US007591036B2
`
`(12) Ulllted States Patent
`Lin et al.
`
`(10) Patent N0.:
`(45) Date of Patent:
`
`US 7,591,036 B2
`Sep. 22, 2009
`
`(54) AIR-INFLATED MATTRESS
`
`5,890,245 A *
`
`4/1999 Klearman et a1. ............ .. 5/714
`
`
`
`(75) I nventors:
`
`
`(CN) Y L X_ H H ua siang in, 1amen ; aW
`
`
`
`Yuan Hsu’ Xiamen (CN); Lan Lee’
`Xiamen (CN)
`
`(73) Assigneei InteX Recreation Corn, Long Beach,
`CA (Us)
`
`( * )
`
`I\IOtiCeZ
`
`Subject to any disclaimer’ the term ofthis
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`
`5/1999 McCarthy et a1. .
`
`5,906,019 A * *
`
`6/2000 Davls .......................... .. 5/711
`6,073,291 A
`6,332,760 B1* 12/2001 Chung ...................... .. 417/411
`6,546,580 B2 *
`4/2003 Shimada ...................... .. 5/710
`6,568,011 B2 *
`5/2003 Fisher et a1. ................. .. 5/706
`6,671,910 B2 *
`1/2004 Hsu et a1. .... ..
`
`6,701,559 B2 *
`
`3/2004 BOSO et a1. ................... ..
`
`(21) Appl. No.2 12/056,578
`-
`22 F1 d:
`16
`(
`)
`(65)
`
`M .27 2008
`at
`’
`Prior Publication Data
`
`(Continued)
`Primary ExamineriRobert G Santos
`74 Allorn ,A enl, 0r FirmiLeWis Brisbois Bis aard &
`_
`@y g
`g
`Smlth LLP; Sanford Astor
`
`US 2008/0209643 A1
`
`Sep. 4, 2008
`
`(57)
`
`ABSTRACT
`
`Related US. Application Data
`(62) Division of application No. 1 1/449,287, ?led on Jun. 8,
`2006, noW Pat. No. 7,406,73 5.
`
`(51) Int- Cl-
`(200601)
`A4 7C 2 7/08
`(52) US. Cl. .................................. .. 5/712; 5/711; 5/713
`(58) Field of Classi?cation Search ................... .. 5/712,
`_
`_
`5/706, 710, 711, 713, 6543 655-3: 644
`See aPPhCaUOn ?le for Complete Search hlstory-
`References Cited
`
`(56)
`
`U.S. PATENT DOCUMENTS
`
`2,318,492 A *
`
`5/1943 Johnson ....................... .. 5/712
`
`7/1952 Reed . . . . . . .
`. . . .. 5/710
`2,604,641 A *
`3/1955 MelZer ........................ .. 5/710
`2,703,770 A *
`4,225,989 A * 10/1980 Corbettet a1. ............... .. 5/713
`
`5,044,030 A *
`
`9/1991 Balaton . . . . . . .
`
`. . . .. 5/710
`
`5,561,873 A * 10/1996 Weedling.
`5,598,593 A *
`2/1997
`5,638,565 A *
`6/1997
`5,729,840 A *
`3/1998
`5,740,573 A *
`4/1998
`
`5/713
`
`A double air-in?ated mattress having an upper chamber and a
`lower chamber, the upper chamber having a top layer, an outer
`shroud band, a plurality of anchor separators and a bottom
`layer, the outer shroud band connecting the top and bottom
`layers to form an in?atable bladder; a middle layer beloW said
`top layer pamany Sealed to the top layer to form aplurality Of
`Sealed or hal?sealed Cavities, in which some or all of said
`cavities are in ?uid communication With the in?atable blad
`der, the loWer chamber having a top layer, an outer shroud
`band, a plurality of anchor separators and a bottom layer, said
`outer shroud band connecting the top and bottom layers to
`form an in?atable bladder. Each chamber of the double mat
`tress may also have a middle shroud band and an inner shroud
`band, both of said middle shroud bands being separately
`Welded to the outer shroud bands and the inner shroud bands
`to form a plurality of closed or half-closed cavities, some or
`all of said cavities being in ?uid communication With its
`respective in?atable bladder to form a plurality of air pockets
`on the outer shroud bands of the double air mattress.
`
`19 Claims, 14 Drawing Sheets
`
`INTEX EXHIBIT 2021, Pg. 1
`Bestway v. Intex; PGR2017-00003
`
`

`

`US 7,591,036 B2
`Page 2
`
`US. PATENT DOCUMENTS
`
`6,754,925 Bl* 6/2004 Wang .......................... .. 5/706
`6,754,926 B2* 6/2004 Wang
`. 5/710
`6,971,134 B2* 12/2005 Wu .......... ..
