Internal supports for inflatable products

Abstract

A tensioning structure for use in inflatable products is provided. The inflatable structure may include a first plastic sheet, a second plastic sheet spaced apart from the first plastic sheet, and an inflatable air chamber defined by the first plastic sheet and the second plastic sheet. A plurality of tensioning structures may be disposed within the air chamber. Each tensioning structure may include a panel made of a single sheet of porous material, a first weld sheet affixed to a first end of the panel and affixed to the first plastic sheet, and a second weld sheet affixed to a second end of the panel opposite the first weld sheet and affixed to the second plastic sheet.

What is claimed is: 
     
         1 . An inflatable product comprising:
 a first sheet;   a second sheet disposed opposite the first sheet, the first sheet and the second sheet being spaced apart to define a gap therebetween; and   at least one tensioning structure spanning the gap between the first sheet and the second sheet, the tensioning structure comprising:
 a panel made of a single sheet of porous material, the panel having a first end and an opposing second end; 
 a first coupling affixed to the first end of the panel, the first coupling being coupled to the first sheet; and 
 a second coupling affixed to the second end of the panel, the second coupling being coupled to the second sheet. 
   
     
     
         2 . The inflatable product of  claim 1 , wherein the panel is made of material having an open cell mesh construction. 
     
     
         3 . The inflatable product of  claim 2 , wherein the open cell mesh construction comprises an array of evenly spaced, hexagon-shaped apertures. 
     
     
         4 . The inflatable product of  claim 2 , wherein the open cell mesh construction comprises an array of evenly spaced, circular-shaped apertures. 
     
     
         5 . The inflatable product of  claim 1 , wherein the first coupling and the second coupling each comprise a first strip of material affixed to a front surface of the panel and a second strip of material affixed to a back surface of the panel. 
     
     
         6 . The inflatable product of  claim 1 , wherein the first coupling and the second coupling each comprise a single strip of material folded about the ends of the panel such that one end of the strip of material is affixed to a front surface of the panel and the opposite end of the strip of material is affixed to a back surface of the panel. 
     
     
         7 . The inflatable product of  claim 1 , wherein the first end of the panel and the second end of the panel are coated with PVC or other durable material having favorable bonding characteristics to form coating layers, wherein the coating layers are coupled to the first sheet and the second sheet. 
     
     
         8 . The inflatable product of  claim 1 , wherein the at least one tensioning structure is arranged in an annular fashion to form a closed columnar structure. 
     
     
         9 . An inflatable product comprising:
 a first plastic sheet;   a second plastic sheet spaced apart from the first plastic sheet;   an inflatable air chamber defined by the first plastic sheet and the second plastic sheet; and   a plurality of tensioning structures disposed within the air chamber, where each tensioning structure is coupled between the first plastic sheet and the second plastic sheet, the plurality of tensioning structures comprising:
 a panel made of a single sheet of porous material, the panel having a first end and an opposing second end; 
 a first weld sheet affixed to the first end of the panel, the first weld sheet being coupled to the first plastic sheet; and 
 a second weld sheet affixed to the second end of the panel, the second weld sheet being coupled to the second plastic sheet. 
   
     
     
         10 . The inflatable product of  claim 9 , wherein the panel is made of material having an open cell mesh construction. 
     
     
         11 . The inflatable product of  claim 10 , wherein the open cell mesh construction comprises an array of evenly spaced, hexagon-shaped apertures. 
     
     
         12 . The inflatable product of  claim 10 , wherein the open cell mesh construction comprises an array of evenly spaced, circular-shaped apertures. 
     
     
         13 . The inflatable product of  claim 9 , wherein the first weld sheet and the second weld sheet each comprise a first strip of material affixed to a front surface of the panel and a second strip of material affixed to a back surface of the panel. 
     
     
         14 . The inflatable product of  claim 9 , wherein the first weld sheet and the second weld sheet each comprise a single strip of material folded about the ends of the panel such that one end of the strip of material is affixed to a front surface of the panel and the opposite end of the strip of material is affixed to a back surface of the panel. 
     
     
         15 . The inflatable product of  claim 9 , wherein the first end of the panel and the second end of the panel are coated with PVC or other durable material having favorable bonding characteristics to form coating layers, wherein the coating layers are coupled to the first sheet and the second sheet. 
     
     
         16 . The inflatable product of  claim 9 , wherein the at least one tensioning structure is arranged in an annular fashion to form a closed columnar structure. 
     
