BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to an inflatable product, and more particularly to an inflatable product with elements thereof connected by sewing and fusion.
Description of the Related Art
Referring to FIGS. 1 and 2, FIG. 1 is a perspective view of a conventional air mattress and FIG. 2 is a sectional view of the air mattress of FIG. 1. The air mattress 1 of FIG. 1 includes an inflatable body 11. The inflatable body 11 includes a top wall 110, a bottom wall 110′ and a side wall 112. The top wall 110, the bottom wall 110′ and the side wall 112, generally made of plastic material such as Polyvinyl Chloride (PVC), are connected to each other by fusion to form the inflatable body 11. In FIG. 2, reference numerals 102 indicate where the top wall 110, the bottom wall 110′ and the side wall 112 are fused.
It is noted that a plurality of straps 14 are provided in the inflatable body 11 and are connected to the top wall 110, the bottom wall 110′ and the side wall 112 by fusion. When the inflatable body 11 is inflated to expand, the stretch of the top wall 110, the bottom wall 110′ and the side wall 112 is limited by the straps 14 (under the pulling forces of the straps 14), thereby controlling expansion of the inflatable body 11 to a desired shape.
Under the action of the straps 14, however, the top wall 110 and the bottom wall 110′ inevitably have a plurality of first depressions 113 and second depressions 113′ formed thereon so that the air mattress 1 is not flat at the top and bottom and user's comfort is affected.
BRIEF SUMMARY OF THE INVENTION
The invention provides an inflatable product. The inflatable product in accordance with an exemplary embodiment of the invention includes an inflatable body and a supplemental layer. The inflatable body includes a first wall and a first auxiliary sheet fused with each other. The supplemental layer is configured to cover the first wall and is fixed to the first auxiliary sheet of the inflatable body by sewing and/or gluing.
In another exemplary embodiment, the inflatable body further includes a second wall fused with the first auxiliary sheet, and the first wall and the second wall do not overlap each other.
In yet another exemplary embodiment, the first wall is substantially perpendicular to the second wall when the inflatable body is inflated to expand.
In another exemplary embodiment, the supplemental layer and the first auxiliary sheet are sewn by sewing threads, the first wall and the first auxiliary sheet are fused along a first fusion line with the sewing threads disposed inner than the first fusion line, and the second wall and the first auxiliary sheet are fused along a second fusion line with the first fusion line disposed inner than the second fusion line.
In yet another exemplary embodiment, the inflatable product further includes a second auxiliary sheet wherein the supplemental layer, the second auxiliary sheet and the first auxiliary sheet are sequentially arranged and the second auxiliary sheet physically contacts the supplemental layer and the first auxiliary sheet.
In another exemplary embodiment, the supplemental layer, the second auxiliary sheet and the first auxiliary sheet are fixed together by sewing and/or gluing.
In yet another exemplary embodiment, the inflatable product further includes a tension element that is connected to the inflatable body, thereby controlling expansion of the inflatable body when the inflatable body is inflated.
In another exemplary embodiment, the tension element is made of fabric or plastic.
In yet another exemplary embodiment, the inflatable product further includes a fusible element wherein the fusible element is fused with the inflatable body, and the tension element is connected to the fusible element to pull the inflatable body through the fusible element when the inflatable body is inflated.
In another exemplary embodiment, the tension element is connected to the fusible element by sewing or gluing.
In yet another exemplary embodiment, the tension element is connected to the inflatable body by fusion.
In another exemplary embodiment, the inflatable body further includes a second wall and a third wall. The third wall includes an edge portion fused with the first auxiliary sheet, and another edge portion fused with the second wall.
In yet another exemplary embodiment, the inflatable product further includes a second wall which includes a first part disposed opposite to the first wall, and a second part integrally formed with the first part as a continuous piece. The first auxiliary sheet includes a third part fused with the first wall, and a fourth part integrally formed with the third part as a continuous piece. The second part of the second wall is fused with the fourth part of the first auxiliary sheet. A thickness of the inflatable body is formed by the fourth part of the first auxiliary sheet and the second part of the second wall when the inflatable body is inflated to expand.
In another exemplary embodiment, the inflatable product further includes a tension element connected to the first wall and the second wall by fusion.
The invention also provides a method of producing an inflatable product that includes steps of connecting a supplemental layer to an auxiliary structure by sewing threads; fusing a first wall with the auxiliary structure along a first fusion line, with the sewing threads disposed inner than the first fusion line; and fusing a second wall with the auxiliary structure along a second fusion line, with the first fusion line disposed inner than the second fusion line.
