Inflatable Mat

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to Great Britain Patent Application No. 2407390.0, filed on May 24, 2024, the disclosure of which is hereby incorporated in its entirety by reference herein.

TECHNICAL FIELD

The present teachings relate to an inflatable mat and a method of manufacturing an inflatable mat.

BACKGROUND

Modern sleeping mats, for example those used for camping, typically include upper and lower layers defining an enclosed volume. The sleeping mat includes a valve or opening for inflating the sleeping mat in order to improve comfort of the sleeping mat. It is known to include reflective layers in the internal volume of the sleeping mat in order to improve the thermal properties of the sleeping mat. The insulating layers help to trap heat and reflect heat back to the user. This improves the thermal efficiency of the mat because the amount of heat energy transferred to the ground through the mat is reduced.

In addition to achieving the desired thermal performance in a sleeping mat, it is important for the sleeping mat to offer optimal comfort for a restful sleep experience. Designing a sleeping mat that achieves both effective thermal insulation and user comfort poses a significant challenge in manufacturing bedding solutions. As the upper and lower layers and the reflective layers are formed from different materials, the insulating layers cannot be heat sealed or welded to the upper and lower layers.

The present teachings seek to overcome or at least mitigate one or more problems associated with the prior art.

SUMMARY

A first aspect of the teachings provides an inflatable mat comprising: an upper outer layer and a lower outer layer defining a substantially enclosed internal volume; and/or at least one valve in selectable fluid communication with the internal volume; and/or at least one insulating layer disposed between the upper outer layer and the lower outer layer; and/or a plurality of tie members each extending between and directly connected to the upper outer layer and the lower outer layer; and/or a plurality of strap members each configured to hold the insulating layer to one of the upper or lower outer layer.

Advantageously, providing the insulating layer helps to trap heat and reflect heat back to the user, thereby improving thermal insulation from the ground. The thermal efficiency of the inflatable mat is improved because the amount of heat energy transferred through the mat is reduced.

The plurality of tie members help to maintain a desired spacing of the upper outer layer with respect to the lower outer layer when the inflatable mat is in an inflated configuration, in order to retain its generally planar shape with a desired thickness. The strap members help to hold the insulating layers with respect to the upper and lower outer layers, thereby maintaining the insulating layers in suitable positions where they are effective to inhibit heat loss when the mat is in an inflated configuration.

Providing tie and strap members to perform the above functions may help to improve ease of manufacture whilst maintaining the desired shape and positioning of the insulating layer of the inflatable mat in the inflated configuration.

Optionally, the plurality of tie members are each discrete from one another. Optionally, the plurality of strap members are each discrete from the plurality of tie members and from one another.

Advantageously, providing a plurality of discrete tie members and/or discrete strap members improves ease of manufacture of the inflatable mat compared, for example to a continuous arrangement of tie members and/or strap members.

Optionally, the tie members are orientated substantially transversely with respect to the strap members.

Advantageously, providing the tie member transverse to the strap members helps to provide support and shape to the inflatable mat in more than one direction.

Optionally, the plurality of tie members are orientated substantially transversely with respect to the upper outer layer and the lower outer layer when the inflatable mat is in an inflated configuration.

Advantageously, the transverse tie members connect the upper outer layer to the lower outer layers, and provide support and shape in the direction transverse to the upper outer layer and lower outer layer.

Optionally, each of the plurality of strap members extends from the respective upper or lower outer layer, through the at least one insulating layer and back towards the same of the respective upper or lower layer to connect the at least one insulating layer to the respective upper or lower outer layer.

Advantageously, providing strap members extending through the at least one insulating layer and back on themselves connects the upper or lower outer layer to the at least one insulating layer, thereby providing support and shape to the inflatable mat.

Optionally, each of the plurality of tie members is connected to the upper outer layer at an upper connection point, and to the lower outer layer at a lower connection point, and wherein the upper and lower connection points are transversely aligned.

Advantageously, providing transversely aligned connection points provides support and shape in the direction transverse to the upper outer layer and lower outer layer which helps to support the weight of a user.

Optionally, the plurality of strap members are directly connected to the respective upper outer layer or lower outer layer at a first connection point and a second connection point spaced apart from the first connection point. Optionally, the first connection point is longitudinally aligned with the second connection point.

Advantageously, the first and connection points enable the connection of the at least one insulating layer to the upper or lower outer layer. Additionally, providing longitudinally aligned connection points provides support and shape in the longitudinal direction.