`. 5/712
`6,973,690 B2* 12/2005 Muciet a1. ................... .. 5/644
`6,996,867 B2* 2/2006 Boso et a1. ................... .. 5/739
`7,089,618 B1* 8/2006 MetZger ..
`. 5/709
`7,107,641 B2* 9/2006 Davis .... ..
`. 5/710
`7,165,283 132* V2007 B030 etal,
`_ 5/739
`7,254,853 B1* 8/2007 Kim ............................ .. 5/712
`7,269,866 B2* 9/2007 Liu ............................. .. 5/711
`7337’485 132*
`3/2008 Metzger ______________________ __ 5,712
`7 367 073 132* 50008 Boyd
`5/7l0
`
`6/2008
`7,380,300 B2 *
`7,406,735 B2* 8/2008
`7,478,448 132* V2009
`7,530,128 132*
`5/2009
`2002/0050010 A1* 5/2002
`2002/0083528 A1* 7/2002
`2003/0024050 A1* 2/2003
`2003/0101516 A1* 6/2003
`2004/0010853 Al* V2004
`2004/0194219 A1* 10/2004 Boso et a1. ................... .. 5/711
`2007/0044243 A1* 3/2007 Metzger --
`-
`2007/0283499 A1* 12/2007 Liner a1~ --------------------- ~
`2008/0209642 A1* 9/2008 Lln et a1. ..................... ..
`2008/0209643 A1* 9/2008 Lin et a1. ..................... ..
`
`7,376,995 B2 *
`
`5/2008 Davis .......................... .. 5/710
`
`* cited by examiner
`
`INTEX EXHIBIT 2021, Pg. 2
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`
`Sep. 22, 2009
`
`Sheet 1 0f 14
`
`US 7,591,036 B2
`
`PRIOR ART
`
`/ 2
`
`F/G. 2
`PRIOR ART
`
`3/
`
`4/
`
`INTEX EXHIBIT 2021, Pg. 3
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`
`Sep. 22, 2009
`
`Sheet 2 0f 14
`
`US 7,591,036 B2
`
`’
`
`Q/f / ¢
`
`I /
`
`21
`
`I 0/
`
`23110110101111
`0
`y i "f
`Ill
`‘Imus
`
`L
`
`‘IV
`
`I,
`
`I,
`
`61
`
`5M I] [/40
`
`,0 o we
`
`|
`
`0
`
`0
`
`\L._-91
`
`FIG. 3
`
`INTEX EXHIBIT 2021, Pg. 4
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`U.S. Patent
`
`Sep. 22, 2009
`Sep. 22, 2009
`
`Sheet 3 0f 14
`Sheet 3 of 14
`
`US 7,591,036 B2
`US 7,591,036 B2
`
`INTEX EXHIBIT 2021, Pg. 5
`
`Bestway v. Intex; PGR2017-00003
`
`INTEX EXHIBIT 2021, Pg. 5
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`
`Sep. 22, 2009
`
`Sheet 4 0f 14
`
`US 7,591,036 B2
`
`
`
`
`
`viii! ‘III. \II
`
`III!
`
`IWNE
`
`Illlll‘il. 1:1
`
`N
`
`Illa
`
`INTEX EXHIBIT 2021, Pg. 6
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`
`US 7,591,036 B2
`
`1
`
`2///%
`
`//
`
`illlllllllllll
`no
`I‘
`
`III.
`
`4
`
`FIG. 9
`
`INTEX EXHIBIT 2021, Pg. 7
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`
`Sep. 22, 2009
`
`Sheet 6 0f 14
`
`US 7,591,036 B2
`
`52
`
`FIG. 77
`
`INTEX EXHIBIT 2021, Pg. 8
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`
`Sep. 22, 2009
`
`Sheet 7 0f 14
`
`US 7,591,036 B2
`
`FIG. 7 7A
`
`INTEX EXHIBIT 2021, Pg. 9
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`Sep. 22, 2009
`
`Sheet 8 of 14
`
`US 7,591,036 B2
`
`1
`
`FIG.
`
`72
`
`INTEX EXHIBIT 2021, Pg. 10
`
`Bestway v. Intex; PGR2017-00003
`
`INTEX EXHIBIT 2021, Pg. 10
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`
`Sep. 22, 2009
`
`Sheet 9 0f 14
`
`US 7,591,036 B2
`
`‘
`
`h.
