o
`
`(12) United States Patent
`Boyd
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 7,694,372 B1
`Apr. 13, 2010
`
`US00769.4372B1
`
`(*) Notice:
`
`(54) AIR MATTRESS
`(76) Inventor: Dennis Boyd, 14457 Rouge River,
`Chesterfield, MO (US) 63017
`Subject to any disclaimer, the term of this
`-
`-
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 da
`.S.C. 154(b) by 0 days.
`(21) Appl. No.: 12/419,434
`-
`(22) Filed:
`Apr. 7, 2009
`(51) Int. Cl.
`(2006.01)
`A47C 27/08
`(52) U.S. Cl. ............................................... 5/712; 5/711
`(58) Field of Classification Search ..................... 5/712,
`/
`5/711, 706–710, 713–715, 644, 654, 655.3,
`-
`. -
`5,682
`See application file for complete search history.
`e
`References Cited
`|U.S. PATENT DOCUMENTS
`
`(56)
`
`5/1883 Blochman et al. .............. 5/712
`277,979 A *
`388,037 A * 8/1888 Hargin .......................... 3/70s
`2,604,641 A
`7/1952 Reed
`2,614,272 A 10/1952 George
`3,042,941 A
`7/1962 Marcus
`3,251,075 A
`5/1966 Saltness et al.
`3,644,950 A
`2/1972 Lindsay, Jr.
`3,772,717. A 11/1973 Yuen et al.
`3,879,776 A.
`4/1975 Solen
`4,225,989 A 10/1980 Corbett et al.
`4,371,997 A
`2/1983 Mattson
`4,424,600 A
`1/1984 Callaway
`4,803,744 A
`2/1989 Peck et al.
`4,896,389 A
`1/1990 Chamberland
`5,044,030 A
`9/1991 Balaton
`5,072,469 A 12/1991 Boyd
`5, 107,557 A
`4/1992 Boyd
`3 * ~ * *
`5,115,526 A
`5/1992 Boyd
`5.243,722 A
`9/1993 Gusakov
`5,423,094. A
`6/1995 Arsenault et al.
`5,490,295 A
`2/1996 Boyd
`5,493,742 A
`2/1996 Klearman
`
`5,566,408 A 10/1996 McCarthy et al.
`5,598,593 A
`2/1997 Wolfe
`5,630,237 A
`5/1997 Ku
`5,638,565 A
`6/1997 Pekar
`5,647,078 A
`7/1997 Pekar
`5,647,079 A
`7/1997 Hakamium et al.
`5,711,041 A
`1/1998 Chen
`5,727,270 A
`3/1998 Cope et al.
`5,740,573 A
`4/1998 Boyd
`5,890,245 A
`4/1999 Klearman et al.
`6,073,291 A
`6/2000 Davis
`6,148,461 A 11/2000 Cook et al.
`6,332,760 B1
`12/2001 Chung
`6,568,011 B2
`5/2003 Fisher et al.
`6,618,884 B1
`9/2003 Wu
`6,701,559 B2
`3/2004 Boso
`6,983,502 B2
`1/2006 Boyd
`7,152,264 B2 12/2006 Boyd
`7,165,283 B2
`1/2007 Boso et al.
`7,234,184 B2 * 6/2007 Yang ............................. 5/712
`7,353,555 B2
`4/2008 Lau
`7,367,073 B2
`5/2008 Boyd
`7,380,300 B2
`6/2008 Boyd
`2006/0288489 A1* 12/2006 Yang ............................. 5/712
`-
`-
`* cited by examiner
`-
`-
`Primary Examiner—Robert G Santos
`(74) Attorney, Agent, or Firm—H. Frederick Rusche; Husch
`Blackwell Sanders LLP
`
`(57)
`
`ABSTRACT
`
`An air mattress includes an inflatable compartment having a
`length and width, when inflated, sufficient to support a human
`body; an internal, generally horizontal wall located between
`the top and bottom of the compartment and connected to and
`horizontally restraining the sides of the compartment; at least
`one internal, generally vertical member connected to and
`restraining the relative vertical movement of the top and
`bottom of the compartment; and wherein one of the internal,
`-
`-
`-
`11
`ical
`b
`d the i
`1
`11y hori
`generally vertical member an the internal, generally nort
`zontal wall possesses an opening that permits at least a por
`-
`-
`-
`tion of the other structure to pass therethrough without inter
`ruption.