Optionally, the plurality of tie members are arranged in an array of rows. Optionally, each row extends in a direction substantially perpendicular to the central longitudinal axis of the inflatable mat.

Advantageously, providing an array of rows provides uniform support and helps to keep the shape of the inflatable mat along each of the rows. Additionally, rows are simple to manufacture.

Optionally, adjacent rows of the plurality of tie members are longitudinally offset.

Advantageously, providing longitudinally offset rows helps to provide support across a larger surface area for a given number of tie members. Additionally, the spacing created by the longitudinally offset rows can be used for the strap members.

Optionally, the plurality of strap members are arranged in an array of rows. Optionally, each row extends in a direction substantially perpendicular to a central longitudinal axis of the inflatable mat.

Advantageously, providing an array of rows provides uniform support and helps to keep the shape of the inflatable mat along each of the rows. Additionally, rows are simple to manufacture.

Optionally, adjacent rows are longitudinally offset.

Advantageously, providing longitudinally offset rows helps to provide support across a larger surface area for a given number of tie members. Additionally, the spacing created by the longitudinally offset rows can be used for the strap members.

Optionally, each of the plurality of strap members is located in between adjacent tie members.

Advantageously, providing strap members located between the tie members helps to provide uniform support and shape, and efficiently utilises the spaces between the adjacent tie members to position the strap members.

Optionally, the at least one insulating layer comprise a plurality of apertures each configured to receive a tie member therethrough.

Advantageously, the apertures in the at least one insulating layer are simple to manufacture, and enable connection and support between the upper outer layer and the lower outer layer.

Optionally, the at least one insulating layer comprises a plurality of apertures. Optionally, each aperture is configured to receive a respective strap member therethrough. Optionally, each strap member extends through more than one of the plurality of apertures of the at least one insulating layer.

Advantageously, the apertures in the at least one insulating layer are simple to manufacture, and enable connection and support between the at least one insulating layer and the upper or lower outer layer.

Optionally, the at least one insulating layer comprises an upper insulating layer connected to the upper outer layer by a plurality of upper strap members, and a lower insulating layer connected to the lower outer layer by a plurality of lower strap members.

Advantageously, providing more than one insulating layer helps to facilitate additional trapping and reflection of heat back to the user, thereby reducing the amount of heat energy transferred through the inflatable mat and improving thermal efficiency of the inflatable mat.

Optionally, the first and second connection points of each of the plurality of upper strap members are located between the upper outer layer and the upper insulating layer and/or the first and second connection points of each of the plurality of lower strap members are located between the lower outer layer and the lower insulating layer.

Optionally, the at least one insulating layer comprises an intermediate insulating layer located between the upper insulating layer and the lower insulating layer.

Advantageously, providing more than one insulating layer helps to facilitate additional trapping and reflection of heat back to the user, thereby reducing the amount of heat energy transferred through the inflatable mat and improving thermal efficiency of the inflatable mat.

Optionally, the plurality of tie members each comprise a neck portion. Optionally, the intermediate insulating layer comprises an aperture dimensioned to be held around the neck portion so as to locate the intermediate insulating layer with respect to the tie member in a direction transverse to the upper and lower outer layers when the inflatable mat is in an inflated configuration.

Optionally, the aperture defines a width, and the minimum width of the neck portion is substantially equal to the width of the aperture.

Optionally, the tie member comprises a substantially hourglass shape defining the neck portion.

Advantageously, providing an hourglass shape enables the neck portion to hold the insulating layer in the correct position when the inflatable mat is in the intended orientation for use and when the inflatable mat is upside down. Additionally, an hour glass construction is simple to manufacture and assemble.

Optionally, the at least one insulating layer comprises a plurality of apertures each configured to receive the neck portion of a respective tie member.

Advantageously, providing a plurality of apertures helps to locate the insulating layer across the area thereof, which may help to improve the thermal performance of the inflatable mat.

Optionally, each of the plurality of tie members is formed from one piece extending between the upper outer layer and the lower outer layer.

Optionally, each of the plurality of tie members are beam members or column members.

Advantageously, beam or column members are a simple way of providing support and shape to the upper and lower outer layers, and are simple to manufacture and assemble.

Optionally, the plurality of tie members and/or strap members are welded or heat sealed to the respective upper or lower outer layer.

Advantageously, such methods of connection provide a strong and durable connection, thereby providing reliable structural integrity of the connection points.

Optionally, the upper and lower outer layers and the at least one insulating layer are manufactured from different materials.

