(19) United States
`(2) Patent Application Publication (10) Pub. No.: US 2013/0230671 A1
`(43) Pub. Date:
`Sep. 5, 2013
`Lin et al.
`
`US 20130230671A1
`
`(54) INTERNAL TENSIONING STRUCTURE
`USEABLE WITH INFLATABLE DEVICES
`
`(71) Applicant: INTEX RECREATION CORP., Long
`Beach, CA (US)
`(72) Inventors: Hua Hsiang Lin, Fujian (CN); Yaw
`Yuan Hsu, Fujian (CN)
`(73) Assignee: INTEX RECREATION CORP., Long
`Beach, CA (US)
`(21) Appl. No.: 13/727,143
`
`Publication Classification
`
`(51) Int. Cl.
`A47C 27/08
`(52) U.S. CI.
`CPC .................................... A47C27/081 (2013.01)
`USPC ..…. 428/12
`
`(2006.01)
`
`(57)
`
`ABSTRACT
`
`(22) Filed:
`
`Dec. 26, 2012
`Related U.S. Application Data
`(63) Continuation of application No. PCT/US2012/
`042079, filed on Jun. 12, 2012.
`Foreign Application Priority Data
`
`(30)
`
`Mar. 2, 2012 (CN) ......................... 20121.0053146.3
`Mar. 2, 2012 (CN) ........................ 20121.00531.83.X
`Mar. 2, 2012 (CN) ......................... 201220075738.0
`Mar. 2, 2012 (CN) ......................... 201220075742.7
`
`
`
`An internal tensioning structure for use in an inflatable prod
`uct fulfills the basic function of maintaining two adjacent
`inflatable surfaces in a desired geometric arrangement when
`the inflatable product is pressurized. The tensioning structure
`is formed by connecting a pair of plastic strips sheets via
`spaced-apart strands, such as strings or wires. When pulled
`taut, the strands provide a high tensile strength between the
`two opposed plastic strips. At the same time, the plastic strips
`facilitate a strong, long-lasting weld between the tensioning
`structure and the inflatable product.
`
`10
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`INTERNAL TENSIONING STRUCTURE
`USEABLE WITH INFLATABLE DEVICES
`
`RELATED APPLICATIONS
`[0001] This application is a continuation of PCT Applica
`tion Serial No. PCT/US2012/042079, filed Jun. 12, 2012,
`which claims priority to Chinese Patent Application Serial
`No. 201210053183.X, filed Mar. 2, 2012, Chinese Patent
`Application Serial No. 201210053146.3, filed Mar. 2, 2012,
`Chinese Patent Application Serial No. 201220075738.0, filed
`Mar. 2, 2012, and Chinese Patent Application Serial No.
`201220075742.7, filed Mar. 2, 2012 and the disclosures of
`which are expressly incorporated by reference herein.
`
`BACKGROUND
`[0002] 1. Technical Field
`[0003] The present disclosure relates to an inflatable prod
`uct structure, and in particular to an inflatable product struc
`ture which is light in weight and low in cost.
`[0004] 2. Description of the Related Art
`[0005] Inflatable products, are light in weight, easy to
`house, and easy to carry. Such products technologies have
`been used for outdoor items and toys, as well as various
`household goods including inflatable beds, inflatable sofas
`and the like.
`[0006] Many inflatable products utilize internal structures
`in order to form the product into its intended, predetermined
`shape upon inflation. For example, one type of inflatable bed,
`referred to as a wave-shaped, straight-strip or I-shaped inflat
`able bed, may include a tension-band type internal structure
`arranged along wave-shaped, straight-line or I-shaped path
`ways within the internal cavity. Another type of inflatable
`bed, referred to as a column-type inflatable bed, has tension
`bands arranged into honeycomb-shaped or cylindrical struc
`tures within the inflatable cavity.
`[0007] These internal tension-band structures disposed in
`the cavity of the inflatable bed give shape to the bed as internal
`pressure increases, thereby preventing the inflatable bed from
`expanding evenly on all sides in the manner of a balloon.
`More particularly, in order to maintain an inflatable bed as a
`rectangular shape, the tension bands join the upper and lower
`surfaces of the inflatable bed to one another. To allow passage
`of pressurized air to both sides of these joining structures, the
`tension bands may be formed as belts stretching between the
`upper and lower surfaces, or as vertical expanses of material
`with air columns formed therein. The number and spacing of
`the tension bands is proportional to the sharpness of the
`rectangularity of the inflated product. That is to say, a greater
`number and/or linear extent of tension bands within the pres
`surized cavity results in a more “flat” bed surface.