`
`19 Claims, 11 Drawing Sheets
`
`/.
`//////
`T//////////j
`
`
`
`72
`
`62
`
`y 62
`
`INTEX EXHIBIT 2022, Pg. 1
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`Apr. 13, 2010
`
`Sheet 1 of 11
`
`US 7,694,372 B1
`
`
`
`
`
`"SUZZZZZZZZ
`//_
`///////
`//
`
`
`
`
`
`1
`
`(PRIOR ART)
`
`Fig. 1
`
`INTEX EXHIBIT 2022, Pg. 2
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`Apr. 13, 2010
`
`Sheet 2 of 11
`
`
`
`* / º .
`.7/////////j-"
`
`80
`
`INTEX EXHIBIT 2022, Pg. 3
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`Apr. 13, 2010
`
`Sheet 3 of 11
`
`US 7,694,372 B1
`
`
`
`Fig. 3
`
`INTEX EXHIBIT 2022, Pg. 4
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`Apr. 13, 2010
`
`Sheet 4 of 11
`
`US 7,694,372 B1
`
`92
`
`80
`
`90
`
`Fig. 4
`
`INTEX EXHIBIT 2022, Pg. 5
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`Apr. 13, 2010
`
`Sheet 5 of 11
`
`US 7,694,372 B1
`
`
`
`
`
`
`
`
`
`
`
`96
`
`94
`
`82
`
`Fig. 5
`
`INTEX EXHIBIT 2022, Pg. 6
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`Apr. 13, 2010
`
`Sheet 6 of 11
`
`US 7,694,372 B1
`
`
`
`y–-
`
`Fig. 5A
`
`INTEX EXHIBIT 2022, Pg. 7
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`Apr. 13, 2010
`
`Sheet 7 of 11
`
`US 7,694,372 B1
`
`
`
`110
`
`102
`
`112
`
`104
`
`Fig. 6
`
`INTEX EXHIBIT 2022, Pg. 8
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`Apr. 13, 2010
`
`Sheet 8 of 11
`
`US 7,694,372 B1
`
`
`
`104
`
`102
`
`110
`
`106
`
`104
`
`Fig. 6A
`
`INTEX EXHIBIT 2022, Pg. 9
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`Apr. 13, 2010
`
`Sheet 9 of 11
`
`US 7,694,372 B1
`
`
`
`128
`
`Fig. 7
`
`INTEX EXHIBIT 2022, Pg. 10
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`Apr. 13, 2010
`
`Sheet 10 of 11
`
`US 7,694,372 B1
`
`
`
`128
`
`126
`
`Fig. 7A
`
`INTEX EXHIBIT 2022, Pg. 11
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`Apr. 13, 2010
`
`Sheet 11 of 11
`
`US 7,694,372 B1
`
`
`
`Fig. 8
`
`INTEX EXHIBIT 2022, Pg. 12
`Bestway v. Intex; PGR2017-00003
`
`

`

`US 7,694,372 B1
`
`1
`AIR MATTRESS
`
`2
`number of seam points and, consequently, the amount of labor
`involved in manufacturing such mattresses.
