Abstract:
This invention relates to recreational flotation devices, and particularly to inflatable lounge chairs, and to methods for manufacturing same.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 62/195,218 filed Jul. 21, 2015 and entitled “METHOD FOR MANUFACTURE OF FLOATING LOUNGE CHAIR,” which is incorporated herein by reference in its entirety for all purposes. 
     
    
     TECHNICAL FIELD 
       [0002]    This invention relates to recreational flotation devices, and particularly to inflatable lounge chairs, and to a method for manufacturing same. 
       BACKGROUND 
       [0003]    Floating mattress, lounges, and the like are among the most popular beach and pool recreational devices. They typically comprise a relatively planar bladder that may have an inflatable raised portion , or pillow, at one end. More elaborate devices may take the shape of a chair that floats upright so that the user may assume a seated position. The manufacture of some known inflatable lounge chairs requires more than 20 welds and a custom welding table. 
         [0004]    Accordingly, there is a need for alternative inflatable lounge chairs and methods of manufacturing the same to reduce and simplify the manufacturing steps required to make them. 
       SUMMARY 
       [0005]    This invention relates to recreational flotation devices, and particularly to inflatable lounge chairs, and to a method for manufacturing same. 
         [0006]    Inflatable lounge chairs are generally described. According to one or more embodiments, the inflatable lounge chair may comprise first and second planar sheets, each comprising: an interior section; a periphery; and first and second cut-out portions proximate the periphery, each of the first and second cut-out portions comprising first and second edges defining a notch. The chair may further comprise a peripheral seam securing the first and second planar sheets at their peripheries. The first and second planar sheets may be folded such that the first and second edges of the first cut-out portions of each of the first and second planar sheets are in proximity with and secured to each other, and such that the first and second edges of the second cut-out portions of each of the first and second planar sheets are in proximity with and secured to each other. 
         [0007]    Methods of manufacturing an inflatable lounge chair are provided. According to one or more embodiments, the method may comprise the following steps: aligning a periphery of a first planar sheet with a periphery of a second planar sheet, wherein first and second cut-out portions of each of the first and second planar sheets each comprise first and second edges defining a v-shaped notch; securing the periphery of the first planar sheet to the periphery of the second planar sheet; folding the first and second planar sheets to bring the first and second edges of the first cut-out portions of each of the first and second planar sheets into proximity with each other; securing the first and second edges of the first cut-out portions of each of the first and second planar sheets to each other; folding the first and second planar sheets to bring the first and second edges of the second cut-out portions of each of the first and second planar sheets into proximity with each other; and securing the first and second edges of the second cut-out portions of each of the first and second planar sheets to each other. 
         [0008]    Other advantages and novel features of the present invention will become apparent from the following detailed description of various non-limiting embodiments of the invention when considered in conjunction with the accompanying figures. In cases where the present specification and a document incorporated by reference include conflicting and/or inconsistent disclosure, the present specification shall control. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    Non-limiting embodiments of the present invention will be described by way of example with reference to the accompanying figures, which are schematic and are not intended to be drawn to scale. In the figures, each identical or nearly identical component illustrated is typically represented by a single numeral. For purposes of clarity, not every component is labeled in every figure., nor is every component of each embodiment of the invention shown where illustration is not necessary to allow those of ordinary skill in the art to understand the invention. In the figures: 
           [0010]      FIG. 1A  is a perspective view of an inflatable lounge chair, in accordance with one or more embodiments; 
           [0011]      FIG. 1B  is an elevational view of the inflatable lounge chair as seen from the left side of  FIG. 1A , the right side elevational view being a mirror image thereof; 
           [0012]      FIG. 1C  is a top plan view of the inflatable lounge chair; 
           [0013]      FIG. 1D  is a front elevational view of the inflatable lounge chair; 
           [0014]      FIG. 2  is a drawing depicting the details of one of the two planar sheets that are welded together to form the chair; and 
           [0015]      FIG. 3  is a drawing illustrating the folding of the bladder into a cup-like configuration, prior to the final welding steps. 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    The present disclosure provides a simpler, more economical, yet effective method of constructing an inflatable lounge chair. 
         [0017]    According to one or more embodiments, one planar sheet is placed atop a second similarly shaped planar sheet, so that they may be welded together along their peripheries to form an inflatable bladder. By appropriately shaping and welding together the two sheets, as explained below, the uninflated bladder may be folded into a cup-like configuration having a seat portion, two side or arm portions , and a back portion, thus forming a floating lounge chair. Two additional welds will fix each side portion to the back portion to secure that bladder in that shape. As a result, fewer welding steps are required to form the chair. 
         [0018]    Turning to the figures, as shown in  FIGS. 1A-1D , an inflatable device made according to the method of the instant invention may be used as an inflatable lounge chair  5 . The chair  5  comprises two planar sheets  10 . A peripheral seam  21  (e.g. a welding seam) secures the two sheets  10  at their peripheries  40  to form a bladder. The planar sheets  10  are folded into a cup-shaped position with a seat portion  18 , two side or arm portions  24 , and a back portion  28 . According to some embodiments, an interior seam  23 , joining the two sheets  10  within their interior sections, defines the seat portion  18 . The seat portion  18  may define a first inflatable region  50  of the chair  5 . The first and second arm portions  24  and the back portion  28  may define a second inflatable region  55  of the chair  55 . The first and second inflatable regions may be fluidically isolated from one another. The interior seam  23  may create the fluidic isolation. 
