Inflatable support system having thermoplastic polyurethane construction

Abstract

An inflatable support system comprised of at least one inflatable chamber that is defined by at least a top and a bottom layer of material. At least one of these layers of material is comprised of thermoplastic polyurethane. The inflatable support system includes at least one support structure that is also comprised of thermoplastic polyurethane. This support structure is attached to at least one of the layers of material that define the inflatable chamber.

1 . An inflatable support system, said system comprising: 
 at least one inflatable chamber, said inflatable chamber defined by at least a top and a bottom layer of material, at least one of said top and said bottom layers of material comprised of thermoplastic polyurethane; and    said inflatable chamber having at least one support structure comprised of thermoplastic polyurethane and being attached to at least one of said top and said bottom layers.    
     
     
         2 . The inflatable support system of  claim 1 , wherein both said top and said bottom layers are comprised of thermoplastic polyurethane.  
     
     
         3 . The inflatable support system of  claim 2 , wherein said at least one support structure is a coil.  
     
     
         4 . The inflatable support system of  claim 3 , wherein said coil is attached to at least one of said top and said bottom layers by welding.  
     
     
         5 . The inflatable support system of  claim 1 , further comprising at least one thermoplastic polyurethane flange.  
     
     
         6 . The inflatable support system of  claim 5 , further comprising a side gusset connecting said top and bottom layers.  
     
     
         7 . The inflatable support system of  claim 6 , wherein said flange is disposed on said side gusset.  
     
     
         8 . The inflatable support system of  claim 7 , wherein said side gusset is comprised of thermoplastic polyurethane.  
     
     
         9 . The inflatable support system of  claim 8 , wherein said flange is adapted to receive a valve.  
     
     
         10 . The inflatable support system of  claim 9 , wherein a second flange is disposed on said side gusset.  
     
     
         11 . The inflatable support system of  claim 10 , wherein said second flange is adapted to receive a pump.  
     
     
         12 . The inflatable support system of  claim 1 , wherein said thermoplastic polyurethane has a thickness of not more than 0.2 mm.  
     
     
         13 . The inflatable support system of  claim 1 , wherein a layer of fabric is laminated to at least one side of at least one of said top and said bottom layers.  
     
     
         14 . The inflatable support system of  claim 13 , wherein said fabric is a polyester fabric.  
     
     
         15 . The inflatable support system of  claim 1 , wherein a layer of flocking is applied to at least one side of at least one of said top and said bottom layers.  
     
     
         16 . An inflatable support system, said system comprising: 
 a substantially airtight chamber;    said substantially airtight chamber defined by a top and a bottom sheet comprised at least partially of thermoplastic polyurethane;    said top sheet being laminated on at least one side to a fabric sheet;    said bottom sheet being laminated on at least one side to a fabric sheet; and    at least one coil attached to said top and said bottom sheets.    
     
     
         17 . The inflatable support system of  claim 16 , further comprising a side gusset, said side gusset being connected to said top and said bottom layers.  
     
     
         18 . The inflatable support system of  claim 17 , further comprising at least one flange comprised of thermoplastic polyurethane defined on said side gusset.  
     
     
         19 . The inflatable support system of  claim 18 , wherein said at least one flange is attached to said side gusset on the inside of said substantially airtight chamber.  
     
     
         20 . The inflatable support system of  claim 19 , further comprising a valve attached to said flange.  
     
     
         21 . A method for constructing an inflatable support system, said method comprising the steps of: 
 forming a first layer comprised of thermoplastic polyurethane;    forming a second layer comprised of thermoplastic polyurethane;    forming at least one coil comprised of thermoplastic polyurethane;    attaching a first end of said coil to said first layer; and    attaching a second end of said coil to said second layer.    
     
     
         22 . The method of  claim 21 , further comprising the step of forming a side gusset comprised of thermoplastic polyurethane and attaching said side gusset to said first layer and said second layer.  
     
     
         23 . The method of  claim 22 , further comprising the steps of supplying a flange mold; 
 heating thermoplastic polyurethane pellets until they are in a liquid state;    injecting said liquid into said flange mold to form a flange;    removing said flange from said mold; and    welding said flange to said side gusset.    
     
     
         24 . The method of  claim 22 , further comprising the step of laminating a fabric layer to at least one side of at least one of said first and said second layers.  
     
     
         25 . The method of  claim 22 , further comprising the step of applying a layer of flocking to at least one side of at least one of said first and said second layers.  
     
     
         26 . A method of constructing an inflatable support system, said method comprising the steps of: 
 laminating a fabric layer to a layer of thermoplastic polyurethane to form a sheet;    cutting said sheet to form at least a top and a bottom layer;    cutting said sheet to form a side gusset;    forming at least one coil from a sheet of thermoplastic polyurethane;    welding a first end of said coil to said top layer on a side opposite said fabric layer;    welding a second end of said coil to said bottom layer on a side opposite said fabric layer; and    welding one edge of said side gusset to said top sheet and welding the opposite edge of said side gusset to said bottom sheet to form an inflatable chamber.    
     
     
         27 . The method of  claim 26 , further comprising the steps of: 
 supplying a mold for a flange;    melting thermoplastic polyurethane material to form a liquid;    injecting said liquid into said mold;    heating said mold until said thermoplastic polyurethane is permanently set;    opening said mold and cooling said flange;    defining an opening in said side gusset; and    welding said flange to said side gusset at said opening.    
     
     
         28 . The method of  claim 27 , further comprising the step of attaching a valve to said flange.  
     
     
         29 . The method of  claim 26 , wherein said sheets of thermoplastic polyurethane are not thicker than 0.2 mm.  
     
     
         30 . The method of  claim 27 , wherein said welding steps are performed by sonic welding.  
     
     
         31 . The method of  claim 27 , wherein said welding steps are performed by heat welding.  
     
     
         32 . The method of  claim 26 , wherein said fabric is polyester.  
     
     
         33 . A method of manufacturing an inflatable support system, said method comprising the steps of: 
 forming a top and a bottom layer from a flexible, substantially airtight material;    forming a side gusset from a flexible, substantially airtight material;    welding one edge of said side gusset to said top layer and welding the opposite edge of said side gusset to said bottom layer;    supplying a mold for a flange;    melting thermoplastic polyurethane material to form a liquid;    injecting said liquid into said mold;    heating said mold until said thermoplastic polyurethane is set;    opening said mold and cooling said flange;    defining an opening in said side gusset; and    welding said flange to said side gusset at said opening.