`[0008] In conventional inflatable products such as the
`inflatable beds described above, the tension bands are made
`of PVC sheets with a sufficient thickness to ensure spreading
`of force and concomitant reductions in stress in the product
`material. For example, the tension bands of known inflatable
`beds or sofas may have a thickness of about 0.36 mm. For
`some known water carrier devices, such as inflatable swim
`ming pools, the internal tension bands may have a thickness
`of about 0.38 mm, while “sandwich’’ type inflatable swim
`ming pools may have a thickness of 0.7–0.8 mm.
`[0009] Thus, conventional inflatable structures utilizing
`belt- or sheet-like PVC tension bands meet the force require
`ments of the product by varying the thickness of the tension
`
`bands. However, where continuous plastic strips or belts are
`utilized, such tension bands contribute to increased weight of
`the inflatable product. Similarly, an increase in thickness
`and/or spatial density of solid-strip tension bands also
`increases the compressed/folded volume of the deflated
`inflatable structure.
`
`SUMMARY
`[0010] The present disclosure provides an internal tension
`ing structure for use in an inflatable product, and a method for
`producing the same. The tensioning structure fulfills the basic
`function of maintaining two adjacent inflatable surfaces in a
`desired geometric arrangement when the inflatable product is
`pressurized. The tensioning structure is formed by connecting
`a pair of plastic strips sheets via spaced-apart strands, such as
`strings or wires. When pulled taut, the strands provide a high
`tensile strength between the two opposed plastic strips. At the
`same time, the plastic strips facilitate a strong, long-lasting
`weld between the tensioning structure and the inflatable prod
`uct.
`[0011] Various configurations of the tensioning structure
`are contemplated within the scope of the present disclosure.
`In one embodiment, a pair of parallel plastic strips has a
`plurality of strands extending therebetween to connect the
`plastic strips to one another, with the strands substantially
`parallel to one another and substantially perpendicular to the
`plastic strips. In another embodiment, a similar arrangement
`of two parallel plastic strips are connected by a plurality of
`strands with each adjacent pair of such strands converging to
`a point at one of the plastic strips in a “V” configuration.
`Either embodiment may be incorporated into a tensioning
`structure with one of a number of geometric arrangements
`within the inflatable cavity, such as linear, cylindrical, wave
`shaped, etc.
`[0012] According to one embodiment thereof, the present
`disclosure provides an inflatable product comprising: a first
`sheet and a second sheet disposed opposite the first sheet, the
`first and second sheets spaced apart to define a gap when the
`inflatable product is inflated. The inflatable product further
`includes a tensioning structure having a gap portion spanning
`the gap between the first sheet and the second sheet to main
`tain a spatial relationship between the first and second sheets
`when the inflatable product is inflated. The gap portion has an
`extent measured along the surface of at least one of the first
`sheet and the second sheet. The gap portion occupies a vol
`ume and has an operable area occupied by gap portion of the
`tensioning structure defined as the total area of the gap
`between the first sheet and the second sheet, as measured
`along the extent of the gap portion of the tensioning structure.
`The gap portion of the tensioning structure defines an oper
`able area-to-volume ratio of at least 10 square millimeters per
`cubic millimeter.
`[0013] According to another embodiment thereof, the
`present disclosure provides an inflatable product comprising:
`a first sheet and a second sheet disposed opposite the first
`sheet. The first and second sheets are spaced apart to define a
`gap when the inflatable product is inflated. The inflatable
`product further includes a tensioning structure having a gap
`portion spanning the gap between the first sheet and the
`second sheet to maintain a spatial relationship between the
`first and second sheets when the inflatable product is inflated.
`The gap portion has an extent measured along the surface of
`at least one of the first sheet and the second sheet. The gap
`portion has an operable area occupied by gap portion of the
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`tensioning structure defined as the total area of the gap
`between the first sheet and the second sheet, as measured
`along the extent of the gap portion of the tensioning structure.
`The gap portion of the tensioning structure has a total weight
`such that the tensioning structure defines an operable area-to
`weight ratio of at least 6,000 square centimeters per kilogram.