         [0019]      FIG. 2  is a drawing depicting the details of one of the two planar sheets  10  that are secured (e.g. welded) together to form the chair  5 . Because both sheets  10  are substantially similar,  FIG. 2  represents either/both of the sheets  10 . 
         [0020]    The sheet  10  includes portions that will become the arm portions  24 , the seat portion  18 , and the back portion  28 . The sheet comprises an interior section  35  and a periphery  40 . The lines labeled  21  show where a peripheral seam will be formed, for example, through a welding process (which may include any appropriate heat-based joining process known in the art). The line labeled  23  shows where an interior seam may be formed. The interior seam  23  may define a seat portion  18  and an inflatable region  50  isolated from a separate inflatable region  55  defined by the arms and back portions  24  and  28 . Separate inflation valves  60  may be used to inflate or deflate the two inflatable regions  50  and  55 . 
         [0021]    Two sets of edges or tabs  20  (shown in  FIGS. 2-3 ) proximate to the periphery  40  of the sheets  10  may then be folded together and welded together to keep the chair  5  in the cup-shaped configuration shown in  FIGS. 1A-1D . 
         [0022]    The particulars of the construction technique may be understood by reference to  FIG. 2 , which depicts one of the two planar sheets  10 , each made of a weldable plastic material such as PVC. According to certain embodiments, the sheet  10  is cut to provide two cut-out portions  45  each having first and second edges  20  defining a v-shaped notch  12 . The cut-out portions  45  may be at approximately the three o′clock and nine o′clock positions, while other positioning is also possible. At the notches  12 , the two sheets  10  are welded together in such a way as to leave a strip of material , or tab, on the edges  20  of the cut-out portions  45  on each side of each notch  12 . The sheets  10  may now be folded into a cup-like shape by raising areas  24  and  28  to a position in which the edges  20  at each notch  12  overlap. The two edges  20  in each pair are then welded together to maintain the chair  5  in a cup-like position. 
         [0023]    As shown in  FIG. 2 , at the vertex of each v-shaped notch  12  an inwardly directed slit  30  may be cut to facilitate the folding and welding operation. Each slit  30  may culminate in a small circular cut-out area that will prevent the edges  20  from tearing at the inward end of the slit  30 . 
         [0024]    According to certain embodiments, before the second plastic sheet  10  of substantially similar or identical shape is positioned over the first sheet  10 , plastic beams may be positioned between the sheets  10  in the positions  22  shown in  FIG. 2 . For example, at least one plastic beam  22  may be positioned in each of the first and second arm portions  24 , the back portion  28 , and the seat portion  18 . Such plastic beams  22  provide stability and maintain the chair  5  in the desired shape when it has been inflated. The beams  22  are then welded between and to each of the sheets  10  and the sheets  10  are secured together at their peripheries  40  to make the peripheral seam  21 . 
         [0025]      FIG. 3  illustrates the folding of the sheets  10 , as indicated by the directional arrow into a cup-like configuration so that the edges  20  may be welded together. According to one or more embodiments a method for manufacturing an inflatable lounge chair  5  is as follows. A periphery  40  of the first planar sheet  10  may be aligned with a periphery  40  of the second planar sheet  10 . The first and second cut-out portions  45  of each of the first and second planar sheets  10  each comprise first and second edges  20  defining a v-shaped notch  12 . The periphery  40  of the first planar sheet  10  may be secured to the periphery  40  of the second planar sheet  10 , for example, through heat welding or a similar process. The first and second planar sheets  10  may be folded (as shown by the directional arrows in  FIG. 3 , for example) to bring the first and second edges  20  of the first cut-out portions  45  of each of the first and second planar sheets  10  into proximity with each other. The first and second edges  20  of the first cut-out portions  45  of each of the first and second planar sheets  10  may be secured to each other. These final steps may be repeated for the second cut-out portions  45  of each of the first and second planar sheets  10 . 
         [0026]    From the description of at least one embodiment of the present disclosure, various alternations, modifications and improvements will readily occur to those skilled in the art. Such alterations, modifications and improvements are intended to be within the scope and spirit of the disclosure. Accordingly, the foregoing description is by way of example only and is not intended to be limiting. 
         [0027]    While several embodiments of the present invention have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the functions and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the present invention. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings of the present invention is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, the invention may be practiced otherwise than as specifically described and claimed. The present invention is directed to each individual feature, system, article, material, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, and/or methods, if such features, systems, articles, materials, and/or methods are not mutually inconsistent, is included within the scope of the present invention. 
         [0028]    The indefinite articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.” 
         [0029]    The phrase “and/or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Other elements may optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified unless clearly indicated to the contrary. Thus, as a non-limiting example, a reference to 
         [0030]    “A and/or B,” when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A without B (optionally including elements other than B); in another embodiment, to B without A (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc. 
         [0031]    As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and/or” as defined above. For example, when separating items in a list, “or” or “and/or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e. “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.” “Consisting essentially of,” when used in the claims, shall have its ordinary meaning as used in the field of patent law. 
         [0032]    As used herein in the specification and in the claims, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, “at least one of A and B” (or, equivalently, “at least one of A or B,” or, equivalently “at least one of A and/or B”) can refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including elements other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc. 
         [0033]    In the claims, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of” and “consisting essentially of” shall be closed or semi-closed transitional phrases, respectively, as set forth in the United States 
         [0034]    Patent Office Manual of Patent Examining Procedures, Section 2111.03.