Patent ID: 6547911
Filing Date: 2003-04-15
Classification: A47C

Abstract:
A method of forming and sealing an air structure having a plurality of upper air nodes, a plurality of lower air nodes which oppose the plurality of upper air nodes and a plurality of air channels which are respectively and integrally connected to the plurality of upper and lower air nodes, the method comprising the steps of:a. providing a mold having a plurality of spaced apart frustum shaped nodes and a plurality of channels; b. providing a flexible first layer of material; c. positioning said first layer of material to a forming machine which retains said mold; d. actively heating said first layer of material; e. drawing said first layer of material against said mold; f. applying a vacuum against said mold to further push said first layer of material tightly into said mold so that said first layer of material forms into said plurality of frustum shaped nodes and said plurality of channels; g. cooling said first layer of material; h. providing a flexible second layer of material; i. positioning said second layer of material to said forming machine which retains said mold; j. actively heating said second layer of material; k. drawing said second layer of material against said mold; l. applying a vacuum against said mold to further push said second layer of material tightly into said mold so that said second layer of material forms into said plurality of frustum shaped nodes and said plurality of channels; m. cooling said second layer of material; n. providing a radio frequency (RF) device; o. positioning said second layer of material against said first layer of material and onto said RF device; p. applying a die tool against said first and second layers of materials to achieve a uniform contact; and q. welding said first and second layers of materials together by using said RF device to form said air structure with said plurality of upper air nodes, said plurality of lower air nodes and said plurality of air channels such that said plurality of upper air nodes are respectively opposing said plurality of lower air nodes.