`
`all
`
`‘q
`
`"hung
`
`a
`
`\
`
`74
`FIG.
`
`INTEX EXHIBIT 2021, Pg. 11
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`U.S. Patent
`
`Sep. 22, 2009
`Sep. 22, 2009
`
`Sheet 10 0f 14
`Sheet 10 of 14
`
`US 7,591,036 B2
`US 7,591,036 B2
`
`INTEX EXHIBIT 2021, Pg. 12
`
`Bestway v. Intex; PGR2017-00003
`
`INTEX EXHIBIT 2021, Pg. 12
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`
`Sep. 22, 2009
`
`Sheet 11 0f 14
`
`US 7,591,036 B2
`
`1
`
`/ :7,
`
`,2; / y
`¢ 7
`J! -1 -1 0
`
`2
`
`‘a ‘a a
`
`a 00 52/,’
`
`‘ (I 0 (I
`
`70
`
`'
`
`'
`
`/
`
`III‘ M
`
`'1'.
`
`FIG. 77
`
`INTEX EXHIBIT 2021, Pg. 13
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`Sep. 22, 2009
`
`Sheet 12 of 14
`
`US 7,591,036 B2
`
`FIG. 78
`
`INTEX EXHIBIT 2021, Pg. 14
`
`Bestway v. Intex; PGR2017-00003
`
`INTEX EXHIBIT 2021, Pg. 14
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`U.S. Patent
`
`Sep. 22, 2009
`Sep. 22, 2009
`
`Sheet 13 0f 14
`Sheet 13 of 14
`
`US 7,591,036 B2
`US 7,591,036 B2
`
`INTEX EXHIBIT 2021, Pg. 15
`
`Bestway v. Intex; PGR2017-00003
`
`INTEX EXHIBIT 2021, Pg. 15
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`
`Sep. 22, 2009
`
`Sheet 14 0f 14
`
`US 7,591,036 B2
`
`
`
`3.1/1.llllllllrllllllirtrllllr’ll llillllll
`
`11:101:1iriasilllrlnirsrl,ilinlillnniixilil.iI...lullrE...E.IE.11¢1r}1|11lililllnlnnnliil._
`
`INTEX EXHIBIT 2021, Pg. 16
`Bestway v. Intex; PGR2017-00003
`
`

`

`US 7,591,036 B2
`
`1
`AIR-INFLATED MATTRESS
`
`This application is a divisional of US. patent application
`Ser. No. 11/449,287, ?led Jun. 8, 2006, now US. Pat. No.
`7,406,735.
`
`FIELD OF THE INVENTION
`
`The present invention relates to an air-in?ated mattress,
`and more particularly to a supporting structure of an air mat
`tress.
`
`DESCRIPTION OF PRIOR ART
`
`The in?atable mattress, by means of its light Weight, easy
`storage and portable features, not only is used as an outdoor
`apparatus, but also is accepted as indoor furniture. The con
`ventional prior art in?atable mattress, shoWn in FIGS. 1 & 2,
`is typically comprised of a top layer 1', a shroud band 2', a
`plurality of cylindrical anchor separators 3' and a bottom
`layer 4', The shroud band 2' connects the top and bottom
`layers 1' and 4' together to form an in?atable bladder. To keep
`the bladder level and even, a plurality of cylindrical anchor
`separators 3' are respectively connected on the top and bottom
`layers 1' and 4', vertically parallel to the shroud band 2',
`thereby keeping the in?ated mattress as similar to a conven
`tional mattress as possible.
`But, there are shortcomings existing in the prior art in?at
`able mattress, as folloWs:
`1. When the bladder is ?lled fully With air, the surface of the
`mattress Will appear to be full of bumps and holes occur
`ring due to the plurality of cylindrical anchor separators
`3'. The joint portion of the cylindrical anchor separator 3'
`is someWhat concave, but the portion betWeen adjacent
`anchor separators 3' is someWhat convex, so that the
`contact area With the body of the user is relatively
`reduced, Which Will make the user uncomfortable.
`2. When the surface of the mattress is pressed doWn With
`extra force, the shroud band Will be squeezed outWardly
`by the compressed air inside of the bladder, to form a
`croWned bump, further affecting the smoothness of the
`mattress.
`3. As some part of the surface of the mattress is exerted With
`extra force, such as, if the edge of the mattress is pressed
`doWn by an extra force, shroud band 2' Will not resist the
`force, and that portion of the mattress Will collapse,
`losing stability.