A detailed description is given in the following embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:
FIG. 1 is a perspective view of a conventional air mattress;
FIG. 2 is a sectional view of the air mattress of FIG. 1;
FIG. 3 is a perspective view of an air mattress in accordance with a first embodiment of the invention;
FIG. 4 is an exploded view of the air mattress of FIG. 3;
FIG. 5A is a local sectional view of the air mattress of FIG. 3;
FIG. 5B is a sectional view of a part of an air mattress in accordance with a second embodiment of the invention;
FIG. 5C is a sectional view of a part of an air mattress in accordance with a third embodiment of the invention;
FIG. 5D is a sectional view of a part of an air mattress in accordance with a fourth embodiment of the invention;
FIG. 5E is a sectional view of a part of an air mattress in accordance with a fifth embodiment of the invention;
FIG. 5F is a sectional view of a part of an air mattress in accordance with a sixth embodiment of the invention;
FIG. 5G is a sectional view of a part of an air mattress in accordance with a seventh embodiment of the invention;
FIG. 5H is a sectional view of a part of an air mattress in accordance with an eighth embodiment of the invention;
FIG. 5I is a sectional view of a part of an air mattress in accordance with a ninth embodiment of the invention;
FIG. 5J is a flowchart of producing the inflatable body in accordance with the ninth embodiment of the invention;
FIG. 6 is a cutaway view of portion VI of the air mattress of FIG. 3;
FIG. 7A is a sectional view of an air mattress in accordance with a tenth embodiment of the invention;
FIG. 7B is a flowchart showing how a part VII of the inflatable body is produced in accordance with the tenth embodiment of the invention;
FIG. 8 is a sectional view of an air mattress in accordance with an eleventh embodiment of the invention;
FIG. 9A is a perspective view of an air mattress in accordance with a twelfth embodiment of the invention;
FIG. 9B is an exploded view of an air mattress in accordance with the twelfth embodiment of the invention;
FIG. 10 is a sectional view of an air mattress in accordance with the twelfth embodiment of the invention;
FIG. 11 is an enlarged view of portion IX of the air mattress of FIG. 10;
FIG. 12 is an enlarged view of portion X of the air mattress of FIG. 10;
FIG. 13 is a sectional view of a part of an air mattress in accordance with a thirteenth embodiment of the invention;
FIG. 14 is a sectional view of another part of an air mattress in accordance with the thirteenth embodiment of the invention;
FIG. 15 is a sectional view of a part of an air mattress in accordance with a fifteenth embodiment of the invention;
FIG. 16 depicts a first air permeable layer, a resilient layer and a first outermost fabric layer fixed together by sewing in accordance with the invention;
FIG. 17 is a cutaway view showing portion XV of the air mattress of FIG. 9A or FIG. 16;
FIG. 18 depicts an inflatable boat in accordance with a sixteenth embodiment of the invention;
FIG. 19 is a sectional view of a part of the inflatable boat of FIG. 18;
FIG. 20 is a sectional view of an inflatable product in accordance with a seventeenth embodiment of the invention;
FIG. 21 is an enlarged view of portion XIX of the inflatable product of FIG. 20;
FIG. 22 depicts an inflatable sofa in accordance with an eighteenth embodiment of the invention;
FIG. 23 is a sectional view of the inflatable sofa of FIG. 22;
FIG. 24 is an enlarged view of portion XXII of the inflatable sofa of FIG. 23;
FIG. 25 is an enlarged view of portion XXIII of the inflatable sofa of FIG. 23;
FIG. 26 is a perspective view of an air mattress with an inflatable headboard in accordance with a nineteenth embodiment of the invention;
FIG. 27 is a top view of the air mattress of FIG. 26; and
FIG. 28 is a sectional view of portion XXVI of the air mattress of FIG. 26.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 3, 4 and 5A, FIG. 3 is a perspective view of an air mattress in accordance with a first embodiment of the invention, FIG. 4 is an exploded view of the air mattress of FIG. 3, and FIG. 5A is a local sectional view of the air mattress of FIG. 3. In the first embodiment, the air mattress 2 includes an inflatable body 21 and a supplemental layer 28. In the invention, the supplemental layer 28 is a first air permeable layer. The inflatable body 21 includes a first wall 210, a second wall 210′ and a third wall 212. The first wall 210, the second wall 210′ and the third wall 212 are connected to each other by fusion to form the inflatable body 21. FIG. 5A only shows one fusion as a representation and a dot 202 indicates where the fusion is. Further, in FIG. 5A, the first wall 210 is the top wall of the inflatable body 21 while the second wall 210′ is the bottom wall of the inflatable body 21. However, that is only for easy description and the invention is not limited thereto. It is understood throughout this disclosure that the first wall 210 can be the bottom wall of the inflatable body 21 and the second wall 210′ can be the top wall of the inflatable body 21. That will not be repeatedly emphasized in the following description.
A plurality of straps 24 are provided in the inflatable body 21 and are connected to the first wall 210, the second wall 210′ and the third wall 212 by fusion. When the inflatable body 21 is inflated to expand, the stretch of the first wall 210, the second wall 210′ and the third wall 212 is limited by the straps 24 (under the pulling forces of the straps 24), thereby controlling expansion of the inflatable body 21 to a desired shape.
Under the action of the straps 24, the first wall 210 and the second wall 210′ have a plurality of first depressions 213 and second depressions (not shown) formed thereon. In the invention, a first air permeable layer 28 is additionally provided on the first wall 210 to cover the first depressions 213 thereby improving the flatness of the air mattress 2 and user's comfort.