Advantageously, manufacturing the upper and lower outer layers and at least one insulating layer from different materials means that the layers can perform the dual function of increasing thermal efficiency of the inflatable mat and providing support to the user, in use.

Additionally, as the upper and lower insulating layers are manufactured from a different material to the upper and lower outer layers the upper and lower insulating layers cannot be heat sealed or welded to the respective upper or lower outer layer. As such, the tie members and strap members help to overcome the problem of how to connect/locate the insulating layer or layers to the upper and lower outer layers.

Optionally, the outer layers are manufactured from a textile material, optionally a nylon or polyester material.

Advantageously, these materials provide user comfort, durability and lightweight.

Optionally, the at least one insulating layer is manufactured from a material configured to reflect heat, optionally a metallic material, optionally a metallic film, for example a woven or non-woven fabric or gauze having a metallic coating.

Advantageously, such materials have a high thermal reflectivity and are lightweight.

A further aspect of the present teachings provides an inflatable mat comprising: an upper outer layer and a lower outer layer defining a substantially enclosed internal volume; and/or at least one valve in selectable fluid communication with the internal volume; and/or at least one insulating layer disposed between the upper outer layer and the lower outer layer; and/or and a plurality of tie members each extending between and directly connected to the upper outer layer and the lower outer layer, wherein each of the tie members comprises a neck portion; and/or wherein the at least one insulating layer comprises an aperture dimensioned to be held around the neck portion so as to locate the insulating layer with respect to the tie member in a direction substantially transverse to the upper and lower outer layers when the inflatable mat is configured for use.

Advantageously, using the tie members help to support the upper outer layer with respect to the lower outer layer when the inflatable mat is in an inflated configuration. Additionally, the tie members perform the secondary function of locating the insulating layer, thereby reducing the complexity of manufacture of the inflatable mat and reducing the number of components.

Optionally, the neck portion defines a minimum width, and the minimum width is located spaced apart from upper and lower ends of the tie member.

Advantageously, providing a minimum width spaced apart from the upper and lower ends of the tie member enables the neck portion to hold the insulating layer in the correct position when the inflatable mat is in the intended orientation for use and when the inflatable mat is upside down.

Optionally, the aperture defines a width, and wherein the minimum width of the neck portion is substantially equal to the width of the aperture.

Optionally, the tie member comprises a substantially hourglass shape defining the neck portion.

Advantageously, providing an hourglass shape enables the neck portion to hold the insulating layer in the correct position when the inflatable mat is in the intended orientation for use and when the inflatable mat is upside down. Additionally, an hour glass construction is simple to manufacture and assemble.

Optionally, the at least one insulating layer comprises a plurality of apertures each configured to receive the neck portion of a respective tie member.

Advantageously, providing a plurality of apertures helps to locate the insulating layer across the area thereof, which may help to improve the thermal performance of the inflatable mat.

Optionally, each of the plurality of tie members is formed from one piece extending between the upper outer layer and the lower outer layer.

Optionally, the inflatable mat comprises a plurality of tie members each extending between and directly connected to the upper outer layer and the lower outer layer.

Advantageously, the plurality of tie members help to maintain a desired spacing of the upper outer layer with respect to the lower outer layer when the inflatable mat is in an inflated configuration, in order to retain its generally planar shape with a desired thickness. The strap members help to hold the insulating layers with respect to the upper and lower outer layers, thereby maintaining the insulating layers in suitable positions where they are effective to inhibit heat loss when the mat is in an inflated configuration.

Providing tie and strap members to perform the above functions may help to improve ease of manufacture whilst maintaining the desired shape and positioning of the insulating layer of the inflatable mat in the inflated configuration.

Optionally, the plurality of tie members are each discrete from one another. Optionally, the plurality of strap members are each discrete from the plurality of tie members and from one another.

Advantageously, providing a plurality of discrete tie members and/or discrete strap members improves ease of manufacture of the inflatable mat compared, for example to a continuous arrangement of tie members and/or strap members.

Optionally, the tie members are orientated substantially transversely with respect to the strap members.

Advantageously, providing the tie member transverse to the strap members helps to provide support and shape to the inflatable mat in more than one direction.

Optionally, the plurality of tie members are orientated substantially transversely with respect to the upper outer layer and the lower outer layer when the inflatable mat is in an inflated configuration.

Advantageously, the transverse tie members connect the upper outer layer to the lower outer layers, and provide support and shape in the direction transverse to the upper outer layer and lower outer layer.