`Since the above-mentioned disadvantages exist, the con
`ventional prior art in?atable mattress cannot compare With an
`innerspring mattress.
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`OBJECTS OF THE INVENTION
`
`It is therefore an object of the present invention to provide
`an air-in?ated mattress that has an improved top surface,
`Which increases the contact area of the mattress With the
`human body, for increasing comfort in use.
`It is a further object of the present invention to provide an
`air-in?ated mattress that not only keeps the evenness of the
`surface of the mattress, but also enhances the support inten
`sity of the edges.
`
`55
`
`60
`
`SUMMARY OF THE INVENTION
`
`To achieve the above-mentioned objects, the present inven
`tion provides an air-in?ated mattress, Which is comprised of a
`top layer, a shroud band, a plurality of anchor separators and
`
`65
`
`2
`a bottom layer. Said shroud band connects the top and bottom
`layers together, to form an in?atable bladder. A middle layer
`is built beloW the top layer, by sealing some portions on the
`inside of the top layer to form a plurality of cross-sealed or
`half-sealed cavities. Some or all of said cavities are in ?uid
`communication With the in?atable bladder, so as to form a
`plurality of small air-pockets on the surface of the mattress.
`Said small air-pockets are arrayed on portions of the sur
`face of the air mattress in contact With the human body.
`Some of said cavities communicate With the in?atable
`bladder via air vents built into the middle layer.
`The joint lines Welding the top and middle layers together,
`create closed or half-closed patterns to form air pockets.
`Anchor separators in cylindrical, or other shapes, have air
`holes on the joint portions of the anchor separator’s trunk, and
`are connected With said middle layer and bottom layer sepa
`rately at opposite ends of the trunk.
`In another embodiment, the in?atable mattress also
`includes a middle shroud band and an inner shroud band,
`Wherein said middle shroud band separately connects, by
`Welded joints, to the outer shroud band and the inner shroud
`band to form alternative anchor points, to divide into several
`closed or half-closed cavities. Some of said cavities are in
`?uid communication With said in?atable bladder to form a
`plurality of air pockets on the outer shroud band of the air
`mattress.
`The middle and inner shroud bands have riser vents com
`municating With said in?atable bladder.
`Said middle shroud band is ?xed on the outer shroud band
`by line Welding to form closed or half-closed air pockets.
`The present invention has the folloWing advantages:
`1. improved evenness and outer look of the surface, due to
`adding a middle layer beloW the top layer, and ?xing the
`anchor separators on the middle layer instead of ?xing
`them on the top layer.
`2. said middle layer is ?xed alternatively With said anchor
`separators, so that When the bladder constructed by the
`top and bottom layers and the outer shroud band is fully
`in?ated With air, the concave points of the middle layer,
`formed by tension of the anchor separators via the joint
`portion, are covered by the top layer, ?xed on the convex
`points betWeen the anchor separators and middle layer
`joint spots. The concave points and convex points are
`balanced as the space of the cavities surrounded by them
`is in?ated fully With air, therefore the surface of the air
`mattress is ?at and the evenness of the mattress is
`improved greatly.
`3. more comfortable, due to several small air pockets
`formed betWeen joint spots Welding the top layer and the
`middle layer, and the communication of small air pock
`ets in the in?atable bladder. When extra force is exerted
`on parts of the surface of the air mattress, the air in the
`small air pockets on the pressed portion of the air mat
`tress Will be baf?ed by the riser vents of the middle layer,
`escaping sloWly Without spreading out rapidly, so that
`the supporting effect of the air mattress is improved, and
`the air pockets Work as air springs to increase the restor
`ing force, so that the user Will feel more comfortable.
`4. enhanced edge support, based on the same principle, due
`to adding a middle shroud band and an inner shroud band
`at the inside of the outer shroud band to construct half
`sealed sub-chambers. MeanWhile, the middle shroud
`band connects to the outer and inner shroud bands, alter
`natively and respectively, to surround the sub -chambers,
`so that the in?ated sub -chambers not only Work as rein
`forcing ribs, but also make the outer shroud band ?at,
`improving the outer look. When the edge of the air
`
`INTEX EXHIBIT 2021, Pg. 17
`Bestway v. Intex; PGR2017-00003
`
`

`

`US 7,591,036 B2
`
`3
`mattress is exerted upon With extra force, due to the
`limitation of the riser vents, the air ?lled in the sub
`chambers Will not ?oW rapidly to the inside of the blad
`der, so that the supporting effect of the edge of the air
`mattress is ef?ciently improved Without collapsing or
`tilting.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is an exploded vieW of the prior art;
`FIG. 2 is a perspective vieW of the prior art;
`FIG. 3 is an exploded vieW of a ?rst embodiment the
`present invention;
`FIG. 4 is a perspective vieW of the ?rst embodiment;
`FIG. 5 is a part-sectional perspective vieW of the ?rst
`embodiment;
`FIG. 6 is a cross-sectional vieW taken on lines 6-6 of FIG.
