Support surface for a patient support apparatus and method for forming an inflatable bladder assembly for a support surface

A support surface for a patient support apparatus, comprising:

• a core having an inflatable bladder assembly including
• a first inflatable bladder including a first air impermeable flexible layer defining a first aperture,
• a second inflatable bladder located adjacent to the first inflatable bladder and including a second air impermeable flexible layer different from the first layer, the second layer defining a second aperture axially aligned and overlapping with the first aperture,
• a first patch connected to the first layer, the first patch extending across and covering the first aperture, and having an exterior face facing the second inflatable bladder, and
• a second patch connected to the second layer, the second patch extending across and covering the second aperture, and having an exterior face facing the first inflatable bladder;
• the exterior face of the first patch connected to the exterior face of the second patch at a patch connection thereby connecting the first inflatable bladder to the second inflatable bladder.

A method for forming an inflatable bladder assembly for an inflatable support surface for a patient support apparatus, comprising:

• receiving a first air impermeable flexible blank defining a first aperture and a second air impermeable flexible blank defining a second aperture;
• connecting a first patch to the first blank so as to extend across and cover the first aperture;
• connecting a second patch to the second blank so as to extend across and cover the second aperture;
• locating the first blank adjacent to the second blank to axially align and overlap the first patch with the second patch;
• connecting an exterior face of the first patch to an exterior face of the second patch at a patch connection and thereby connecting the first blank to the second blank;
• folding the first blank to have corresponding edges superposed and engaged to one another;
• coupling the corresponding edges of the first blank in an airtight manner to form a first inflatable bladder;
• folding the second blank to have corresponding edges superposed and engaged to one another;
• and
• coupling the corresponding edges of the second blank in an airtight manner to form a second inflatable bladder.

An inflatable bladder assembly for a support surface for a patient support apparatus, comprising:

• a first inflatable bladder including a first air impermeable flexible layer defining a first aperture,
• a second inflatable bladder located adjacent to the first inflatable bladder and including a second air impermeable flexible layer different from the first layer, the second layer defining a second aperture axially aligned and overlapping with the first aperture,
• a first patch connected to the first layer, the first patch extending across and covering the first aperture, and having an exterior face facing the second inflatable bladder, and
• a second patch connected to the second layer, the second patch extending across and covering the second aperture, and having an exterior face facing the first inflatable bladder;
• the exterior face of the first patch connected to the exterior face of the second patch at a patch connection and thereby connecting the first inflatable bladder to the second inflatable bladder.