Under the consideration of air permeability, support ability and manufacturing cost, the first air permeable layer 28 may be (for example) netting. However, the first wall 210, the second wall 210′ and the third wall 212 are generally made of plastic (for example Polyvinyl Chloride, PVC). The differences between the qualities of net and plastic in terms of material make connection by fusion difficult and/or disadvantageous. In the invention, therefore, the first air permeable layer 28 is not connected to the inflatable body 21 by fusion but in another way, as described in the following.
Referring to FIG. 5A, the first wall 210 includes a first edge portion 2101. The third wall 212 includes a second edge portion 2121. The first air permeable layer 28 includes a third edge portion 281. The invention provides a trim sheet 26 to wrap around the first edge portion 2101, the second edge portion 2121 and the third edge portion 281. Then, the trim sheet 26, the first edge portion 2101, the second edge portion 2121 and the third edge portion 281 are fixed together by sewing (reference numeral 201 indicates the seam). It is understood that in this embodiment the first air permeable layer 28 is directly fixed to the inflatable body 21 by sewing.
It is noted that the first edge portion 2101, the second edge portion 2121 and the third edge portion 281 are covered by the trim sheet 26 so that the inflatable mattress of this embodiment can have an improved aesthetic appearance. The material of the trim sheet 26 may be fabric. Alternatively, the material of the trim sheet 26 may be plastic, so that the trim sheet 26, the first wall 210, the second wall 210′ and the third wall 212 have the same material.
FIG. 5B is a sectional view of a part of an air mattress in accordance with a second embodiment of the invention, wherein the second edge portion 2121 of the third wall 212 in the second embodiment protrudes beyond the fusion line 202 less than that in the first embodiment. Alternatively, the second edge portion 2121 of the third wall 212 in the second embodiment does not protrude beyond the fusion line 202 (not shown in figures). Thus, in the second embodiment, the second edge portion 212 is not covered by the trim sheet 26. Only the first edge portion 2101 and the third edge portion 281 are covered thereby.
FIG. 5C is a sectional view of a part of an air mattress in accordance with a third embodiment of the invention, wherein the first edge portion 2101 of the first wall 210 in the third embodiment protrudes beyond the fusion line 202 less than that in the first embodiment. Alternatively, the first edge portion 2101 of the first wall 210 in the third embodiment does not protrude beyond the fusion line 202 (not shown in figures). Thus, in the third embodiment, the first edge portion 2101 is not covered by the trim sheet 26. Only the second edge portion 2121 and the third edge portion 281 are covered thereby.
FIG. 5D is a sectional view of a part of an air mattress in accordance with a fourth embodiment of the invention, wherein the third wall 212 and the trim sheet 26 are integrally formed as one continuous piece, while the third wall 212 and the trim sheet 26 in the second embodiment are two discrete elements. In the fourth embodiment, the trim sheet 26 wraps around the first edge portion 2101 and the third edge portion 281 and is fixed thereto by sewing.
FIG. 5E is a sectional view of a part of an air mattress in accordance with a fifth embodiment of the invention, wherein the first edge portion 2101 and the second edge portion 2121 are folded to wrap around the third edge portion 281, and the trim sheet 26 is folded to wrap around the first edge portion 2101, the second edge portion 2121 and the third edge portion 281. In the first embodiment, however, the first edge portion 2101 and the second edge portion 2121 are not folded to wrap around the third edge portion 281. Instead, the first edge portion 2101, the second edge portion 2121 and the third edge portion 281 are directly covered by the trim sheet 26.
FIG. 5F is a sectional view of a part of an air mattress in accordance with a sixth embodiment of the invention. The sixth embodiment differs from the fifth embodiment in that in the sixth embodiment the first edge portion 2101 and the third edge portion 281 are covered by the trim sheet 26 and the second edge portion 2121 is not covered thereby. Further, the second edge portion 2121 is not sewn together with the trim sheet 26, the first edge portion 2101 and the third edge portion 281. However, it is understood that the second edge portion 2121 which is not folded can be modified to be sewn together with the trim sheet 26, the first edge portion 2101 and the third edge portion 281.
FIG. 5G is a sectional view of a part of an air mattress in accordance with a seventh embodiment of the invention. The seventh embodiment differs from the fifth embodiment in that in the seventh embodiment the second edge portion 2121 and the third edge portion 281 are covered by the trim sheet 26 and the first edge portion 2101 is not covered thereby. Further, the first edge portion 2101 is not sewn together with the trim sheet 26, the second edge portion 2121 and the third edge portion 281. However, it is understood that the first edge portion 2101 which is not folded can be modified to be sewn together with the trim sheet 26, the second edge portion 2121 and the third edge portion 281.
FIG. 5H is a sectional view of a part of an air mattress in accordance with an eighth embodiment of the invention, wherein the air mattress further includes an auxiliary sheet 27 and the auxiliary sheet 27 is fused with the third wall 212. The trim sheet 26 does not wrap around the first edge portion 2101 and the second edge portion 2121. Instead, the trim sheet 26 only wraps around the third edge portion 281 and a part of the auxiliary sheet 27, and the trim sheet 26, the third edge portion 281 and the auxiliary sheet 27 are sewn together. It is noted that the first air permeable layer 28 of the first embodiment through the seventh embodiment is directly fixed to the inflatable body 21 by sewing. However, the first air permeable layer 28 of the eighth embodiment is indirectly fixed to the inflatable body 21 by sewing.