`4;
`FIG. 7 is a cross-sectional vieW taken on lines 7-7 of FIG.
`4;
`FIG. 8 is a cross-sectional vieW taken on lines 8-8 of FIG.
`4;
`FIG. 9 is an exploded vieW of a second embodiment of the
`present invention;
`FIG. 10 is a perspective vieW of the second embodiment;
`FIG. 11 is a cross-sectionvieW taken on lines 11-11 ofFIG.
`10;
`FIG. 11A is a depiction of the outer side of the mattress of
`the second embodiment;
`FIG. 12 is an exploded vieW of a third embodiment of the
`present invention;
`FIG. 13 is a perspective vieW of the third embodiment;
`FIG. 14 is a cross-sectionvieW taken on lines 14-14 ofFIG.
`13;
`FIG. 15 is a perspective vieW
`shoWing the in?ation mechanism;
`FIG. 16 is a perspective vieW
`shoWing the de?ation mechanism;
`FIG. 17 is an exploded vieW of the top portion of a fourth
`embodiment;
`FIG. 18 is an exploded vieW of the bottom portion of the
`fourth embodiment;
`FIG. 19 is a part-sectional perspective vieW of the fourth
`embodiment;
`FIG. 20 is a cross-sectionvieW taken on lines 20-20 ofFIG.
`19; and,
`FIG. 21 is a cross-sectionvieW taken on lines 21-21 ofFIG.
`20.
`
`of the ?rst embodiment
`
`of the ?rst embodiment
`
`DETAILED DESCRIPTION OF PREFERRED
`EMBODIMENTS
`
`Referring noW to FIG. 3, there is shoWn an air-in?ated
`mattress provided by the present invention comprising a top
`layer 1, a middle layer 2, a plurality of anchor separators 3, an
`outer shroud band 4, an inner shroud band 5, a middle shroud
`band 6 and a bottom layer 7. All embodiments Will have an
`in?ation input means to in?ate the mattress, such as a built-in
`air pump, a valve to receive an external air source, or other
`in?ation means.
`Said anchor separators 3 are generally cylindrical in shape,
`and connect at their top, to middle layer 2 and at their bottom,
`to bottom layer 7.
`Referring to FIGS. 3, 4, 5, 6, 7 and 8, the inner surface 10
`of middle shroud band 6 is partly Welded to the outer surface
`12 of the inner shroud band 5. The outer surface 14 of middle
`shroud band 6 is partly Welded to the inside surface 16 of
`
`4
`outer shroud band 4. The joint portion 18, 18' is arranged
`alternating to the joint portion 20 of the middle shroud band 6
`and the inner shroud band 5. The loWer edge of outer shroud
`band 4 is Welded to the rim or edge 22 of bottom layer 7, all
`around, and the loWer edge 24 of inner shroud band 5 is
`Welded to the inside of bottom layer 7, all around. Every
`anchor separator 3 is put in place, and the separator trunks 25
`are Welded to the inside 26 of middle layer 2 and to the inner
`surface 28 of bottom layer 7, respectively.
`Middle layer 2 and top layer 1 are Welded 30 alternating
`With the joint portion 32 of middle layer 2 and anchor sepa
`rators 3 (see FIG. 7). The upper edge 34 of inner shroud band
`5 is Welded to the inner surface of top layer 1 all around, and
`?nally, the top rim 36 of outer shroud band 4 is Welded to the
`edge of the top layer 1 all around, to ?nish the Whole air
`mattress. Optionally, an in?ating and de?ating air pump is
`built into outer shroud band 4, so that the bladder can be
`in?ated full With air, to form a mattress, (see FIG. 15).
`Referring speci?cally to FIG. 6 and FIG. 7, When the air
`mattress is ?lled full With air the air enters the space betWeen
`outer shroud band 4 and inner shroud band 5 ?lling up side
`sub -chamber B, then the air passes through inner shroud band
`5 entering the space betWeen middle layer 2, bottom layer 7
`and inner shroud band 5, to form main bladder A.
