Patent Publication Number: US-6217116-B1

Title: Slipcover with an inflatable pillow

Description:
PRIOR APPLICATION 
     This application is a divisional of Ser. No. 08/745,328 filed on Nov. 8,1996 entitled “Slipcover with an Inflatable Pillow” by Alexander Sloot now patent number 5,802,643. 
    
    
     FIELD OF THE INVENTION 
     The invention relates to an inflatable pillow which is used in conjunction with furniture, and more specifically with outdoor furniture. 
     BACKGROUND OF THE INVENTION 
     Inflatable appliques for creating unique articles are known in the art and include a variety of features for converting articles such as towels, shirts, coats, and displays into uniquely configured articles with novel shapes and uses. 
     There are several U.S. Patents which teach the attachment or addition of a pillow to a towel for use in, for example, sunbathing. U.S. Pat. No. 4,097,944 (Yulish) discloses a stuffed pillow which is permanently formed in the top portion of a towel. U.S. Pat. No. 4,200,942 (Case) and U.S. Pat. No. 3,689,947 (Wolf) teach a towel with a removable pillow which is either inflatable or stuffed. U.S. Pat. No. 2,883,682 (Kwake) teaches an inflatable pillow which is attachable and detachable from a towel using snapping means. 
     U.S. Pat. No. 3,176,315 (Freund) discloses a beach robe which doubles as a towel with an inflatable pillow. The article taught by Freund fails to teach a means for holding the pillow in place on a piece of furniture when the article is used in its towel configuration. 
     U.S. Pat No. 4,370,755 (Crumby) discloses a poncho which has a rear panel which can be inflated to create a seat cushion for sitting. Crumby fails to teach an inflatable pillow for the head for use on a piece of furniture which is held in place even when not in use. 
     I have previously obtained two U.S. Pat. Nos. 5,079,778 &amp; 5,251,337 for inflatable appliques for clothing and towels and a method for producing those appliques. Those patents describe the production of an inflatable applique on material by sealing the pieces of the applique to the material and cutting away the excess. Because many of the techniques and materials described in those patents are also useful in conjunction with the teachings herein disclosed, they are incorporated by reference. 
     What is desired, therefore, is a pillow which retains its position on a piece of furniture even when not engaged by someone sitting on the furniture. Preferably, the pillow could be used with outdoor chairs or lounges and would be cheaply produced, portable and waterproof, yet comfortable for the user. 
     SUMMARY OF THE INVENTION 
     Accordingly, it is an object of the invention to provide a slipcover for furniture that incorporates an inflatable pillow so that the pillow retains its position on a piece of furniture even when not in use. 
     Still another object of the invention is to provide a slipcover for furniture that contains an inflatable pillow and is relatively easily and inexpensively manufactured. 
     These and other objects are achieved by a first embodiment in accordance with the invention in which a slipcover is formed from a first sheet having an outer fabric layer that is attached to an inner thermoplastic layer. A second, smaller sheet is attached to the inner thermoplastic layer of the first sheet, and is fitted with a valve so as to form an inflatable pillow. The valve may also be located so that it pierces the first sheet so as to enable inflation outside the slipcover. A backing layer is attached to the first sheet to create a pocket-shaped slipcover inside of which is the inflatable pillow. The backing layer can be an extension of the first sheet which is folded over so that the inner thermoplastic layer overlaps itself, and the inflatable pillow, and is attached at opposing edges to form the pocket shape of the slipcover. Alternatively, a separate backing layer can be attached to cover the inflatable pillow and form the slipcover. The slipcover can then be slipped over a portion of a piece of furniture, such as the back of an arm chair, and thus, hold the inflatable pillow in place whether or not a person occupies the furniture. 
     Preferably, the outer fabric layer is made from a soft, water-absorbing material like terry cloth affixed to an inner thermoplastic layer made from vinyl. The outer fabric provides comfort to the user, since the user&#39;s head will not be in direct physical contact with the vinyl layer of the inflatable pillow, and further enables fast, economic processing. 
     Also preferably, when polymeric materials are used for the appropriate pieces, the process employed to attach the different components is either radio frequency (RF) sealing or sonic sealing. These methods both allow fast processing times and form strong, air impenetrable seals required for the inflatable pillow. 
     In a second embodiment, the slipcover with inflatable pillow can be formed by attaching an entirely fabric slipcover to a vinyl material inflatable pillow. The fabric is preferably either a cloth material such as T-shirting or terry cloth or a spunbonded polyolefin such as Tyvek™. This provides additional options for processing, starting materials, and final look of the slipcover with inflatable pillow. 