Optionally, each of the plurality of strap members extends from the respective upper or lower outer layer, through the at least one insulating layer and back towards the same of the respective upper or lower layer to connect the at least one insulating layer to the respective upper or lower outer layer.

Advantageously, providing strap members extending through the at least one insulating layer and back on themselves connects the upper or lower outer layer to the at least one insulating layer, thereby providing support and shape to the inflatable mat.

Optionally, each of the plurality of tie members is connected to the upper outer layer at an upper connection point, and to the lower outer layer at a lower connection point, and wherein the upper and lower connection points are transversely aligned.

Advantageously, providing transversely aligned connection points provides support and shape in the direction transverse to the upper outer layer and lower outer layer which helps to support the weight of a user.

Optionally, the plurality of strap members are directly connected to the respective upper outer layer or lower outer layer at a first connection point and a second connection point spaced apart from the first connection point. Optionally, the first connection point is longitudinally aligned with the second connection point.

Advantageously, the first and connection points enable the connection of the at least one insulating layer to the upper or lower outer layer. Additionally, providing longitudinally aligned connection points provides support and shape in the longitudinal direction.

Optionally, the plurality of tie members are arranged in an array of rows. Optionally, each row extends in a direction substantially perpendicular to the central longitudinal axis of the inflatable mat.

Advantageously, providing an array of rows provides uniform support and helps to keep the shape of the inflatable mat along each of the rows. Additionally, rows are simple to manufacture.

Optionally, adjacent rows of the plurality of tie members are longitudinally offset.

Advantageously, providing longitudinally offset rows helps to provide support across a larger surface area for a given number of tie members. Additionally, the spacing created by the longitudinally offset rows can be used for the strap members.

Optionally, the plurality of strap members are arranged in an array of rows. Optionally, each row extends in a direction substantially perpendicular to a central longitudinal axis of the inflatable mat.

Advantageously, providing an array of rows provides uniform support and helps to keep the shape of the inflatable mat along each of the rows. Additionally, rows are simple to manufacture.

Optionally, adjacent rows are longitudinally offset.

Advantageously, providing longitudinally offset rows helps to provide support across a larger surface area for a given number of tie members. Additionally, the spacing created by the longitudinally offset rows can be used for the strap members.

Optionally, each of the plurality of strap members is located in between adjacent tie members.

Advantageously, providing strap members located between the tie members helps to provide uniform support and shape, and efficiently utilises the spaces between the adjacent tie members to position the strap members.

Optionally, the at least one insulating layer comprise a plurality of apertures each configured to receive a tie member therethrough.

Advantageously, the apertures in the at least one insulating layer are simple to manufacture, and enable connection and support between the upper outer layer and the lower outer layer.

Optionally, the at least one insulating layer comprises an upper insulating layer connected to the upper outer layer by a plurality of upper strap members, and a lower insulating layer connected to the lower outer layer by a plurality of lower strap members.

Advantageously, providing more than one insulating layer helps to facilitate additional trapping and reflection of heat back to the user, thereby reducing the amount of heat energy transferred through the inflatable mat and improving thermal efficiency of the inflatable mat.

Optionally, the first and second connection points of each of the plurality of upper strap members are located between the upper outer layer and the upper insulating layer and/or the first and second connection points of each of the plurality of lower strap members are located between the lower outer layer and the lower insulating layer.

Optionally, each of the plurality of tie members are beam members or column members.

Advantageously, beam or column members are a simple way of providing support and shape to the upper and lower outer layers, and are simple to manufacture and assemble.

Optionally, the plurality of tie members and/or strap members are welded or heat sealed to the respective upper or lower outer layer.

Advantageously, such methods of connection provide a strong and durable connection, thereby providing reliable structural integrity of the connection points.

Optionally, the upper and lower outer layers and the at least one insulating layer are manufactured from different materials.

Advantageously, manufacturing the upper and lower outer layers and at least one insulating layer from different materials means that the layers can perform the dual function of increasing thermal efficiency of the inflatable mat and providing support to the user, in use.

Additionally, as the upper and lower insulating layers are manufactured from a different material to the upper and lower outer layers the upper and lower insulating layers cannot be heat sealed or welded to the respective upper or lower outer layer. As such, the tie members and strap members help to overcome the problem of how to connect/locate the insulating layer or layers to the upper and lower outer layers.

Optionally, the outer layers are manufactured from a textile material, optionally a nylon or polyester material.

Advantageously, these materials provide user comfort, durability and lightweight.

Optionally, the at least one insulating layer is manufactured from a material configured to reflect heat, optionally a metallic material, optionally a metallic film.