`Middle shroud band 6 is Welded onto inner shroud band 5
`at 20 and onto outer shroud band 4 at 18, 18' alternatively and
`respectively betWeen said side sub-chambers B to Work as a
`reinforcing rib. On the other hand, the joint spot 18, 18' of
`middle shroud band 6 and outer shroud band 4 is line or point
`Welded, to form a plurality of closed or half-closed circle,
`rhombus, or otherpattern, small side airpockets B1 on shroud
`band 4 of the air mattress. Air pockets B1 communicate With
`side sub-chamber B, via riser vents 61 of middle shroud band
`6, and via riser vents 91 of middle shroud 6. Side sub-chamber
`B communicates With main bladder A, via riser vents 51 of
`inner shroud band 5.
`Middle layer 2 is Welded 30 to top layer 1 to construct a
`plurality of closed or half-closed circle or rhombus or other
`pattern air pockets C, Which are arrayed on the top surface of
`the air mattress Which is in contact With the human body. Air
`pockets C are in communication With main bladder A via
`overlapped riser vents 21 of middle layer 2.
`The present invention has the folloWing advantages:
`1. improved evenness and outer look of the surface, due to
`adding a middle layer 2 beloW the top layer 1, and ?xing
`anchor separators 3 onto middle layer 2 instead of onto
`the top layer 1. Also, said top and middle layers 1 and 2
`are Welded alternatively With said anchor separators 3,
`so that When bladder A, constructed by the top layer 1
`and bottom layer 7 and the outer shroud band 4, is fully
`in?ated With air, the concave points of the middle layer
`2, formed by draWing of the anchor separators 3 via the
`joint portion 32, are covered by convex pockets C of top
`layer 1, betWeen anchor separators 3 and middle layer 2
`joint spots 30 so that they are balanced, the surface of the
`air mattress is relatively ?at and the evenness of the
`mattress is improved greatly.
`2. more comfortable, due to small air pockets C formed
`betWeen joint spots Welding the top layer 1 and the
`middle layer 2, and the communication of small air
`pockets C in the in?atable bladderA. When extra force is
`exerted on parts of the surface of the air mattress, the air
`in small air pockets C, on the pressed portion of the air
`mattress, Will be baf?ed by the riser vents of the middle
`layer 2, escaping sloWly Without spreading out rapidly,
`so that the supporting effect of the air mattress, and the
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`INTEX EXHIBIT 2021, Pg. 18
`Bestway v. Intex; PGR2017-00003
`
`

`

`US 7,59l,036 B2
`
`5
`airpockets C Work as air springs to increase the restoring
`force, so that the user Will feel more comfortable.
`3. enhanced edge support, based on the same principle, due
`to adding a middle shroud band 6 and an inner shroud
`band 5, inside of outer shroud band 4, to construct half
`sealed sub-chambers B. In addition, middle shroud band
`6 connects to outer and inner shroud bands 4 and 5
`alternatively and respectively to surround sub-chambers
`B1, so that in?ated sub-chambers B1 not only Work as
`reinforcing ribs, but also make outer shroud band 4 ?at
`for improving the outer look of the mattress. When extra
`force is exerted on the edge of the air mattress, due to the
`effect of riser vents 61 and 51, the air ?lled in sub
`chambers B1 Will not ?oW rapidly to the inside of blad
`der A, so the supporting effect of the edge of the air
`mattress is e?iciently improved, Without any collapsing
`or tilting.
`A second embodiment of the invention is described by
`reference to FIGS.9,10,11 and 11A. As can be seen, there are
`no vent holes in the tops of anchor separators 3 and there are
`no riser vent holes in the sides of middle shroud 6. There are
`only tWo vent holes 52 and 53, in one side of inner shroud 5,
`for air to pass from main bladder A into sub-chamber B. In
`addition, air passes into the space betWeen top layer 1 and
`middle layer 2 to ?ll air pockets C by passing around and over
`the outer edges of middle layer 2, Which edges are not Welded
`to top layer 1. Air enters sub-chambers B-1 by gaps at the air
`inlet. FIG. 11A shoWs the pattern of side sub-chambers B1 as
`seen on the surface of outer shroud 4. In this embodiment, the
`air moves in and out much more sloWly than in embodiment
`one, making it a stiffer mattress.