     In another aspect of the invention, the slipcover with its inflatable pillow is transformed into a tote bag. This is achieved by folding the slipcover and pillow to bisect the pillow and adding holes positioned so that when the slipcover is folded they align to create a handle at the open end of the slipcover. 
    
    
     These and other objects and advantages of the invention will become apparent from the following detailed description considered with reference to the accompanying drawings. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a front isometric view of a first embodiment of a slipcover with an inflatable pillow in accordance with the invention. 
     FIG. 2 a front isometric view of a first sheet, with an inner layer of thermoplastic material facing up, used to form the slipcover with inflatable pillow in accordance with the invention. 
     FIG. 3 is an exploded front isometric view of the different components of the slipcover with inflatable pillow to illustrate the spatial relationship between the components prior to forming the slipcover. 
     FIG. 4 is a front isometric view of a completed inflatable pillow a attached to the inner layer of the first sheet to illustrate the location and direction for folding the first sheet to form the slipcover. 
     FIG. 5 is a front isometric view of an alternative configuration of the slipcover with inflatable pillow of FIG.  1 . 
     FIG. 6 is a side isometric view of an alternative method for forming the slipcover with inflatable pillow of FIG.  1 . 
     FIG. 7 is a cross-sectional view of the slipcover with inflatable pillow, taken along line VII—VII in FIG. 1, to illustrate the positioning of the inflatable pillow on the slipcover and the different layers of materials from which the first sheet is formed. 
     FIG. 8 is a front isometric view of the slipcover with inflatable pillow in place on an outdoor lounge chair in accordance with the invention. 
     FIG. 9 is an exploded front isometric view of the different components of a second embodiment of a slipcover with an inflatable pillow in accordance with this invention. 
     FIG. 10 is an exploded front isometric view of an alternative method for forming the slipcover with the inflatable pillow of FIG  9 . 
     FIG. 11 is a front isometric view of a slipcover, with an inflatable pillow inside (indicated by ghost lines), to illustrate an optional method for forming the slipcover of FIG. 9 
     FIG. 12 is a front isometric view of a slipcover, with an inflatable pillow inside (indicated by ghost lines), to illustrate a second optional method for forming the slipcover of FIG.  9 . 
     FIG. 13 is a front isometric partially broken away view of an alternative configuration of the inflatable pillow of FIGS. 1,  4 - 8 , and  10 - 12  to illustrate the interconnected chambers created in the inflatable pillow. 
     FIG. 14 a front elevation view of an optional addition to the slipcovers in accordance with this invention to create a tote. 
     FIG. 15 is a front elevation view of the tote in FIG. 14 opened to allow its use as a slipcover with inflatable pillow. 
     FIG. 16 is a front elevation view of the tote of FIG. 14 in use. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     With reference to FIGS. 1 and 8, a slipcover  20  is shown with an inflatable pillow  22  in accordance with the invention to hold the inflatable pillow  22  in place on furniture, such as a lounge chair  24 , whether or not the chair is in use. Slipcover  20  is a pocket  23  that enables slipcover  20  to be slipped over the back  25  of chair  24  to hold inflatable pillow  22  in place. Slipcover  20  with its inflatable pillow  22 , typically may be used on outdoor furniture as illustrated in FIG. 8; it is understood, however, that a slipcover of this invention can be used on other types of furniture such as on the back of a chair in an airplane, office or car. 
     FIGS. 2-4 illustrate the construction of a first embodiment of a slipcover  20  in accordance with the invention. A first sheet  26  is formed and includes two layers,  28  and  30 , that are attached together either along edges or otherwise adhered so as to form a laminate. Outer layer  28  is a fabric layer for the comfort of the user. The fabric can be any desired for the intended use of the slipcover  20 , but is preferably a durable, soft, water-absorbing material, such as terry cloth. The fabric can be printed for decoration, for an indication of ownership, or for advertising. 
     Inner layer  30  is a thermoplastic layer that is suitable for forming one side of inflatable pillow  22 . Although inner layer  30  can be formed from any sufficiently air impermeable material, preferably it is formed from a vinyl sheeting material, expanded vinyl, supported vinyl, neoprene compounds, polypropylene, polyethylene, polyesters, nylons, polyamides, rubber or rubber compounds. The most preferred material is vinyl sheeting as it is simple and cost effective to use in the construction of slipcover  20 . 
     A second, smaller sheet  32  constitutes the other side of inflatable pillow  22 . Second, smaller sheet  32  is formed from similar material as that used for inner layer  30 . Again the preferred material is vinyl sheeting. 