FIG. 5I is a sectional view of a part of an air mattress in accordance with a ninth embodiment of the invention, wherein no trim sheet is used in this embodiment. The air mattress further includes an auxiliary structure 22. The auxiliary structure 22 includes two auxiliary sheets 222, 224 wherein the material of the auxiliary sheet 222 may be fabric and the material of the auxiliary sheet 224 may be plastic. The two auxiliary sheets 222, 224 may be bonded together by ways such as gluing or sewing. The third edge portion 281 of the first air permeable layer 28 is folded and fixed with the auxiliary structure 22 by sewing. The auxiliary sheet 224 of the auxiliary structure 22 is fused with the first edge portion 2101 of the first wall 210 and the second edge portion 2121 of the third wall 212. The material of the auxiliary sheet 222 is fabric so that the air mattress can have an improved aesthetic appearance. However, the auxiliary sheet 222 cannot be fused with the first wall 210 and the third wall 212, both of which are made of plastic, because their materials are incompatible with each other. Therefore, an additional auxiliary sheet 224, which is made of plastic and can be fused with the first wall 210 and the third wall 212, is used as a medium for connecting the auxiliary sheet 222 to the first wall 210 and the third wall 212. Further, thanks to the auxiliary sheet 222 (made of fabric), shrinkage of the auxiliary sheet 224 (made of plastic) after fusion can be effectively alleviated and the structural strength of the fusion line of the air mattress can be enhanced. Further, in embodiments of the application, it is contemplated that the auxiliary sheet 224 is fused with only the first wall 210 or only the third wall 212. In other embodiments of the application, it is contemplated that the auxiliary structure 22 is directly fixed with the first wall 210 and/or the third wall 212 by sewing without any fusion. Further, as described above, the auxiliary sheet 222 is provided for improvements of the appearance of the air mattress. It is therefore understood that the auxiliary sheet 222 can be omitted.
In the ninth embodiment, three plastic sheets (the auxiliary sheet 224, the first wall 210 and the third wall 212) are connected by fusion. If the three plastic sheets are fused simultaneously, then the fusion zone (the fusion line 600) will have reduced structural strength. That is, the fusion zone of three plastic sheets is weaker than that of two plastic sheets in structural strength if the three plastic sheets are fused simultaneously by a fusing action. In order to obtain a reliable structural strength of the fusion zone, the fusion is made twice in the ninth embodiment. FIG. 5J is a flowchart of producing the inflatable body in accordance with the ninth embodiment of the invention. In step S1100, an auxiliary structure 22 that includes an auxiliary sheet 224 is provided. In step S1200, the third edge portion 281 of the first air permeable layer 28 is connected to the auxiliary structure 22 by sewing, to form a first combined structure. In step S1300, the first edge portion 2101 of the first wall 210 is fused with the second edge portion 2121 of the third wall 212 along a fusion line 600, to form a second combined structure. In step S1400, the part of the first edge portion 2101 that protrudes beyond the fusion line 600 is removed. Alternatively, the part of the second edge portion 2121 that protrudes beyond the fusion line 600 is removed. In step S1500, the first combined structure is fused with the second combined structure along the fusion line 600. It is worth noting that the auxiliary sheet 224 of the auxiliary structure 2, the first edge portion 2101 of the first wall 210, and the second edge portion 2121 of the third wall 212 are not fused simultaneously. Instead, the fusion is performed twice, wherein a fusion of the first edge portion 2101 of the first wall 210 and the second edge portion 2121 of the third wall 212 is performed at a predetermined zone or location, and then another fusion of the auxiliary sheet 224 of the auxiliary structure 22 and the first edge portion 2101 of the first wall 210 is performed at the same zone or location. By such arrangement, the air mattress can have reliable structural strength at the fusion zone (the fusion line 600).
In all the above embodiments, the first air permeable layer 28 is netting. However, the invention is not limited thereto. It is understood that in embodiments of the application the material of the first air permeable layer 28 may be fabric and/or netting.
FIG. 6 is a cutaway view of portion VI of the air mattress of FIG. 3, wherein a part of the third wall 212 is removed to expose the interior of the inflatable body 21. As shown, at least one strap 24′ is provided in the inflatable body 21, with the lower portion fused with the second wall 210′ and the upper portion fused with the third wall 212. When the inflatable body 21 is inflated, a pulling force is generated by the strap 24′ to limit expansion of the third wall 212. It is noted that the strap 24′ is slanted and the inflatable body 21 is angled (not rounded) at its corners. Under such circumstance, the upper edge of the strap 24′ may be wrinkled at the corner of the inflatable body 21. To avoid the wrinkles, the upper edge of the strap 24′ of the invention is not fused with the inflatable body 21 at the corner. In FIG. 6, the thick lines 203 indicate the fusion lines. A portion 2123 at the upper edge of the strap 24′ is not fused with the third wall 212. According to experiments, the inflatable body 21 suffers from less stress at the corner and therefore is less liable to rupture even without fusion at the corner. In FIG. 6, the second wall 210′ is the bottom wall of the inflatable body 21. However, that is only for easy description and the invention is not limited thereto. It is understood that the second wall 210′ can be the top wall of the inflatable body 21. Further, the structure of FIG. 6 can apply to both of the top wall and the bottom wall of the inflatable body 21.