`A third embodiment of the invention is described by refer
`ence to FIGS. 12, 13 and 14 in Which middle layer 2 has a
`plurality of riser vents 54 adjacent to the joint points 56 of
`anchor separators 3 to middle layer 2. In addition there are a
`plurality of riser vent holes 58 and 60 in inner and middle
`shrouds 5 and 6, but only in alternating side sub-chambers B1
`Where shrouds 5 and 6 are joined. Riser vents 62 provide
`air?oW betWeen bladder A and subchamber B. This embodi
`ment alloWs air to ?oW more quickly than the second embodi
`ment but not as quickly as embodiment one.
`FIGS. 15 and 16 shoW the embodiment of FIG. 4 and shoW
`in?ation pump 65 set into a housing in the side of shroud 4 of
`the mattress. Electrical line 66 With a plug (not shoWn) is
`connected to pump 65. The other side of the mattress has an
`optional valve 67 Which may be opened to in?ate or de?ate
`the mattress.
`A fourth embodiment is shoWn in FIGS. 17 through 21.
`This embodiment comprises a double mattress, having an
`upper chamber 70 and a loWer chamber 72. Upper chamber
`70, shoWn in FIG. 17, comprises top layer 1, middle layer 2,
`a plurality of anchor separators 3, an outer shroud 4, an inner
`shroud 5, a middle shroud 6 and a bottom layer 7. Bottom
`layer 7 has a plurality of vent holes 41.
`LoWer chamber 72, shoWn in FIG. 18, comprises an upper
`layer 8, a plurality of I-beam anchor separators 9, an outer
`shroud 4, an inner shroud 5, a middle shroud 6, and a bottom
`layer 10. Upper layer 8 has a plurality of vent holes 42 Which
`match up With vent holes 41 in layer 7 of upper chamber 70,
`so that air may pass betWeen the tWo chambers, 70 and 72.
`Layers 7 and 8 are Welded together around air vent holes 41
`and 42.
`Air passes through vent holes 51 and 61 into sub-chambers
`B and B1 and into bladder A and through riser vents 21 into
`small air pockets C. This embodiment provides a high-rise
`mattress With superior support provided by loWer chamber 72
`having I-beam anchor separators 9 for added support. I-beam
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`anchor separators 9 are Welded to the top of layer 10 and to the
`bottom of layer 8 and are placed beloW and in betWeen anchor
`separators 3, to keep the loWer bladder D level and even. The
`double mattress is easier to sit on, or lie doWn on, because of
`its greater height from the ?oor and it also raises the user
`farther from a cold ?oor.
`While I-beams are used as anchor separators in the loWer
`chamber, as shoWn in this embodiment, any other types of
`anchor separators, as described previously hereinabove, may
`be utiliZed.
`Variations of the placement and the number of riser vents or
`holes betWeen the chambers described may be made at the
`desire of the manufacturer, Which Will change the stiffness
`and feel of the mattress. HoWever, the use of additional
`shrouds and the additional layer in the construction as
`described, provides an air mattress Which is ?rmer, more
`comfortable for the user and more like an innerspring mat
`tress.
`While the air-in?ated mattress of the present invention has
`been described With reference to certain embodiments, the
`invention is not limited to the particular embodiments dis
`closed. Other variations, in design may occur to those skilled
`in the art Without departing from the scope of the invention.
`The scope of the invention is limited only by the claims
`appended hereto.
`We claim:
`1. A double air-in?ated mattress comprising an upper
`chamber and a loWer chamber, said upper chamber compris
`ing a top layer, an outer shroud band, a plurality of anchor
`separators spaced apart from each other and a bottom layer,
`said outer shroud band connecting the top and bottom layers
`to form an in?atable bladder, a middle layer beloW said top
`layer partially sealed to the top layer to form a plurality of
`sealed or half-sealed cavities, in Which some or all of said
`cavities are in ?uid communication With the in?atable blad
`der, said loWer chamber comprising a top layer, an outer
`shroud band, a plurality of anchor separators and a bottom
`layer, said outer shroud band connecting the top and bottom
`layers to form an in?atable bladder, in Which the upper cham
`ber anchor separators are Welded at the top to the middle layer
`and at the bottom to the bottom layer and the middle layer has
`a plurality of air vent holes Which communicate With the
`in?atable bladder.
`2. The double air-in?ated mattress of claim 1 Wherein the
`anchor separators in the loWer chamber are I-beams.
`3. The double air-in?ated mattress of claim 1 in Which
`bottom layer of the upper chamber has a plurality of vent
`holes, the top layer of the loWer chamber has a plurality of
`vent holes, in Which the vent holes of the bottom layer of the
`upper chamber and the vent holes of the top layer of the loWer
`chamber are concentric.