`[0014] According to another embodiment thereof, the
`present disclosure provides an inflatable product comprising:
`a first sheet and a second sheet disposed opposite the first
`sheet. The first and second sheets are spaced apart to define a
`gap when the inflatable product is inflated; The inflatable
`product further comprises a tensioning structure having a gap
`portion spanning the gap between the first sheet and the
`second sheet to maintain a spatial relationship between the
`first and second sheets when the inflatable product is inflated.
`The gap portion of the tensioning structure has an average
`thickness of less than 0.125 millimeters.
`[0015] According to yet another embodiment thereof, the
`present disclosure provides an inflatable product comprising:
`a first sheet; a second sheet disposed opposite the first sheet,
`the first and second sheets spaced apart to define a gap; a
`tensioning structure spanning the gap between the first sheet
`and the second sheet, the tensioning structure comprising: a
`plurality of strands uniformly spaced apart and arranged sub
`stantially parallel to one another; and a plurality of weld strips
`spaced apart from one another and substantially perpendicu
`lar to the plurality of strands, each of the plurality of weld
`strips affixed to each of the plurality of strands, and each of the
`plurality of weld strips affixed to at least one of the first sheet
`and the second sheet.
`[0016] According to still another embodiment thereof, the
`present disclosure provides an inflatable product comprising:
`a first sheet; a second sheet disposed opposite the first sheet,
`the first and second sheets spaced apart to define a gap; a
`tensioning structure spanning the gap between the first sheet
`and the second sheet, the tensioning structure comprising: a
`plurality of strands uniformly spaced apart and arranged in
`parallel; and a first weld sheet having the plurality of strands
`affixed to an upper surface of the first weld sheet.
`[0017] According to still another embodiment thereof, the
`present disclosure provides an inflatable product comprising:
`a first sheet; a second sheet disposed opposite the first sheet,
`the first and second sheets spaced apart to define a gap; a
`tensioning structure spanning the gap between the first sheet
`and the second sheet, the tensioning structure comprising: an
`upper weld strip; a lower weld strip arranged substantially
`parallel to the upper weld strip and spaced apart from the
`upper weld strip span the gap between the first sheet and the
`second sheet; and a plurality of end-to-end V-shaped strands
`arranged between weld strips, each of the V-shaped strands
`having upper and lower ends fixed to the upper and lower
`weld strips, respectively.
`[0018] According to still another embodiment thereof, the
`present disclosure provides an inflatable product comprising:
`a first sheet; a second sheet disposed opposite the first sheet,
`the first and second sheets spaced apart to define a gap, the
`first sheet and the second sheet cooperating to at least partially
`bound an inflatable chamber; a plurality of tensioning struc
`tures welded to respective inner surfaces of the first and
`second sheets such that the plurality of tensioning structure
`span the gap, each of the plurality of tensioning structures
`comprising: an upperweld strip affixed to one of the first sheet
`and the second sheet; a lower weld strip affixed to the other of
`
`the first sheet and the second sheet; and a plurality of strands
`connecting the upper and lower weld strips to one another.
`[0019] According to still another embodiment thereof, the
`present invention provides an inflatable product comprising:
`a first sheet; a second sheet disposed opposite the first sheet,
`the first and second sheets spaced apart to define a gap, the
`first sheet and the second sheet cooperating to at least partially
`bound an inflatable chamber; a plurality of tensioning struc
`tures welded to inner surfaces of the first and second sheets
`such that the plurality of tensioning structures span the gap,
`each of the plurality of tensioning structures comprising: a
`weld sheet; a plurality of strands, and the plurality of strands
`substantially evenly spaced and arranged substantially paral
`lel to one another, the plurality of strands affixed to the weld
`sheet; and a weld strip affixed to each end of the weld sheet
`such that a longitudinal extent of the weld strip is substan
`tially perpendicular to the plurality of strands, respective ends
`of the plurality of strands are affixed to the weld strip, and
`each of the weld strips are welded to one of the first sheet and
`the second sheet.
`[0020] According to still another embodiment thereof, the
`present invention provides a method for producing a tension
`ing structure of an inflatable product, the method comprising:
`arranging at least one of a welder and an adhesive device
`downstream of a strand guide; supplying a plurality of strands
`to the welder or the adhesive device via the strand guide, such
`that the supplied strands are substantially uniformly spaced
`apart and arranged substantially parallel to one another; posi
`tioning weld strips on a first die of the welderor gluing device,
`the weld strips having a longitudinal extent corresponding to
`an overall width of the plurality of strands; advancing a sec
`ond die of the welder or gluing device into an operable posi
`tion in which the first and second dies are disposed at oppos
`ing sides of the weld strips, activating the welder or gluing
`device to fixedly connect the weld strips to the plurality of
`strands, such that the weld strips are affixed to the plurality of
`strands in a spaced apart and substantially parallel arrange
`ment, and such that the weld strips are substantially perpen
`dicular to the plurality of strands.