FIG. 7A is a sectional view of an air mattress in accordance with a tenth embodiment of the invention, wherein the auxiliary structure 22 includes two auxiliary sheets 222, 224, the material of the auxiliary sheet 222 may be fabric, and the material of the auxiliary sheet 224 may be plastic. Similar to that of the ninth embodiment, the auxiliary sheet 222 of the tenth embodiment can be omitted. The two auxiliary sheets 222, 224 may be bonded together by various ways such as gluing or sewing, or may merely physically contact each other. The third edge portion 281 of the first air permeable layer 28 is folded and fixed with the auxiliary structure 22 by sewing. It is worth noting that the first wall 210 is not directly connected to the third wall 212. Instead, the first edge portion 2101 of the first wall 210 is fused with the auxiliary sheet 224 of the auxiliary structure 22, and the auxiliary sheet 224 of the auxiliary structure 22 is fused with the second edge portion 2121 of the third wall 212. The first wall 210 and the third wall 212 of the tenth embodiment does not overlap each other, while the first wall 210 and the third wall 212 of the ninth embodiment overlap each other. It is therefore understood that the first wall 210 of the tenth embodiment is smaller than that of the ninth embodiment. The tenth embodiment can save material because of the reduced size of the first wall 210.
In the tenth embodiment, the first air permeable layer 28 and the auxiliary sheets 222 and 224 are fixed together by sewing (in FIG. 7A, reference numeral 601 indicates the sewing threads). However, the invention is not limited thereto. For example, the first air permeable layer 28 and the auxiliary sheets 222 and 224 can be fixed together by gluing. For another example, the first air permeable layer 28 and the auxiliary sheet 222 is fixed together by sewing, while the auxiliary sheets 222, 224 are fixed together by gluing. For another example, the first air permeable layer 28 and the auxiliary sheet 222 is fixed together by gluing, while the auxiliary sheets 222, 224 are fixed together by sewing. For another example, the auxiliary sheet 222 that is disposed between the supplemental layer 28 and the auxiliary sheet 224 physically contacts the supplemental layer 28 and the auxiliary sheet 224. In brief, the first air permeable layer 28 and the auxiliary sheets 222 and 224 can be fixed together by sewing and/or gluing, or merely contacts each other.
In the invention, one or more tension elements are provided in the inflatable body to connect the first wall 210, the second wall 210′ and the third wall 212. The connection can be performed by fusion, sewing and/or gluing. In FIG. 7A, for example, the tension elements 25 are straps made of fabric or plastic. An end of the strap 25 is sewn with a fusible element 29 which is made of plastic material or other fusible material. The fusible element 29 is fused with the first wall 210. Another end of the strap 25 is sewn with another fusible element 29′ which is made of plastic material or other fusible material. The fusible element 29′ is fused with the second wall 210′. The tension elements 25 are used for pulling the inflatable body when the inflatable body is inflated to expand, thereby controlling expansion of the inflatable body to a desired shape. For some other embodiments, as shown in FIGS. 5A-5I and 6, the straps 24, 24′ are directly connected to the first wall 210, the second wall 210′ and the third wall 212 by fusion.
The tension elements of the invention for controlling expansion of the inflatable body can be implemented in any forms, for example, in form of straps, bands, sleeves, strings, lines, threads, cords, ropes, twines, strips, ribbons and so on.
FIG. 7B is a flowchart showing how a part VII of the inflatable body is produced in accordance with the tenth embodiment of the invention. In step S2100, an auxiliary structure 22 that includes auxiliary sheets 222, 224 is provided. The auxiliary sheet 222 can be omitted. In step S2200, the third edge portion 281 of the first air permeable layer 28 is connected to the auxiliary structure 22 by sewing. When the auxiliary structure 22 includes two auxiliary sheets 222, 224, the third edge portion 281 of the first air permeable layer 28 is connected to both of the auxiliary sheets 222, 224 by sewing. When the auxiliary structure 22 includes only the auxiliary sheet 224, the third edge portion 281 of the first air permeable layer 28 is connected to only the auxiliary sheet 224 by sewing. In step S2300, the first edge portion 2101 of the first wall 210 is fused with the auxiliary sheet 224, with the sewing threads 601 disposed inner than the fusion line 602 where the first edge portion 2101 of the first wall 210 and the auxiliary sheet 224 are fused. In step S2400, the second edge portion 2121 of the third wall 212 is fused with the auxiliary sheet 224, with the fusion line 602 disposed inner than the fusion line 603 where the second edge portion 2121 of the third wall 212 and the auxiliary sheet 224 are fused.
The invention is not limited to the order of steps shown in FIG. 7B. For example, step S2400 can be performed before step S2300. Briefly, the order of steps S2200, S2300 and S2400 can be changed.