`Finally, higher end versions of these standard mattresses
`utilize a flocked material on the upper, exterior (or sleeping)
`surface of the mattress. These flocked surfaces are intended to
`enhance the aesthetic appeal and comfort of the mattress by
`providing a somewhat softer, non-vinyl surface for the user to
`rest upon. These surfaces are almost universally made of very
`fine polyester fibers that are flocked to the upper vinyl layer of
`the mattress. Flocking is a process that involves applying an
`adhesive to the surface to be flocked and ionizing the surface,
`typically by applying an electric field to the surface. The
`ionized surface attracts the flocking material to the surface in
`a relatively even layer where the material is then secured to
`the surface by the adhesive.
`While the flocked polyester material does provide a some
`what softer feel to the mattress, it is not an ideal sleeping
`surface. In particular, the flocked polyester surface does not
`“breathe" as the user lies on the surface. This feature can lead
`to moisture, in the form of the user’s own perspiration and
`other natural secretions, collecting on the flocked surface.
`This collected surface moisture, especially when combined
`with the elevated surface temperatures resulting from the
`user’s body heat, produces ideal conditions for rapid bacterial
`growth on the mattress surface. An alternative to polyester
`flocking is laminating a woven material to the top surface of
`the mattress. While this approach does produce a more
`breathable surface, it is also adds significant expense to the
`overall manufacturing process.
`Therefore, it would be desirable to produce an air mattress
`having a sleeping surface that provides the preferred aesthetic
`appeal and comfort of a flocked surface while providing an
`impediment to bacterial growth and avoiding a significant
`increase in the cost to produce the mattress.
`SUMMARY OF THE INVENTION
`
`Among the various features of the present invention may be
`noted the provision of an air mattress having enhanced envi
`ronmental qualities.
`Another feature is the provision of such an airmattress with
`an enhanced internal structure that simplifies the manufactur
`ing process.
`A third feature is the provision of such an air mattress with
`enhanced comfort, aesthetic, and health characteristics.
`Other objects and features will be in part apparent and in
`part pointed out hereinafter.
`Briefly, in its broadest aspect, an air mattress of the present
`invention includes an inflatable compartment having a length
`and width, when inflated, sufficient to support a human body;
`an internal, generally horizontal wall located between the top
`and bottom of the compartment that serves to horizontally
`restraining the sides of the compartment; at least one internal
`member connected to and restraining the relative vertical
`movement of the top and bottom surfaces of the compart
`ment; and wherein either the internal member of the internal,
`horizontal wall have at least one opening that permits at least
`a portion of the other structure to pass through without inter
`ruption.
`In an alternate embodiment, the air mattress incorporates
`various components manufactured from non-vinyl materials
`to enhance the overall weight, aesthetics, and comfort of the
`mattress.
`These aspects are merely illustrative of the various aspects
`associated with the present invention and should not be
`deemed as limiting in any manner. These and other objects,
`aspects, features and advantages of the present invention will
`
`CROSS-REFERENCE TO RELATED
`APPLICATIONS
`
`Not applicable.
`
`STATEMENT REGARDING FEDERALLY
`SPONSORED RESEARCH OR DEVELOPMENT
`
`10
`
`Not applicable.
`
`BACKGROUND OF THE INVENTION
`
`15
`
`20
`
`This invention relates generally to air mattresses and more
`particularly to an improved air mattress that reduces the
`amount of polyvinylchloride necessary to manufacture the
`mattress.
`Almost all current air mattress use polyvinylchloride
`(“PVC") or thermoplastic polyurethanes (“TPU”) as the pri
`mary or exclusive materials for manufacture. These materials
`are widely available, adaptable to many forms of use, and
`provide the stable and flexible structure necessary for these
`mattresses. However, greater attention has been recently
`25
`focused on the potential environmental pitfalls of both PVC
`and TPU. In particular, concerns revolve around the plasti
`cizers that must be used with PVC in order to make the
`material flexible. These plasticizers may leach out of the PVC
`sheets used to produce air mattresses and have been con
`30
`nected to significant potential health hazards. In addition,
`PVC, and to a lesser extent TPU, takes hundreds of years to
`degrade in landfills.