`[0021] According to still another embodiment thereof, the
`present invention provides a method for producing a tension
`ing structure of an inflatable product comprises: arranging a
`hot roller downstream of a strand guide; supplying a plurality
`of strands to the hot roller via the strand guide, such that the
`supplied strands are substantially uniformly spaced apart and
`arranged substantially parallel to one another; arranging a
`conveying roller downstream of the strand guide, the convey
`ing roller operable to deliver at least one weld sheet to the hot
`roller, the at least one weld sheet having a width correspond
`ing to an overall width of the plurality of strands; and passing
`the plurality of strands and the at least one weld sheet through
`the hot roller, such that the plurality of strands become affixed
`to the at least one weld sheet.
`[0022] According to still another embodiment thereof, the
`present invention provides a method for producing a tension
`ing structure, the method comprising: arranging a first pair of
`weld strips parallel to one another on a joining device; wrap
`ping at least one continuous strand around a plurality of
`members arranged along a pair of rows adjacent the first pair
`of weld strips, respectively, each of the pair of rows of mem
`bers offset with respect to the other of the pair of rows of
`members, the step of wrapping comprising alternating
`between the pair of rows, such that the at least one continuous
`strand forms a plurality of end-to-end V-shaped strands; and
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`using the joining device to join the first pair of weld strips to
`the plurality of strands at respective V-shaped corners formed
`by the at least one continuous strand, such that the tensioning
`structure has a tensile strength along a direction perpendicu
`lar to a longitudinal extent of the first pair of weld strips.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`[0023] The above mentioned and other features and advan
`tages of this disclosure, and the manner of attaining them, will
`become more apparent and the invention itself will be better
`understood by reference to the following description of
`embodiments of the invention taken in conjunction with the
`accompanying drawings, wherein:
`[0024] FIG. 1 is an exploded, perspective view of an inflat
`able structure incorporating a tensioning structure made in
`accordance with the present disclosure;
`[0025] FIG. 2 is an enlarged perspective view of the ten
`sioning structure shown in FIG. 1;
`[0026] FIG. 3 is an exploded, perspective view of an inflat
`able bed incorporating tensioning structures made in accor
`dance with the present disclosure;
`[0027] FIG. 4 is an assembled view of the inflatable bed of
`FIG. 3, in which the inflatable bed material is made transpar
`ent to show the internal arrangement of the tensioning struc
`tures;
`[0028] FIG. 5 is an exploded, perspective view of an inflat
`able bed incorporating an alternative geometric arrangement
`of tensioning structures made in accordance with the present
`disclosure;
`[0029] FIG. 6 is an assembled view of the inflatable bed of
`FIG. 5, in which the inflatable bed material is made transpar
`ent to show the internal spatial arrangement of the tensioning
`structures;
`[0030] FIG. 7 is a perspective view of an apparatus for
`producing bulk material for the tensioning structures shown
`in FIGS. 3-6,
`[0031] FIG. 8 is an exploded, perspective view showing a
`first embodiment of the bulk material created by the apparatus
`of FIG. 7;
`[0032] FIG. 9 is a perspective view showing a first embodi
`ment of the bulk material created by the apparatus of FIG. 7;
`[0033] FIG. 10 is a perspective view showing a second
`embodiment of the bulk material created by the apparatus of
`FIG. 7;
`[0034] FIG. 11 is a perspective view showing a second
`embodiment of the bulk material created by the apparatus of
`FIG. 7;
`[0035] FIG. 12 is an exploded, perspective view of a first
`alternative tensioning structure made in accordance with the
`present disclosure;
`[0036] FIG. 13 is an assembled, perspective view of the first
`alternative tensioning structure shown in FIG. 12;
`[0037] FIG. 14 is an exploded, perspective view of a second
`alternative tensioning structure made in accordance with the
`present disclosure;
`[0038] FIG. 15 is an exploded, perspective view of a third
`alternative tensioning structure made in accordance with the
`present disclosure;
`[0039| FIG. 16 is an assembled, perspective view of the
`third alternative tensioning structure shown in FIG. 15;
`[0040] FIG. 17 is an exploded, perspective view of a fourth
