Patent ID: 6446289
Filing Date: 2002-09-10
Classification: A47C

Abstract:
A method of making an inflatable mattress of the type having an inner foam core and an outer fabric cover surrounding and enclosing the inner foam core forming an interior and with air spaces in the interior to allow inflating and deflating of the mattress, said method comprising:a) providing an inner foam core having closely spaced apart recesses and projections formed on a portion of an upper surface thereof; b) providing a bonding material surrounding said inner foam core of the type which will melt and enable a bonding of the foam core to an outer fabric material upon application of heat; c) surrounding the foam core and bonding material in an outer fabric material to provide a fully enclosed interior to the mattress with air spaces to allow inflating and deflating of the mattress through a valve structure; d) heating said bonding material and fabric material and to enable a bonding of the outer fabric material to the foam core; and e) simultaneously with the heating of the bonding material and fabric material causing a platen to press into an upper surface of said outer fabric material and simultaneously force the fabric into the plurality of closely spaced apart recesses causing a complete integral bonding of the fabric material to the foam core on the entire upper exterior surface having the recesses and projections, thereby defining an integral construction across a major portion of the upper exterior surface of said mattress with the recesses and the projections constituting the upper reclining surface so that air may flow between the mattress and a person reclining thereon to permit dissipation of body heat.