`4. The double air-in?ated mattress of claim 1 in Which the
`bottom layer of the upper chamber and the top layer of the
`loWer chamber are Welded together.
`5. The double air-in?ated mattress of claim 3 in Which the
`bottom layer of the upper chamber and the top layer of the
`loWer chamber are Welded together around said vent holes.
`6. The air in?ated mattress of claim 1, further comprising a
`built-in in?ation or in?ation/ de?ation pump.
`7. A double air-in?ated mattress comprising an upper
`chamber and a loWer chamber, said upper chamber compris
`ing a top layer, an outer shroud band, a plurality of anchor
`separators and a bottom layer, said outer shroud band con
`necting the top and bottom layers to form an in?atable blad
`der, a middle layer beloW said top layer partially sealed to the
`top layer to form a plurality of sealed or half-sealed cavities,
`in Which some or all of said cavities are in ?uid communica
`
`INTEX EXHIBIT 2021, Pg. 19
`Bestway v. Intex; PGR2017-00003
`
`

`

`US 7,591,036 B2
`
`7
`tion With the in?atable bladder, said lower chamber compris
`ing a top layer, an outer shroud band, a plurality of anchor
`separators and a bottom layer, said outer shroud band con
`necting the top and bottom layers to form an in?atable bladder
`in Which said upper chamber further comprises a middle
`shroud band and an inner shroud band, and said loWer cham
`ber further comprises a middle shroud band and an inner
`shroud band, Wherein both of said middle shroud bands are
`separately Welded to the outer shroud band and the inner
`shroud band to form a plurality of closed or half-closed cavi
`ties, some or all of said cavities being in ?uid communication
`With said in?atable bladder to form a plurality of air pockets
`on the outer shroud bands of the air mattress.
`8. The double air-in?ated mattress of claim 7, Wherein each
`of said middle and inner shroud bands have riser vents Which
`communicate With the in?atable bladder in their respective
`chambers.
`9. A double air-in?ated mattress comprising an upper
`chamber and a loWer chamber, said upper chamber compris
`ing a top layer, an outer shroud band, a plurality of anchor
`separators and a bottom layer, said outer shroud band con
`necting the top and bottom layers to form an in?atable blad
`der, a middle layer beloW said top layer partially sealed to the
`top layer to form a plurality of sealed or half-sealed cavities,
`in Which some or all of said cavities are in ?uid communica
`tion With the in?atable bladder, said loWer chamber compris
`ing a top layer, an outer shroud band, a plurality of anchor
`separators and a bottom layer, said outer shroud band con
`necting the top and bottom layers to form an in?atable blad
`der, in Which the upper chamber anchor separators are gen
`erally cylindrical in shape, are Welded at the top to the middle
`layer and at the bottom to the bottom layer and have an air vent
`hole through the top Weld With the middle layer.
`10. A double air-in?ated mattress comprising an upper
`chamber and a loWer chamber, said upper chamber compris
`ing a top layer, an outer shroud band, a plurality of anchor
`separators and a bottom layer, said outer shroud band con
`necting the top and bottom layers to form an in?atable blad
`der, a middle layer beloW said top layer partially sealed to the
`top layer to form a plurality of sealed or half-sealed cavities,
`in Which some or all of said cavities are in ?uid communica
`tion With the in?atable bladder, forming a plurality of air
`pockets on the top surface of the mattress, said loWer chamber
`comprising a top layer, an outer shroud band, a plurality of
`anchor separators and a bottom layer, said outer shroud band
`connecting the top and bottom layers to form an in?atable
`bladder; the upper chamber and the loWer chamber both fur
`ther comprising a middle shroud band and an inner shroud
`band, Wherein each of said middle shroud bands is separately
`Welded to the outer shroud band and the inner shroud band to
`form a plurality of closed or half-closed cavities, some or all
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`of said cavities being in ?uid communication With its respec
`tive in?atable bladder to form a plurality of air pockets on the
`outer shroud band of the air mattress.
`11. The double mattress of claim 10 Wherein the anchor
`separators in the loWer chamber are l-beams.
`12. The double mattress of claim 10 in Which the bottom
`layer of the upper chamber and the top layer of the loWer
`chamber are Welded together.
`13. The double air-in?ated mattress of claim 10 in Which
`bottom layer of the upper chamber has a plurality of vent
`holes, the top layer of the loWer chamber has a plurality of
`vent holes, in Which the vent holes of the bottom layer of the
`upper chamber and the vent holes of the top layer of the loWer
`chamber are concentric.
`14. The double air-in?ated mattress of claim 13 in Whi