Method of constructing an inflatable support system having thermoplastic polyurethane constuction

Abstract

A method for constructing an inflatable support system by forming a first layer comprised of thermoplastic polyurethane and a second layer comprised of thermoplastic polyurethane. At least one coil is formed from thermoplastic polyurethane and a first end of the coil is attached to the first layer. A second end of the coil is attached to the second layer.

1 . 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.    
   
   
       2 . The method of  claim 1 , 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.  
   
   
       3 . The method of  claim 2 , 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.    
   
   
       4 . The method of  claim 2 , 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.  
   
   
       5 . The method of  claim 2 , 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.  
   
   
       6 . 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.    
   
   
       7 . The method of  claim 6 , 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.    
   
   
       8 . The method of  claim 7 , further comprising the step of attaching a valve to said flange.  
   
   
       9 . The method of  claim 6 , wherein said sheets of thermoplastic polyurethane are not thicker than 0.2 mm.  
   
   
       10 . The method of  claim 7 , wherein said welding steps are performed by sonic welding.  
   
   
       11 . The method of  claim 7 , wherein said welding steps are performed by heat welding.  
   
   
       12 . The method of  claim 6 , wherein said fabric is polyester.  
   
   
       13 . 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.