`Other drawbacks to the use of these materials include cost
`and weight. These are petroleum-based products and, there
`fore, the cost associated with these materials can vary greatly
`with fluctuations in the price of oil. Furthermore, the weight
`of these materials can present issues for the manufacturer in
`shipping the products and for the consumer in carrying the
`mattress.
`Therefore, it would be desirable to produce an air mattress
`capable of reduced usage of PVC and TPU while maintaining
`the same performance characteristics of current mattresses.
`Standard mattresses, and in particular, “pillowtop”
`designs, tend to utilize a basic structure that involves top and
`bottom horizontal layers of vinyl that are separated by one or
`more internal, horizontal layers of vinyl on the interior of the
`mattress. These internal layers serve to restrain the sides of
`the mattress when the mattress is loaded. These layers can
`also serve to isolate the mattress into separate upper and lower
`chambers, if desired. These mattress also utilize multiple,
`vertically-oriented members or “beams” that traverse the
`interior of the mattress from side to side. These beams serve
`to provide vertical support to the mattress and help prevent
`“bowing” of the mattress during loading.
`In these standard mattresses, it is obviously necessary to
`secure the beams to the exterior layers of vinyl. However, in
`mattresses utilizing an internal horizontal layer, it is neces
`sary to actually utilize two sets of beams—one above and one
`below the internal horizontal layer, and to secure, by sonic
`welding, for example, each beam to the internal horizontal
`layer and, as appropriate, either the top or bottom external
`layer of the mattress. This structure results in a large number
`of seam points, requiring extensive labor on such mattresses.
`Therefore, it would be desirable to produce an air mattress
`having an internal structure capable of restraining the external
`surfaces of the mattress from bowing while reducing the
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`INTEX EXHIBIT 2022, Pg. 13
`Bestway v. Intex; PGR2017-00003
`
`

`

`3
`become apparent from the following detailed description
`when taken in conjunction with the referenced drawings.
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`Reference is now made to the drawings which illustrate the
`best known mode of carrying out the invention and wherein
`the same reference numerals indicate the same or similar
`parts throughout the several views.
`FIG. 1 is a cross-sectional view of a prior art mattress.
`FIG. 2 is a cross-sectional view of a mattress according to
`an embodiment of the present invention.
`FIG. 3 is a plan view of an internal horizontal layer that is
`suitable for use in a mattress according to one or more
`embodiments of the present invention.
`FIG. 4 is an enlarged cross-sectional view of an internal
`vertical member from the mattress of FIG. 2.
`FIG. 5 is a cross-sectional view of a mattress according to
`another alternative embodiment.
`FIG. 5A is an enlarged cross-sectional view of an internal
`vertical member from the mattress of FIG. 5.
`FIG. 6 is a cross-sectional view of a mattress according to
`another alternative embodiment.
`FIG. 6A is an enlarged cross-sectional view of an internal
`vertical member from the mattress of FIG. 6.
`FIG. 7 is a cross-sectional view of a mattress according to
`another embodiment.
`FIG. 7A is an enlarged cross-sectional view of an internal
`vertical member from the mattress of FIG. 7.
`FIG.8 is a cross-sectional view of an alternate embodiment
`of the mattress shown in FIG. 2.
`
`DESCRIPTION OF THE PREFERRED
`EMBODIMENT
`
`In the following detailed description, numerous specific
`details are set forth in order to provide a thorough understand
`ing of the invention. However, it will be understood by those
`skilled in the art that the present invention may be practiced
`without these specific details. For example, well-known
`methods, procedures, and components have not been
`described in detail so as not to obscure the present invention.
`As illustrated in FIG. 1, prior art mattresses that utilize a
`dual chamber design have a structure that includes a top layer
`of vinyl 10, a bottom layer 12, and one or more intermediate
`layers 14. The sides of such mattresses are enclosed by one or
`more generally vertical strips of vinyl 16. In order to maintain
`a relatively consistent vertical height across the surface of the
`mattress, multiple internal vertical ribs 18 are also provided.