`alternative tensioning structure made in accordance with the
`present disclosure;
`
`[0041] FIG. 18 is an exploded, perspective view of a fifth
`alternative tensioning structure made in accordance with the
`present disclosure;
`[0042] FIG. 19 is an assembled, perspective view of the
`fifth alternative tensioning structure shown in FIG. 18;
`[0043] FIG. 20 is an exploded, perspective view of an
`inflatable bed incorporating alternative tensioning structures
`made in accordance with the present disclosure;
`[0044] FIG. 21 is an assembled view of the inflatable bed of
`FIG. 22, in which the inflatable bed material is made trans
`parent to show the internal arrangement of the tensioning
`structures;
`[0045] FIG. 22 is an exploded, perspective view of an
`inflatable bed incorporating an alternative tensioning struc
`tures made in accordance with the present disclosure, config
`ured in an alternative geometric arrangement;
`[0046] FIG. 23 is an assembled view of the inflatable bed of
`FIG. 22, in which the inflatable bed material is made trans
`parent to show the internal spatial arrangement of the tension
`ing structures;
`[0047] FIG. 24 is a perspective view of an apparatus for
`producing bulk material for the first through fifth alternative
`tensioning structures shown in FIGS. 12-19;
`[0048] FIG. 25 is an exploded, perspective view of a sixth
`alternative tensioning structure made in accordance with the
`present disclosure;
`[0049] FIG. 26 is an assembled, perspective view of the
`sixth alternative tensioning structure shown in FIG. 25;
`[0050 FIG. 27 is an exploded, perspective view of an
`inflatable bed incorporating the sixth alternative tensioning
`structure shown in FIG. 25;
`[0051] FIG. 28 is an assembled view of the inflatable bed of
`FIG. 27, in which the inflatable bed material is made trans
`parent to show the internal arrangement of the tensioning
`structures;
`[0052] FIG. 29 is a perspective view of an apparatus for
`producing bulk material for the sixth alternative tensioning
`structures shown in FIGS. 25-28;
`[0053] FIG. 30 is an exploded, perspective view of a sev
`enth alternative tensioning structure made in accordance with
`the present disclosure;
`[0054] FIG. 31 is an assembled, perspective view of the
`seventh alternative tensioning structure shown in FIG. 30;
`[0055] FIG. 32 is a perspective view of an apparatus for
`producing bulk material for the seventh alternative tensioning
`structures shown in FIGS. 30 and 31:
`[0056] FIG. 33 is a top plan view of portions of tensioning
`structures bunched together during a welding process;
`[0057] FIG. 34 is a top plan view of portions of a tensioning
`structure collapsed when the mattress is deflated for storage
`or shipment;
`[0058] FIG. 35 is a view similar to FIG. 33 showing por
`tions of tensioning structures with strands placed in piles
`during a welding process; and
`[0059 FIG. 36 is a view similar to FIG. 33 showing por
`tions of tensioning structures shifted relative to each other
`during a welding process.
`[0060] Corresponding reference characters indicate corre
`sponding parts throughout the several views. The exemplifi
`cations set out herein illustrate exemplary embodiments of
`the present invention, and such exemplifications are not to be
`construed as limiting the scope of the invention in any man
`Iler.
`
`BESTWAY EXHIBIT 1010-0032
`IPR2017-01655
`
`

`

`US 2013/0230671 A1
`
`Sep. 5, 2013
`
`DETAILED DESCRIPTION
`[0061] The present disclosure provides tensioning struc
`tures which give shape to inflatable devices, such as inflatable
`couches, beds or swimming pools. The tensioning structures
`are lightweight and occupy minimal volume when the device
`is deflated and packed away, while also functioning as a
`strong and durable internal support upon inflation and use of
`the inflatable device.
`[0062] An exemplary tensioning structure in accordance
`with the present disclosure utilizes thin and flexible string- or
`wire-like strands which join two areas of fabric to one
`another. The strands are firmly connected to the adjacent
`fabric via an intermediate material, such as a strip or sheet,
`and the intermediate materialis in turn firmly connected to the
`fabric. The area of contact between intermediate material and
`the attached strands may be manipulated to impart a connec
`tion strength commensurate with the tensile strength of the
`strand. Similarly, the area of contact between the intermediate
`material and the adjacent fabric may also be manipulated to
`impart a fabric/tensioning structure connection strength com
`mensurate with the aggregate tensile strength of all strands in
`the tensioning structure.