     
         17 . The inflatable product of  claim 9 , wherein the plurality of tensioning structures are spaced apart and arranged substantially parallel to one another. 
     
     
         18 . An inflatable product comprising:
 a first wall;   a second wall spaced apart from the first wall;   an inflatable air chamber defined by the first wall and the second wall; and   a plurality of tensioning structures disposed within the air chamber, where each tensioning structure is coupled between the first wall and the second wall, the plurality of tensioning structures comprising:
 a panel made of single sheet of porous material, the panel having a first end and an opposing second end; 
 a first weld sheet affixed to the first end of the panel and coupled to the first sheet; and 
 a second weld sheet affixed to the second end of the panel and coupled to the second sheet. 
   
     
     
         19 . The inflatable product of  claim 18 , wherein the panel is made of material having an open cell mesh construction. 
     
     
         20 . The inflatable product of  claim 18 , wherein the open cell mesh construction comprises an array of evenly spaced, hexagon-shaped apertures. 
     
     
         21 . The inflatable product of  claim 19 , wherein the open cell mesh construction comprises an array of evenly spaced, circular-shaped apertures. 
     
     
         22 . The inflatable product of  claim 18 , wherein the first weld sheet and the second weld sheet each comprise a first strip of material affixed to a front surface of the panel and a second strip of material affixed to a back surface of the panel. 
     
     
         23 . The inflatable product of  claim 18 , wherein the first weld sheet and the second weld sheet each comprise a single strip of material folded about the ends of the panel such that one end of the strip of material is affixed to a front surface of the panel and the opposite end of the strip of material is affixed to a back surface of the panel. 
     
     
         24 . The inflatable product of  claim 18 , wherein the first end of the panel and the second end of the panel are coated with PVC or other durable material having favorable bonding characteristics to form coating layers, wherein the coating layers are coupled to the first wall and the second wall. 
     
     
         25 . The inflatable product of  claim 18 , wherein the at least one tensioning structure is arranged in an annular fashion to form a closed columnar structure. 
     
     
         26 . The inflatable product of  claim 18 , wherein the plurality of tensioning structures are spaced apart and arranged substantially parallel to one another. 
     
     
         27 . The inflatable product of  claim 18 , wherein the plurality of tensioning structures are radially arranged within the inflatable chamber at spaced intervals. 
     
     
         28 . The inflatable product of  claim 18 , wherein the first wall is concentric to the second wall. 
     
     
         29 . A method for producing an inflatable product, the method comprising the steps of:
 providing a first sheet made of weldable material;   providing a second sheet made of weldable material, the first sheet being spaced apart from the first sheet to define a gap therebetween;   providing at least one tensioning structure spanning the gap between the first sheet and the second sheet, the at least one tensioning structure including a tensile sheet made of porous material, the tensile sheet having a first end and an opposing second end;   applying a first weld strip along the first end of the tensile sheet;   applying a second weld strip along the second end of the tensile sheet;   coupling the first weld sheet to the first sheet; and   coupling the second weld sheet to the second sheet.   
     
     
         30 . The method of  claim 29 , where the inflatable product is an air mattress having an upper sheet, a lower sheet, and a side wall, the method further comprising the steps of:
 creating an inflatable chamber defined by the upper sheet, the lower sheet, and the side wall by coupling the side wall to the upper sheet, and coupling the side wall to the lower sheet; and   providing a valve in communication with the inflatable chamber to facilitate inflation and deflation of the air mattress.   
     
     
         31 . The method of  claim 29 , where the inflatable product is an inflatable spa having an inner wall, an outer wall, a top wall, and a bottom wall, the method further comprising the steps of:
 creating an inflatable chamber defined by the inner wall, the outer wall, the top wall, and the bottom wall by coupling the inner wall the top wall and the bottom wall, and coupling the outer wall to the top wall and the bottom wall; and   providing a valve in communication with the inflatable chamber to facilitate inflation and deflation of the inflatable spa.   
     
     
         32 . The method of  claim 29 , wherein the tensile sheet is made of material having an open cell mesh construction. 
     
     
         33 . The method of  claim 32 , wherein the open cell mesh construction comprises an array of evenly spaced, hexagon-shaped apertures. 
     
     
         34 . The method of  claim 32 , wherein the open cell mesh construction comprises an array of evenly spaced, circular-shaped apertures. 
     
     
         35 . The method of  claim 29 , further comprising the steps of:
 coating the first end and the second end of the tensile sheet with PVC or other durable material having favorable bonding characteristics to form coating layers; and   coupling the coating layers to the first sheet and the second sheet.