     As illustrated in FIGS. 3 and 4, second, smaller sheet  32  is attached to inner layer  30  of first sheet  26  to form inflatable pillow  22 . Any means of attaching the sheets is sufficient so long as air is not leaked when pillow  22  is inflated. Preferably second, smaller sheet  32  is sealed or welded to inner layer  30  using radio frequency sealing (RF sealing), sonic sealing, heat sealing, gluing or similar operations. Because RF sealing is fast and cost effective, it is the preferred means of attaching the two sheets when the materials are compatible with the RF sealing operation. 
     In either first sheet  26  or second, smaller sheet  32 , a valve  34  is located to enable the inflation of inflatable pillow  22  when formed. Although all of the figures illustrate the placement of valve  34  in first sheet  26 , at a position which enables the inflation of inflatable pillow  22 , it is not necessary to locate valve  34  on first sheet  26 . So long as first sheet  26  is of sufficient flexibility that a valve  34  located in second, smaller sheet  32 , inside slipcover  20 , can be reached to inflate pillow  22 , valve  34  can be located in second, smaller sheet  32  to insure maximum comfort when slipcover  20  is in use. Valve  34  preferably is made of a material that is compatible with the materials of sheets  26  and  32 , and is properly placed for comfort. Preferably valve  34  will either be a positive sealing valve or a stem valve as illustrated in my prior patents (U.S. Pat. Nos. 5,079,778 and 5,251,337). 
     The method for forming slipcover  20  is dependent on the size of first sheet  26  and the placement of second, smaller sheet  32  in relation to first sheet  26 . Typically, inflatable pillow  22  is attached to first sheet  26  off center such that when first sheet  26  is folded along fold  36 , a backing layer  42  is formed from the portion of first sheet  26  opposite inflatable pillow  22 . 
     When first sheet  26  is folded along fold  36 , inner layer  30  of first sheet  26  overlaps itself to completely encase inflatable pillow  22 , see FIG.  4 . FIG. 7 illustrates the location of the different components of slipcover  20  with respect to each other after folding first sheet  26  along fold  36 . opposed edges  40  of first sheet  26  are attached so as to form pocket  23  of slipcover  20  with its inflatable pillow  22  which has at least one opening  37  in slipcover  20  to enable the slipping of slipcover  20  over chair  24  to envelope the back  25  of chair  24 , as illustrated in FIG.  1 . 
     The method used to attach the opposed edges  40  of first sheet  26  should be sufficient to create a slipcover which can withstand the type of use slipcover  20  with its inflatable pillow  22  is intended to endure. The edges can be sewn, RF sealed, sonic sealed, heat sealed, glued, or the like, depending on the materials chosen to form first sheet  26 . Preferably, when inner layer  30  is formed from vinyl, RF sealing or sonic sealing is employed. 
     First sheet  26  is either folded to exactly bisect its longitudinal axis so that the edges of first sheet  26  at opening  37  meet (FIG. 1) or offset so that the edges of first sheet  26  at opening  37  are askew (FIG.  5 ). 
     As depicted in FIG. 8, slipcover  20  with its inflatable pillow  22  can now be slipped over a back  25  of a chair  24  and will hold inflatable pillow  22  in place whether or not in use. 
     An alternative method for forming slipcover  20  described in the first embodiment is illustrated in FIG.  6 . In this method, instead of folding first sheet  26  a backing layer  42  is attached to inner layer  30  of first sheet  26  so as to create pocket  23  of slipcover  20 . As illustrated in FIG. 6, first sheet  26 , with attached inflatable pillow  22 , is placed in register with a separate backing layer  42 . Opposed edges  40  are attached to form pocket  23  of slipcover  20 . The same methods taught above to attach opposed edges  40  of first sheet  26  to form slipcover  20  above, can also be employed here for attaching backing layer  42  to first sheet  26 . Backing layer  42  can be formed from any material which is compatible with the desired use of slipcover  20 . For example, backing layer  42  can be formed from any type of fabric, a thermoplastic material like those used to form inner layer  30 , or a laminate thereof. Preferably, both backing layer  42  and inner layer  30  are formed from vinyl sheeting and are RF sealed or sonic sealed at opposing edges  40  to form pocket  23 . 
