Method for making self-inflatable mattresses and cushions

A method for making a self-inflatable apparatus (10) from a core (20) of open pore foam having a predetermined shape, said method comprising the steps of:

• a. substantially surrounding said core (20) with at least two non-fabric dual melting point films (22, 42) each having a first surface (S1) that melts at a first temperature T1 and a second surface (S2) substantially adjacent to said first surface (S1) that melts at a second temperature T2 which is lower than T1 and such that said second surface (S2) substantially contacts the entire exterior surface (12) of said core of open pore foam (20), and wherein at least a portion of said first film (22) and said second film (42) overlap each other;
• and,
• b. heating said first surface (S1) of said first film (22) and said second film (42) with a heating means (26, 36, 38) to a temperature TR lower than T1 but higher than T2 so that said second surface (S2) melts and adheres to substantially the entire exterior surface (12) of said core of open pore foam (20) and wherein the top surface (S1) softens and conforms to said predetermined shape of said core (20),
• wherein the overlapping portions of said first film (22) and second film (42) form airtight thermoplastic seals and further wherein when said self-inflatable apparatus (10) has cooled, the first outer surface (S1) assumes said predetermined shape of said core (20) and stretches and moves with said core (20) of open pore foam.

A method of making a self-inflatable apparatus (10) from a contoured core (20) of open pore foam, comprised in the steps of:

• a. substantially surrounding said contoured core (20) with a non-fabric containing, dual melting point film (22, 42) having a first surface (S1) that melts at a first temperature T1 and a second surface (S2) substantially adjacent to said first surface (S1) that melts at a second temperature T2 which is lower than T1 and such that the second surface (S2) substantially contacts the entire exterior surface (12) of said core of open pore foam (20);
• and,
• b. heating said first surface (S1) with a heating means (26, 36, 38) to a temperature TR that is lower than T1 but higher than T2 so that said second surface (S2) melts and adheres to substantially the entire exterior surface (12) of said core of open pore foam (20) and the first surface (S1) softens and conforms to the contour of said core (20),
• wherein after said self-inflatable apparatus (10) has cooled said first surface (S1) assumes the contour of said foam core (20) and stretches and moves with said foam core (20).

A method for making a self-inflatable apparatus (10) from a contoured core (20) of open pore foam, comprising the steps of:

• a. substantially surrounding said contoured core (20) with at least two non-fabric dual melting point films (22, 42) each having a first surface (S1) that melts at a first temperature T1 and a second surface (S2) substantially adjacent to said first surface (S1) that melts at a second temperature T2 which is lower than T1 and such that said second surface (S2) substantially contacts the entire exterior surface (12) of said core of open pore foam (20), and wherein at least a portion of said first film (22) and said second film (42) overlap each other;
• and,
• b. heating said first surface (S1) of said first film (22) and said second film (42) with a heating means (26, 36, 38) to a temperature TR lower than T1 but higher than T2 so that said second surface (S2) melts and adheres to substantially the entire exterior surface (12) of said core of open pore foam (20) and wherein the top surface (S1) softens and conforms to the contour of said contoured core (20),
• wherein the overlapping portions of said first film (22) and second film (42) form airtight thermoplastic seals and further wherein when said self-inflatable apparatus (10) has cooled, the first outer surface (S1) assumes said contour of said foam core(20) and stretches and moves with said core (20) of open pore foam.

A method for making a self-inflatable apparatus (10) from a core (20) of open pore foam having a predetermined shape and at least one edge, said method comprising the steps of:

• a. substantially surrounding said core (20) with at least two (2) non-fabric dual melting point films (22, 42) each having a surface (S1) that melts at a first temperature T1 and a second surface (S2) substantially adjacent to said first surface (S1) that melts at a second temperature T2 which is lower than T1 and such that said second surface (S2) substantially contacts the entire exterior surface (12) of said core of open pore foam (20) and wherein at least a portion of said first film (22) and said second film (42) overlap each other adjacent to said edge;
• b. heating said first surface (S1) of said first film (22) and said second film (42) with a heating means (26, 36, 38) to a temperature TR lower than T1 but higher than T2 such that said second surface (S2) melts and adheres to substantially the entire exterior surface (12) including said edge of said core of open pore foam (20) and wherein the top surface (S1) softens and conforms to said predetermined shape of said core (20) including said edge, wherein the overlapping portions of said first film (22) and said second film (42) form airtight thermoplastic end seam seals and further wherein when said self-inflatable apparatus (10) has cooled, the first outer surface (S1) assumes said predetermined shape of said core (20) and stretches and moves with said core (20) of open pore foam.