm, 0.55 mm, 0.6 mm, 0.65 mm, 0.7 mm, 0.75 mm, 0.8 mm, 0.85 mm, 0.9 mm, 0.95 mm, 1.0 mm, or the like, or a range between such example values. In some embodiments, extension member 5 comprises, consists essentially of or consists of PVC.
Also, while various examples herein illustrate a single extension member 5 extending from one end of the length of the alternating pressure pad 100, further embodiments can include any suitable plurality of extension members 5 including extension members 5 extending from opposing sides of the length of the alternating pressure pad 100, one or more extension members 5 extending from one or both sides of the width edges of the alternating pressure pad 100, or the like.
Turning to
In various embodiments, the pump system 610 can be a suitable electronic or computing device, which can include elements like a processor, memory and the like. The pump system 610 can comprise a computer readable medium (e.g., memory) that stores instructions that when executed cause the pump system 610 to perform various functions including an automated alternating pressure routine that can include alternatingly inflating and deflating the first and second chambers 110A, 110B as discussed herein. Such a routine can alternatingly inflate and deflate the first and second chambers 110A, 110B in a looping cycle in various examples.
In some embodiments, the pump system 610 can comprise an interface that comprises a power switch 614, a routine selection switch 616, and a pressure slider 618. In various examples, the power switch 614 can power or de-power the pump system 610, with power supplied to the pump system 610 in various suitable ways including via plugging into a wall receptacle, a battery, or the like. In various examples, the routine selection switch 616 can allow for selection between a static inflation state or an automated alternating pressure routine as discussed herein. In various examples, the pressure slider 618 can allow a user to select a firmness setting of the alternating pressure pad 100, which can include a firmness for a static pressure mode, a maximum pressure for the chambers 110 during an alternating pressure routine, or the like. Additionally, in various embodiments, the pump system 610 can comprise other suitable components such as one or more pumps, one or more valves, a touchscreen, a wired or wireless communication device (e.g., that allows communication with a local device such as a smartphone or remote devices via the Internet, or the like). In some embodiments, the pump system 610 can be configured to inflate and/or deflate one or more extension members 5.
An alternating pressure pad 100 can be manufactured in various suitable ways. For example, sheets for first and second layers 1, 2 can be provided (e.g., flocked and/or non-flocked planar PVC sheets) and the first and second layers 1, 2 can be coupled together in various suitable ways with one preferred embodiment including high-frequency welding. Further embodiments can include any suitable welding or coupling method including heat sealing, radio frequency (RF) welding, ultrasonic welding, solvent bonding, hot gas welding, an adhesive, a tape, mechanical fastening, and the like.
In one preferred embodiment, a hydraulic press uses 30 kg of pressure to press the first and second layers 1, 2 together while a 9 amp current melts and couples the first and second layers 1, 2 in about 2.3 seconds. In some embodiments, a welding current can be between 6-13 amps; hydraulic pressure can be between 20-40 kg; and welding time can be between 1-5 seconds. In various embodiments, a flocked portion of a layer 1,2 can have a thickness of 0.01 mm-1.0 mm; a sheet portion of a layer 1, 2 can have a thickness of 0.01 mm-1.0 mm (e.g., a PVC sheet); and a total thickness of a layer 1, 2 can be between 0.01-2.0 mm.
The novel thicknesses or ranges of thicknesses of the first layer 1, the flocked portion of the first layer 1 and the sheet portion of the first layer 1 can be specifically selected to have a thickness that is no greater than necessary so as to minimize weight of the alternating pressure pad 100, provide suitable flexibility of the alternating pressure pad 100, and to provide for desired manufacturing within parameters discussed herein. Accordingly, arguing that such novel thicknesses or ranges of thicknesses are obvious design choices or obvious optimizations would be impermissibly relying on hindsight reasoning in view of the present disclosure.
Embodiments of the disclosure can be described in view of the following clauses:
The described embodiments are susceptible to various modifications and alternative forms, and specific examples thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the described embodiments are not to be limited to the particular forms or methods disclosed, but to the contrary, the present disclosure is to cover all modifications, equivalents, and alternatives. Additionally, elements of a given embodiment should not be construed to be applicable to only that example embodiment and therefore elements of one example embodiment can be applicable to other embodiments. Additionally, elements that are specifically shown in example embodiments should be construed to cover embodiments that comprise, consist essentially of, or consist of such elements, or such elements can be explicitly absent from further embodiments. Accordingly, the recitation of an element being present in one example should be construed to support some embodiments where such an element is explicitly absent.
Puncture tests were performed on different flocked and non-flocked PVC sheets of different thicknesses. The following procedure was followed for each of the tests:
(1) Cut a piece of specimen from the sample sized to fit into the serrated clamping plate with an open area 6″ diameter (˜15.24 cm); (2) Clamp the specimen on the serrated clamping plate; (3) Set a force gage and a ¼″ (˜0.635 cm) diameter steel rod for puncture; (4) Push the steel rod into the specimen at a constant rate 1 inch/minute (˜2.54 cm/min.); (5) Measure the force used to puncture through the specimen in lbf (lbf=pound-force, which is approximately equal to 4.44822 newtons); (6) Observe and record all findings or any other unusual changes; and (7) Repeat steps 1 to 5 for other specimen(s) if necessary.
A test on a flocked PVC sheet having a thickness of 0.6 mm (with 0.2 mm of a PVC sheet portion and 0.4 mm of a flocking portion) yielded the following results: Specimen #1: 31.3 lbf; Specimen #2: 29.8 lbf; Specimen #3: 30.2 lbf; Specimen #4: 30.4 lbf; Specimen #5: 30.5 lbf.
A test on a non-flocked PVC sheet having a thickness of 0.35 mm yielded the following results: Specimen #1: 25.2 lbf; Specimen #2: 26.0 lbf; Specimen #3: 24.6 lbf; Specimen #4: 25.4 lbf; Specimen #5: 25.3 lbf.
An alternating pressure pad 100 comprising first and second layer 1, 2 of the tested flocked PVC sheet having a thickness of 0.6 mm (with 0.2 mm of a PVC sheet portion and 0.4 mm of a flocking portion) and a non-flocked PVC sheet having a thickness of 0.35 mm was found to be desirable for the application of providing a flocked alternating pressure pad for bedsore prevention.
A test on a non-flocked PVC sheet having a thickness of 0.559 mm yielded the following results: Specimen #1: 40.6 lbf; Specimen #2: 39.8 lbf; Specimen #3: 39.3 lbf; Specimen #4: 39.5 lbf; Specimen #5: 39.8 lbf.
A test on a non-flocked PVC sheet having a thickness of 0.28 mm yielded the following results: Specimen #1: 17.5 lbf; Specimen #2: 17.8 lbf; Specimen #3: 17.9 lbf; Specimen #4: 17.3 lbf; Specimen #5: 18.3 lbf.
| Number | Date | Country | Kind |
|---|---|---|---|
| 202322577987.0 | Sep 2023 | CN | national |