Referring to FIG. 8, an air mattress of an eleventh embodiment includes a first wall 210, a second wall 210′, a first air permeable layer 28 and one or more tension elements 24. The first air permeable layer 28 is placed to cover the first wall 210. As described above, the first air permeable layer 28 can be fixed to the auxiliary structure 22 by sewing and/or gluing. The auxiliary structure 22 includes an auxiliary sheet 224 and another auxiliary sheet 222 wherein the auxiliary sheet 222 can be omitted. The second wall 210′ includes a first part 2101′ disposed opposite to the first wall 210, and a second part 2102′ integrally formed with the first part as a continuous piece. The first auxiliary sheet 224 includes a third part 2241 fused with the first wall 210, and a fourth part 2242 integrally formed with the third part 2241 as a continuous piece. The second part 2102′ of the second wall 210′ is fused with the fourth part 2242 of the first auxiliary sheet 224 (in FIG. 8, reference numeral 604 indicates the fusion line). A thickness of the inflatable body is formed by the fourth part 2242 of the first auxiliary sheet 224 and the second part 2102′ of the second wall 210′ when the inflatable body is inflated to expand. It is worth noting that the fusion lines 602, 604 of the eleventh embodiment (FIG. 8) are less than those 602, 603, 603′ of the tenth embodiment (FIG. 7A) in number. Therefore, the labors can be saved and the production efficiency can be promoted.
In FIG. 8, the tension elements 24 are connected to the first wall 210 and the second wall 210′ by fusion. However, the invention is not limited thereto. As described above, the connection can be performed by fusion, sewing and/or gluing.
Referring to FIGS. 9A, 9B, 10, 11 and 12, in a twelfth embodiment, an air mattress 3 includes an outermost fabric layer 33, a resilient layer 37, a first air permeable layer 38, an inflatable body 31, an outermost fabric layer 35 and a second air permeable layer 39. The inflatable body 31 includes a first wall 310, a second wall 310′ and a third wall 312. The first wall 310, the second wall 310′ and the third wall 312 are fused with each other to form the inflatable body 31. A plurality of straps 34 are provided in the inflatable body 31. The straps 34 are fused with the first wall 310, the second wall 310′ and the third wall 312. Under the action of the straps 34, the first wall 310 has a plurality of first depressions 313 and the first air permeable layer 38 is disposed on the first wall 310 to cover the first depressions 313 thereby improving the flatness of the air mattress 3. The first air permeable layer 38 may be netting. The resilient layer 37 is disposed between the outermost fabric layer 33 and the first air permeable layer 38. The resilient layer 37 may be, for example, a foam to improve user's comfort. The outermost fabric layer 35 is disposed to surround the third wall 312, both of which may be glued together or not glued together. The outermost fabric layer 33 and the outermost fabric layer 35 may be made of ordinary fabric for providing the air mattress 3 with an improved aesthetic appearance.
FIG. 11 is an enlarged view of portion IX of the air mattress of FIG. 10. As shown, the outermost fabric layer 35, the third wall 312, the first wall 310, the first air permeable layer 38 and the outermost fabric layer 33 are partially covered by the trim sheet 36, and all of them are fixed together by sewing.
FIG. 12 is an enlarged view of portion X of the air mattress of FIG. 10. As shown, the outermost fabric layer 35, the third wall 312, the second wall 310′ and the second air permeable layer 39 are partially covered by another trim sheet 36′, and all of them are fixed together by sewing. In this embodiment, the second air permeable layer 39 is netting.
FIGS. 13 and 14 depicts an air mattress in accordance with a thirteenth embodiment of the invention, wherein the outermost fabric layer 35 and the trim sheets 36, 36′ are integrally formed as one continuous piece, while the outermost fabric layer 35 and the trim sheets 36, 36′ in the twelfth embodiment are discrete elements. In the thirteenth embodiment, the third wall 312, the first wall 310, the first air permeable layer 38 and the outermost fabric layer 33 (FIG. 13) are partially covered by the trim sheet 36 and all of them are fixed together by sewing. Similarly, the third wall 312, the second wall 310′ and the second air permeable layer 39 (FIG. 14) are partially covered by another trim sheet 36′ and all of them are fixed together by sewing. Other structure and arrangements of this embodiment are identical to those of the twelfth embodiment and therefore the descriptions thereof are omitted.
The second air permeable layer 39 of the twelfth embodiment is netting. In a fourteenth embodiment, however, the second air permeable layer is an outermost fabric layer. Alternatively, the second air permeable layer includes an outermost fabric layer and netting. Other structure and arrangements of the fourteenth embodiment are identical to those of the twelfth embodiment and therefore the descriptions thereof are omitted.
FIG. 15 is a sectional view of a part of an air mattress in accordance with a fifteenth embodiment of the invention. The fifteenth embodiment differs from the twelfth embodiment in that the air mattress 3 of the fifteenth embodiment further includes an auxiliary sheet 32 fused with the third wall 312. The trim sheet 36 does not wrap around the third wall 312 and the first wall 310 but partially wraps around the outermost fabric layer 35, the auxiliary sheet 32, the first air permeable layer 38 and the outermost fabric layer 33. Further, the trim sheet 36, the outermost fabric layer 35, the auxiliary sheet 32, the first air permeable layer 38 and the outermost fabric layer 33 are fixed together by sewing.