     A second embodiment for slipcover  20  is illustrated in FIG.  13 . This second embodiment incorporates the use of an entirely fabric slipcover  20  and an inflatable pillow  22  which is constructed from two separate thermoplastic pieces. First sheet  100  is formed from fabric. Although any fabric can be used depending on the intended use of the slipcover  20 , preferably a soft, water-absorbing material will be employed which could contain polyester, cotton or a blend thereof. Most preferably fabric sheet  100  will be formed from terry cloth made from polyester, cotton or a blend thereof. If, however, a more economical or disposable slipcover  20  is desired, fabric sheet l 00  could be formed from, for example, a spunbonded polyolefin or olefin material such as Tyvek™(a Dupont material). 
     A valve  102  is placed in a first piece of thermoplastic material  104 . Valve  102  can be any type compatible with the materials, but is preferably either a positive sealing valve or a stem valve. A second piece of thermoplastic material  106 , sized similar to first piece of thermoplastic material  104 , is placed in register with first piece of thermoplastic material  104 . Formation of inflatable pillow  22  can happen using two optional methods. In a first method, illustrated in FIG. 10, first piece of thermoplastic material  104  and second piece of thermoplastic material  106  are attached to construct inflatable pillow  22  separate from fabric sheet  100 . After constructing inflatable pillow  22 , it is attached to fabric sheet  100  using RF sealing, sonic sealing, heat sealing, sewing, gluing, adhering, or the like. 
     FIG. 9 illustrates a second method, in which fabric sheet  100  is placed in register with second piece of thermoplastic material  106  in register with first piece of thermoplastic material  104 , and all three pieces are attached in a single operation. The means used to attach the different pieces can be any which will form an air tight inflatable pillow  22  that is sufficiently attached to fabric sheet  100  for its intended use. The pieces can be attached by RF sealing, sonic sealing, heat sealing, gluing or any combination thereof. If fabric sheet  100  is made from cotton material, the preferred method is RF sealing. If fabric sheet  100  is made from polyester or a blend thereof, preferably either RF sealing or sonic sealing is used. 
     Processing fabric sheet  100  into slipcover  20  is substantially the same as that described above in the first embodiment for forming a slipcover having a two-layered first sheet  26 . Either fabric sheet  100  can be folded or a backing layer  42  can be employed to create opposing edges  40  which are attached by sewing, RF sealing, sonic sealing, heat sealing, gluing, adhering, or any combination thereof. If RF or sonic sealing are employed, a strip  108  of vinyl sheeting is placed between opposing edges  40 , or around so as to encase opposing edges  40 , of fabric sheet  100  to provide a means for adhering those edges. If fabric sheet  100  is formed from Tyvek™, a strip  108  of adhesive could be employed either between or around the opposing edges to form pocket  23 . 
     An alternative configuration of inflatable pillow  22  is illustrated in FIG.  13 . In FIG. 13, inner layer  30 , or first piece of thermoplastic material  104 , is attached to second, smaller sheet  32 , or second piece of thermoplastic material  106 , at several locations to create a quilted effect of interconnected chambers  110 . Quilted effect of interconnected chambers  110  can be accomplished using any means which creates portions  112  where inner layer  30  is attached to second, smaller sheet  32  while ensuring that all detached portions  114  of inflatable pillow  22  are interconnected so that air entering valve  34  can reach all detached portions  114 . For example, inner layer  30  can be RF, sonic, or heat sealed to second, smaller sheet  32  at all locations which are intended to create attached portions  112 , thus forming interconnected chambers  110 . 
     Additionally, the inventive slipcover  20  with inflatable pillow  22  is not limited to the use of a single inflatable pillow where both the slip cover and inflatable pillow have the shapes illustrated in the accompanying drawings. Multiple inflatable pillows  22  may be affixed to slipcover  20  for a desired use or design. Likewise, the shape of slip cover  20  and inflatable pillow  22  may be any which is desired for the intended use (e.g. a lumbar support, decorative headrest) but which continues to operate in such a manner that inflatable pillow(s)  22  are held at the desired location on the furniture by slipcover  20 . 
     An optional addition to slipcover  20  with its inflatable pillow  22  is a handle  120  which converts slipcover  20  with a deflated inflatable pillow  22  into a tote  122 . FIGS. 15 and 16 illustrate the removal of four oblong holes  124  near opening  37  of slipcover  20 , aligned so that when slipcover  20  with its inflatable pillow  22  is folded along a line  126  which bisects inflatable pillow  22  (FIG.  15 ), a single handle  120  is formed, FIG.  14 . Therefore, when folded into tote  122 , articles can be stored in both sections of the interior of slipcover  20  and carried as illustrated in FIG.  16 . 
     Although the invention has been described with reference to a particular arrangement of parts, features and the like, these are not intended to exhaust all possible arrangements or features, and indeed many other modifications and variations will be ascertainable to those of skill in the art.