`More specifically, two separate sets of these ribs are provided,
`one set being incorporated into the top chamber of the mat
`tress and the second set positioned in the bottom chamber.
`In this arrangement, the intermediate layers 14 of the prior
`art mattress extend entirely from side to side within the mat
`tress. Each set of vertical ribs within the mattress must, there
`fore, be secured to both the intermediate layer and to either the
`top or bottom layer of the mattress. In a very real sense, the
`prior art dual chamber mattresses have required the creation
`of two separate mattresses that are joined together. The
`arrangement of these prior art mattresses, and, in particular,
`the separate sets of vertical beams required therein, require a
`significant amount of labor and, due to the shear number of
`seams required to secure the separate sets of beams, present
`an increased chance of defects occurring in the product.
`Turning to the embodiments of the present invention and
`more specifically to FIG. 2, an air mattress 50 of the present
`invention includes a first inflatable compartment 52 having a
`
`4
`length and width, when inflated, sufficient to support a human
`body. Compartment 52 is composed of a first sheet 60 form
`ing a top of the compartment, a second sheet 62 forming a
`bottom of the compartment, and a strip 64 forming the sides
`of the compartment. Preferably the first inflatable compart
`ment 52 may be inflated by means of a standard inflate, or
`inflate/deflate, valve disposed at a convenient location in the
`wall of compartment 52.
`Air mattress 50 also includes a second inflatable compart
`ment 54 disposed on the top 60 of the first inflatable compart
`ment 52 and secured thereto at least along a portion of the first
`inflatable compartment. Second compartment 54 extends
`generally the length and width of the top of the first compart
`ment 52 and is of a size, when inflated, sufficient to support a
`human body. The second compartment 54 is composed of a
`first layer 70 forming the top of the second compartment, a
`second layer 72 forming the bottom of the second compart
`ment, and a strip 74 forming the sides of the second compart
`ment.
`The bottom 72 of the second compartment 54 and the top
`60 of the first compartment 52 may be composed of a single,
`common layer of material or of separate layers. Similarly, the
`strips 64, 74 from the sides of the first and second compart
`ments may comprise either a single piece of material or sepa
`rate pieces without affecting the nature of the present inven
`tion.
`It is preferred that the compartments have a single infla
`tion/deflation valve, and that the inflation air for the second
`compartment flows initially into the first compartment. Of
`course, the single inflation/deflation valve could be disposed
`in a wall of the second compartment instead, in which case
`inflating air flow would be from the second compartment to
`the first.
`As is more clearly illustrated in FIGS. 2-7, the lowermost
`and uppermost horizontal layers of the mattress are connected
`internally by a plurality of spaced vertical members 80. These
`vertical members 80 extend transversely across the width of
`the mattress. As will be described in more detail below, these
`vertical members encompass a number of different embodi
`ments within the scope of the present invention.
`As previously noted, the top 60 of the first compartment
`and bottom 72 of the second compartment may be formed
`from either a single or multiple layers of material. In the case
`of the embodiment illustrated in FIGS. 2-7, these items are
`formed from a single layer of material 82. This layer of
`material possesses at least one opening 84 and, preferably, as
`many openings as there are internal vertical members 80 in
`the mattress. In the preferred embodiment, the position and
`alignment of these openings 84 in the internal horizontal layer
`82 will generally correspond to the position of the internal
`vertical members 80. This arrangement allows the internal
`vertical members 80 to pass through the internal horizontal
`layer 82 without interruption, which removes the necessity
`for a seam between the internal vertical members 80 and the
`internal horizontal layer 82. More specifically, this arrange
`ment results in a fifty percent (50%) reduction in the number
`of seams in the mattress, thereby greatly reducing the labor
`required to manufacture the mattress and the number of seam
`sites that can later fail. Advantageously, this arrangement also
`naturally provides confluence between the two chambers of
`the mattress. FIG. 4 illustrates one embodiment of an internal
`horizontal layer of this general arrangement.