`[0063] Various tensioning structures and methods of manu
`facturing the same are described in detail below. It is contem
`plated that any of the present described tensioning structures
`may be used in any inflatable product, either alone, as a group
`or in combination with one another as required or desired for
`a particular design. In addition, it is contemplated that ten
`sioning structures in accordance with the present disclosure
`can be used in other contexts, such as in camping equipment,
`or in any other context where a lightweight, packable struc
`ture is needed to join two pieces of material that are urged
`away from one another in use.
`[0064] 1 Weld Strips Joined by Spaced-Apart Strands.
`[0065] Turning now to FIGS. 1 and 2, tensioning structure
`3 is shown joining upper material 1 to lower material 2. In the
`illustrated embodiment, tensioning structure 3 includes upper
`and lower weld strips 31 connected to one another by a
`plurality of substantially parallel strands 32 that define a gap
`portion extending between a gap between upper and lower
`sheets 1, 2. The upper and lower weld strips 31 are in turn
`welded to the upper material 1 and the lower material 2,
`respectively, such that forces urging upper and lower materi
`als 1, 2 are encountered by tension in strands 32.
`[0066] Optionally, reinforcing strands 5 (FIG. 3) may be
`provided along the longitudinal extent of weld strip 31 (i.e.,
`substantially perpendicular to strands 32). Reinforcing
`strands 5, when provided, may be coupled to tensile strands
`32, such as by folding strands 32 over reinforcing strands 5,
`tying strands 5, 32 to one another, or adhesively securing
`strands 5, 32 to one another. When so coupled, reinforcing
`strands 5 provide additional surface area contact with weld
`strips 31 and thereby improve the resistance of securing
`strands 5 to pulling free from weld strips 31. In addition, the
`presence of reinforcing strands 32 within weld strips 31
`improves the tensile strength of weld strips 31 along their
`longitudinal extents.
`[0067] The plurality of strands 32 in the tensioning struc
`ture 3 as shown in FIGS. 1 and 2 are arranged such that the
`strands 32 are substantially parallel to one another when
`strands 32 are pulled taut (i.e., when weld strips 31 are drawn
`away from one another). In addition, adjacent pairs of strands
`32 may have even intervals therebetween, such that a substan
`tially constant tensile strength of tensioning structure 3 is
`
`maintained across the longitudinal extent of weld strips 31. In
`an exemplary embodiment, strands 32 may extend along the
`entire width of weld strips 31, as illustrated in FIGS. 1 and 2,
`such that a large area of contact between strands 32 and weld
`strips 31 is achieved. For clarity, FIGS. 1 and 2 illustrate only
`a limited number of strands 32 affixed to strips 31 in this way,
`it being appreciated that all strands 32 in a tensioning struc
`ture 3 may be so affixed.
`[0068| Strands 32 include first and second terminal ends 34
`positioned along first longitudinal edges 36, 38 of strips 31.
`Strands 32 extends through second longitudinal edges 40, 42
`of strips 31 that are parallel and spaced apart from first lon
`gitudinal edges 36, 38. Strips 32 have a length 44 extending
`along longitudinal edges 36, 38, 40, 42 and a width 46 defined
`between respective first longitudinal edges 36, 38 and second
`longitudinal edges 40, 42. Strips have upper surfaces 48, 50
`and lower surfaces 52, 54. When attached to upper and lower
`sheets 1, 2, strands 32 are bent to form a first leg 56, relative
`to the bend, that extends along gap portion 33 and a pair of
`second legs 58 having a length substantially equal to width 46
`of strips 32.
`[0069] When tensioning structures 3 are affixed to upper
`and lower sheets 1, 2, air mattress 10 has different ply counts
`at different locations. For example, air mattress 10 has a
`single ply count at portions of upper and lower sheets 1, 2 that
`are spaced apart from tensioning structures 3 and has a triple
`ply count at portions of upper and lower sheets 1, 2 that are
`adjacent to the tensioning structure. For example, upper sheet
`1 defines a single ply count away from tensioning structure 3
`and cooperates with the pair of weld strips 31 of an adjacent
`tensioning structure 3 to define a triple ply count. In embodi
`ments using a