In the twelfth embodiment through the fifteenth embodiment, the first air permeable layer 38, the resilient layer 37 and the outermost fabric layer 33 can be further fixed together by sewing as shown in FIG. 16, in which reference numeral 301 indicates the sewing seam. Such arrangement can prevent sliding of the first air permeable layer 38, the resilient layer 37 and the outermost fabric layer 33 with respect to each other when the air mattress is in use.
FIG. 17 is a cutaway view showing portion XV of the air mattress of FIG. 9A or FIG. 16, wherein a part of the third wall 312 is removed to expose the interior of the inflatable body 31. As shown, in the inflatable body 31, at least one of strap 34′ is fused with the second wall 310′ and the third wall 312 to control the expansion of the third wall 312. It is noted that the strap 34′ is slanted and the inflatable body 31 is angled (not rounded) at its corners. Under such circumstance, the upper edge of the strap 34′ may be wrinkled at the corner of the inflatable body 31. To avoid the wrinkles, the upper edge of the strap 34′ of the invention is not fused with the inflatable body 31 at the corner. In FIG. 17, the thick lines 303 indicate the fusion lines. A portion 3123 at the upper edge of the strap 34′ is not fused with the third wall 312. According to experiments, the inflatable body 31 suffers from less stress at the corner and therefore is less liable to rupture even without fusion at the corner. In FIG. 17, the second wall 310′ is the bottom wall of the inflatable body 31. However, it is understood that the second wall 310′ can be the top wall of the inflatable body 21. Further, the structure of FIG. 17 can be applied to both of the top wall and the bottom wall of the inflatable body 31.
In the above embodiments, a part or all of fusion can be changed to gluing. For example, the first wall 210, 310 and the third wall 212, 312 can be glued together instead of fixed together by fusion.
It is understood that various inflatable products such as an inflatable sofa, an inflatable chair, an inflatable boat, and an inflatable swimming pool can apply the techniques of the invention. Referring to FIGS. 18 and 19, FIG. 18 depicts an inflatable boat in accordance with a sixteenth embodiment of the invention, and FIG. 19 is a sectional view of a part of the inflatable boat of FIG. 18. As shown, the inflatable boat 4 of this embodiment includes a plurality of inflatable bodies 40, 41 connected by sewing and fusion. In detail, the inflatable body 41 includes a first wall 410 and a second wall 410′ connected with their edge portions fused together. A plurality of straps 44 are provided in the inflatable body 41 and are connected to the first wall 410 and the second wall 410′ by fusion. When the inflatable body 41 is inflated to expand, the stretch of the first wall 410 and the second wall 410′ is limited by the straps 44, thereby controlling expansion of the inflatable body 41 to a desired shape. An outermost fabric layer 43 is provided to cover the first wall 410 of the inflatable body 41. The inflatable body 40 includes a first wall 400, a third wall 402 and the above-mentioned second wall 410′. It is noted that the inflatable bodies 40, 41 have the second wall 410′ in common. The first wall 400, the third wall 402 and the second wall 410′ are connected with their edge portions fused together. As shown in FIG. 19, an outermost fabric layer 43 is disposed to cover the first wall 410 of the inflatable body 41 while an outermost fabric layer 43″ is disposed to cover the first wall 400 of the inflatable body 40. The edge portions of the outermost fabric layers 43″, 43 and the first walls 400, 410 are sewn together. Further, an outermost fabric layer 45 is disposed to cover the third wall 402. The edge portions of the outermost fabric layer 45, the third wall 402, the first wall 400 and the outermost fabric layer 43″ are sewn together. Further, an outermost fabric layer 43′ is disposed to cover the second wall 410′. The edge portions of the outermost fabric layer 45, the third wall 402, the second wall 410′ and the outermost fabric layer 43′ are covered by a trim sheet 46 and fixed together by sewing.
In the above embodiments, the location of sewing is away from that of fusion. However, the invention is not limited thereto. In some examples, the sewing is made along (to coincide with) the fusion line to connect different elements. It is noted that the holes generated by sewing will not cause any air leakage of the inflatable product because the sewing is made on the fusion line.
Referring to FIGS. 20 and 21, FIG. 20 is a sectional view of an inflatable product in accordance with a seventeenth embodiment of the invention, and FIG. 21 is an enlarged view of portion XIX of the inflatable product of FIG. 20. As shown, the inflatable product 5 includes a first wall 510 and a second wall 510′ fused together at their edge portions to form an inflatable body 51. A first air permeable layer 58 is disposed to cover the first wall 510 and a second air permeable layer 59 is disposed to cover the second wall 510′. The edge portions of the first air permeable layer 58, the first wall 510, the second wall 510′ and the second air permeable layer 59 are covered by a trim sheet 56, and all of them (including the trim sheet 56) are fixed together by sewing. In this embodiment, the first wall 510 and the second wall 510′ are made of plastic material such as Polyvinyl Chloride (PVC). The first air permeable layer 58, the second air permeable layer 59 and the trim sheet 56 are netting or fabric sheets. In FIG. 21, reference numeral 504 indicates the fusion line and reference numeral 505 indicates the sewing threads. It is noted that the sewing is made on the fusion line. The fusion line 504 has an outer edge 5042 and an inner edge 5041 closer to an interior of the inflatable body 51 than the outer edge 5042. In this embodiment, the sewing threads 505 are at least 2.5 mm away from the inner edge 5041 of the fusion line 504. That is, d≥2.5 mm where d is the distance between the sewing threads 505 and the inner edge 5041 of the fusion line 504. Such an arrangement guarantees duration of the connection.