`It should be noted that while a preferred embodiment in
`which the internal horizontal layer 82 is provided with open
`ings 84 to allow the free passage of the internal vertical
`members 80 has been shown and described, an arrangement
`in which the internal vertical members possess openings to
`
`US 7,694,372 B1
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`INTEX EXHIBIT 2022, Pg. 14
`Bestway v. Intex; PGR2017-00003
`
`

`

`5
`allow the horizontal layer 82 to pass therethrough is also
`encompassed within the scope of the present invention. In
`such an embodiment, each internal vertical member would
`possess one or more openings therein to accommodate the
`passage of the horizontal layer. Once again, this arrangement
`would allow for the desired structure and support of the two
`chamber mattress while eliminating approximately halfof the
`typically required internal seams in the mattress. Similarly, it
`is also contemplated that openings in both the internal vertical
`members and the internal horizontal layer may be utilized.
`The internal vertical members 80 themselves can take a
`number of differentforms. In a first embodimentillustrated in
`FIG. 3A, the internal vertical members 80 include three sepa
`rate parts. The members 80 are provided with two vertically
`spaced apart bases 90 that are secured to the top and bottom
`layer of the mattress. These bases 90 are made of a vinyl
`material to facilitate seaming to the layers of the mattress in a
`known manner, including, for example, sonic welding. A
`middle section 92 is stretched between and secured to each of
`the bases 90. The middle section 92 in the illustrated embodi
`20
`ment is a panel, preferably composed of a stretch fabric mate
`rial, such as spandex or certain polyester materials. It is also
`possible to utilize natural materials, such as cotton.
`The use of a stretch fabric for the middle section provides
`a number of benefits over the prior art. Stretch polyester, in
`particular, represents a significantly less inexpensive and
`more readily sourced material option relative to vinyl. Such
`materials also typically weigh less than comparably sized
`pieces of vinyl, thereby reducing the overall weight of the
`mattress by a significant margin, given the number of internal
`vertical members that are typically used in a mattress. In
`addition, the use of a stretch fabric enhances the actual per
`formance of the mattress. The greater elasticity of the fabric
`relative to vinyl leads to additional resilience in the mattress,
`which imparts a more “natural” feel that is more similar to a
`traditional innerspring mattress. The greater elasticity also
`results in a more durable mattress that resists bursting when
`heavily loaded better than traditional vinyl members. Finally,
`the reduction in the use of vinyl that results from utilizing a
`fabric material represents an improvement of the environ
`mental “footprint” of the mattress. This last feature can be
`further emphasized through the use of polyesters manufac
`tured from recycled material.
`The above qualities can be extended to the internal hori
`zontal layer 82 by utilizing the same or a similar fabric mate
`rial for this piece as well.
`FIGS. 5A, 6A, and 7A illustrate alternate embodiments for
`the internal vertical members 80. For the sake of clarity in
`some of the figures, the internal horizontal layer 82 is not
`shown.
`In the embodiment of FIG. 5A, the bases 94 are formed
`from elongated strips of material, for example, vinyl. These
`strips 94 are secured to the top and bottom layer of the mat
`tress transverse to the long axis of the mattress. In a preferred
`version of this embodiment, the strips 94 are secured to the
`top and bottom layers along the two long edges 98 of each
`strip 94. When the strips 94 are connected to one another by
`the middle section 96, this arrangement results in the strips
`forming a generally semi-circular shape when viewed in
`cross-section. The middle section 96 is formed by fabric
`loops that are based through vent holes 100 in the strips 94.
`The middle section 96 can be formed by many loops or by a
`single extended cord that is alternately looped between the
`top and bottom strips as it extends from one side of the
`mattress to the other.
`FIG. 6A illustrates yet another embodiment in which each
`vertical member 80 is actually formed by rows of individual
`
`50
`
`40
`
`45
`
`55
`
`60
`
`65
`
`US 7,694,372 B1
`
`10
`
`15
`
`25
`
`30
`
`35
`
`6
`restraints 102. Each restraint 102 includes a base 104 that is
`secured to the top or bottom layer of the mattress. The bases
`104 includea flat circular foundation 104 with a semi-circular
`loop 106 attached thereto. The middle section of the restraint
`102 includes an extended “S”-shaped tether 108. This tether
`108 includes plastic clasps 110 at each end that are connected
`by a cord 112 preferably made of a stretch fabric. The plastic
`clasps 110 allow the tether 108 to be readily connected to the
`semi-circular loops 106 of the bases 104. This particular
`embodiment possesses the advantage of not requiring seam
`ing, welding, stitching or another similar process to connect
`the constituent pieces of the restraints 102.
`The embodiment of FIG. 7A possesses similarities to both
`of the prior embodiments. As with the embodiment of FIG.
`6A, it utilizes rows of individual restraints 120 to form the
`vertical members of the mattress. The restraints include bases
`122 that are formed by semi-circular loops 124 that are cre
`ated by securing the ends of a vinyl strap to the top or bottom
`layer of the mattress. In a similar manner to the embodiment
`of FIG. 5A, the bases 122 are connected to one another by a
`fabric loop 126. In a preferred embodiment, the fabric loops
`126 are created from a strip of material in which the ends are
`secured to one another by any suitable means after the strip
`has been threaded through both the upper and lower bases
`122. In the illustrated embodiment, the ends of fabric strip are
`secured by a plastic rivet 128. However, those of skill in the art
`will generally recognize multiple alternative methods of con
`necting the ends, including, for example, sewing.
`FIG. 8 illustrates a variation of the mattress structure
`shown in FIG. 2 and described above. While the basic struc
`ture of the mattress is similar to the previously disclosed
`embodiment, there is an additional flange member 132
`attached to the vertical members 80 and to the internal hori
`zontal layer 82 to provide additional stability to the mattress
`if desired. This modification can be incorporated into the
`other embodiments shown and described herein. As with the
`other internal structural components of the embodiments
`described herein, the flange member 132 can be made from a
`stretch fabric material for improved failure resistance and
`lighter weight. The flange member 132 can be attached to the
`vertical member 80 and internal horizontal layer 82 by sew
`ing, sonic welding, dielectric seaming, or other known
`method. The flange member 132 can be of a shorter length
`than the vertical member 80, in which case multiple flange
`members 132 may be used to connect each vertical member
`and the internal horizontal layer, or the same length. Further,
`flange members 132 may be utilized with only selected ver
`tical members 80 rather than all such members.
`The enhanced comfort and environmental qualities of the
`above described embodiments can be further enhanced
`through the use of an improved arrangement for the upper
`surface of the top layer 70 of the mattress 50. In such an
`embodiment, the upper surface is provided with a flocked
`surface 130 formed from natural fibers. In a particularly pre
`ferred embodiment, bamboo is used for the flocking fibers of
`the surface 130. Bamboo is first processed into finely cut
`fibers. An adhesive material is then applied to the upper
`surface of the mattress 50. The upper surface is then ionized
`by applying an electric field to the surface. The ionized sur
`face attracts the flocking fibers to the surface in a relatively
`even layer. The adhesive then secures the fibers to the upper
`surface as the adhesive dries. The bamboo flocked surface
`provides natural anti-microbial properties and wicks excess
`moisture away from the user. Bamboo also represents a
`widely available and renewal natural resource. In addition to
`
`INTEX EXHIBIT 2022, Pg. 15
`Bestway v. Intex; PGR2017-00003
`
`

`

`20
`
`7
`bamboo, both cotton and wool also present similar advanta
`geous qualities are encompassed within the scope of the
`present invention.
`It should be appreciated that the air mattress of the present
`invention may be constructed in various sizes and shapes. It
`may be packaged and sold or stored in a bag, if desired.