In the seventeenth embodiment, the inflatable body 51 (formed by the first wall 510 and the second wall 510′) is disposed in an envelope 50 (formed by the first air permeable layer 58 and the second air permeable layer 59) and fixed thereto by sewing on the fusion line. Such an arrangement has many merits, especially when the inflatable product is complicated in structure and shape. For example, the inflatable body 51, before inflated, can have every portions set well in the envelope 50. During inflation, therefore, expansion of the inflatable body 51 will be under control that can facilitate expansion of the inflatable body 51 to a predetermined shape and can effectively avoid rupture of the inflatable body 51. Specifically, the described arrangement can avoid that during inflation the plastic material continues to be stretched, becomes thinner and thinner, and ends up being ruptured (generally, the rupture of the plastic material occurs next to the fusion lines arising from an over-stretch of plastic material). For another example, the inflatable body 51, after deflation, can be readily folded in order to occupy less space.
Referring to FIGS. 22-24, FIG. 22 depicts an inflatable sofa in accordance with an eighteenth embodiment of the invention, FIG. 23 is a sectional view of the inflatable sofa of FIG. 22, and FIG. 24 is an enlarged view of portion XXII of the inflatable sofa of FIG. 23. The inflatable sofa 6 includes an inflatable body (backrest and armrest) 60 and an inflatable body (seat) 61. The inflatable body 60 includes a first wall 600, a second wall 600′, a third wall 602 and an outermost fabric layer 65′ wherein the third wall 602 and the outermost fabric layer 65′ are disposed at the outer circumference of the inflatable body (backrest and armrest) 60. The first wall 600, the third wall 602 and the second wall 600′ are fused together at their edge portions. The outermost fabric layer 65′, the third wall 602 and the second wall 600′ are sewn together at their edge portions where the third wall 602 and the second wall 600′ are connected by fusion. The inflatable body 61 includes a first wall 610, a second wall 610′ and a third wall 612 which are connected at their edge portions by sewing and/or fusion. A plurality of straps 64 are provided in the inflatable body 61 and connected to the first wall 610 and the second wall 610′. A first air permeable layer 68 is disposed to cover the first wall 610. An outermost fabric layer 65 is disposed to cover the third wall 612. The first air permeable layer 68, the first wall 610, the third wall 612 and the outermost fabric layer 65 are sewn together at their edge portions where the first wall 610 and the third wall 612 are connected by fusion. It is noted that the edge portions of the outermost fabric layer 65′, the third wall 602 and the second wall 600′ sewn together and the edge portions of the first permeable layer 68, the first wall 610, the third wall 612 and the outermost fabric layer 65 sewn together are covered by a trim sheet 66 and fixed together.
Referring to FIG. 25, FIG. 25 is an enlarged view of portion XXIII of the inflatable sofa of FIG. 23. The inflatable body (backrest and armrest) 60 further includes a third wall 602′ which is covered with an outermost fabric layer 65″. The third wall 602′ and the outermost fabric layer 65″ are disposed at the inner circumference of the inflatable body 60. The third wall 602′ and the second wall 600′ are fused together at their edge portions, while the outermost fabric layer 65″ and the first air permeable layer 68 are sewn together. It is noted that the location of sewing is away from that of fusion. Specifically, the armrest is directly connected to the seat by sewing without any fusion at the inner circumference and the bottom of the armrest. Such a connecting way is easy and fast.
Referring to FIGS. 26-28, an air bed with an inflatable headboard in accordance with a nineteenth embodiment of the invention includes an inflatable body (mattress) 71, an inflatable body (headboard) 70 and a passage 79 connecting the two inflatable bodies 70, 71. The inflatable body 71 includes a first wall 710 and a third wall 712 fused together at their edge portions. A first air permeable layer 78 is disposed to cover the first wall 710. The inflatable body 70 includes a second wall 700′ and third walls 702, 702′ fused together. Outermost fabric layers 75′, 75″ are respectively disposed to cover the third walls 702, 702′. The edge portions of the outermost fabric layer 75′, the first air permeable layer 78, the first wall 710 and the third wall 712 are covered by a trim sheet 76, all of which are sewn together. It is noted that the sewing is made on the fusion line of the first wall 710 and the third wall 712. Further, the outermost fabric layer 75″ and the first air permeable layer 78 are sewn together without any fusion therebetween. That is, the bottom of the headboard is directly connected to the mattress by sewing the outermost fabric layer 75″ and the first air permeable layer 78 together without fusion therebetween. Such a connecting way is easy and fast.
While the invention has been described by way of example and in terms of preferred embodiment, it is to be understood that the invention is not limited thereto. To the contrary, it is intended to cover various modifications and similar arrangements (as would be apparent to those skilled in the art). Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.
Patent Application
20240335050