`Other objects, features and advantages of the present
`invention will be apparent to those skilled in the art. While
`preferred embodiments of the present invention have been
`illustrated and described, this has been by way of illustration
`and the invention should not be limited except as required by
`the scope of the appended claims and their equivalents.
`What is claimed is:
`1. An air mattress comprising:
`an inflatable compartment having a length and width, when
`inflated, sufficient to support a human body;
`said inflatable compartment having a top, bottom, and
`sides, said top and bottom being generally parallel to one
`another;
`an internal, generally horizontal wall substantially extend
`ing along the length and the width and being located
`between said top and said bottom, said internal, gener
`ally horizontal wall connected at least at a first location
`to and horizontally restraining said sides,
`at least one internal member connected to and restraining
`the relative vertical movement of said top and bottom of
`said inflatable compartment; and
`wherein one of said at least one internal member and said
`internal, generally horizontal wall defining an elongated
`opening therein permitting at least a portion of the other
`of said at least one internal member and said internal,
`generally horizontal wall to pass therethrough without
`interruption.
`2. The air mattress of claim 1, wherein said at least one
`internal member comprises first and second bases, said first
`base attached to said top of said inflatable compartment and
`said second base attached to said bottom of said inflatable
`compartment, and a middle section extending between and
`connecting said first and second bases.
`3. The air mattress of claim 2, wherein said middle section
`comprises an elastic material.
`4. The air mattress of claim 2, wherein said first and second
`bases comprise a vinyl material.
`5. The air mattress of claim 2, wherein said middle section
`comprises a panel of material.
`6. The air mattress of claim 2, wherein:
`said first and second bases each comprise a strip of material
`having a length and a width, said length of said strip
`50
`being substantially greater than said width of said strip,
`said length of said strip extending along said width of
`said internal compartment, said strip having first and
`second edges extending along the length of said strip,
`and said strip being connected to one of said top and
`bottom of said inflatable compartment at said first and
`second edges of said strip;
`said strip defines a series of holes therein; and
`said middle section comprises a plurality of loops passing
`through said holes to engage said panel.
`7. The air mattress of claim 2, wherein said first and second
`bases each comprise a closed loop and said middle section
`comprises first and second hook structures, said first hook
`engaging said closed loop of said first base and said second
`hook engaging said closed loop of said second base, and an
`elastic section connecting said first and second hook struc
`tures.
`
`40
`
`45
`
`55
`
`60
`
`65
`
`US 7,694,372 B1
`
`10
`
`15
`
`25
`
`30
`
`35
`
`8
`8. The air mattress of claim 2, wherein:
`said first and second bases each comprise a strip of material
`attached to one of said top and bottom of said inflatable
`compartment adjacent first and second ends of said strip
`of material; and
`said middle section comprises a loop connecting said first
`and second bases.
`9. The air mattress of claim 1, wherein said internal, gen
`erally horizontal wall comprises an elastic material.
`10. The air mattress of claim 9, wherein said elastic mate
`rial is a stretch polyester.
`11. The air mattress of claim 1, wherein said other of said
`at least one internal member and said internal, generally
`horizontal wall passes through said opening in said one of
`said at least one internal member and said internal, generally
`horizontal wall without connection of said at least one inter
`nal member and said internal, generally horizontal wall with
`each other.
`12. The airmattress of claim 1, further comprising a second
`inflatable compartment adjacent to and connected with said
`first inflatable compartment, said second inflatable compart
`ment having a length and width, when inflated, sufficient to
`support a human body;
`said second inflatable compartment having a top, bottom,
`and sides, said top and bottom being generally parallel to
`one another;
`an internal, generally horizontal wall located between said
`top and said bottom of said second inflatable compart
`ment, said internal, generally horizontal wall connected
`at least at a first location to and horizontally restraining
`said sides of said second inflatable compartment, and
`at least