Advantageously, such materials have a high thermal reflectivity and are lightweight, for example a woven or non-woven fabric or gauze having a metallic coating.

A further aspect of the present teachings provides a method of manufacturing an inflatable mat, the method comprising the steps of: providing an upper outer layer and a lower outer layer; providing at least one insulating layer; providing a plurality of tie members and/or a plurality of strap members; optionally connecting the insulating layer to the upper outer layer or lower outer layer via the plurality of strap members; optionally connecting each of the tie members to the upper outer layer and the lower outer layer such that each of the tie members optionally extend between the upper outer layer and the lower outer layer and the insulating layer is optionally located between the upper outer layer and the lower outer layer.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described with reference to the accompanying drawings, in which:

FIG. 1 is a top view of an inflatable mat according to the present teachings.

FIG. 2 is an exploded view of a section of the inflatable mat of FIG. 1;

FIG. 3 is a schematic view of a cross-section of the inflatable mat of FIG. 1;

FIG. 4 is a top view of tie members and strap members of the inflatable mat of FIG. 1; and

FIG. 5A to 5C are exploded views showing alternative embodiments of inflatable mats according to the present teachings.

DETAILED DESCRIPTION OF EMBODIMENT(S)

Referring firstly to FIG. 1, an inflatable mat according to the present teachings is indicated generally at 10. The term “upper” is taken to mean a side of the inflatable mat which is intended to face away from the ground (i.e. substantially upward) when the inflatable mat 10 is in an intended orientation for use by a user. The term “lower” is taken to mean a side of the inflatable mat which is intended to face the ground (i.e. substantially downward) when the inflatable mat 10 is in the intended orientation for use by a user. For ease of understanding the inflatable mat 10 is described below in its inflated state. It will be appreciated that when deflated for storage or transport, the relative positions of the components described below may change.

The inflatable mat 10 includes an upper outer layer 12a and a lower outer 12b defining a substantially enclosed internal volume, at least one valve 14 in selectable fluid communication with the internal volume, at least one insulating layer 16a-c disposed between the upper outer layer 12a and the lower outer layer 12b, a plurality of tie members 18 extending between and directly connected to the upper outer layer 12a and the lower outer layer 12b, and a plurality of strap members 20a, 20b each configured to connect the at least one insulating layer 16a, 16c to one of the upper or lower outer layers 12a, 12b. It shall be appreciated that in some embodiments, the strap members 20a, 20b may be omitted, as will be described in more detail below.

The inflatable mat 10 is inflated into an inflated configuration by supplying air to the enclosed internal volume via the valve 14. The valve 14 may be connected to a supply of pressurised air, for example a pump, or the valve 14 may be supplied with air by a user manually blowing up the inflatable mat 10. In the embodiment of FIG. 1, the valve 14 is located on the upper outer layer 12a towards a perimeter thereof, however in alternative embodiments the valve 14 may be located on the lower outer layer 12b, or on a seam between the upper outer layer 12a and the lower outer layer 12b. It shall be appreciated that the valve 14 may be any suitable valve 14, for example a Boston valve or a pinch valve, or the valve 14 may be any form of closable opening.

The upper and lower outer layers 12a, 12b are manufactured from a composite of a flexible textile sheet material, for example a nylon or polyester material arranged outermost, and a flexible and air impermeable plastics sheet innermost—e.g. a thermoplastic urethane (TPU) material. These materials provide user comfort whilst being durable and lightweight. The upper and lower outer layers 12a, 12b may be connected together using any suitable manufacturing process, for example ultrasonic welding, heat sealing or using an adhesive. It shall be appreciated that in other embodiments the upper and lower outer layers 12a, 12b may be manufactured from any suitable material known in the art.

The upper outer layer 12a defines a substantially planar surface for directly supporting the weight of the user when they lie on the inflatable mat. The lower outer layer 12b defines a substantially planar surface for contacting a ground surface, in use. The upper outer layer 12a and the lower outer layer 12b are substantially parallel when the inflatable mat 10 is in the inflated configuration.

The upper and lower outer layers 12a, 12b are elongate along a longitudinal axis a-a of the inflatable mat 10. This approximately conforms to the proportions/shape of the user, i.e. a human, thereby providing a comfortably shaped inflatable mat 10 for the user to sleep on. It shall be appreciated that in some embodiments, the upper and lower outer layers 12a, 12b may be formed from more than one upper and lower outer layers respectively. By way of example, the upper and/or lower outer layers 12a, 12b may each be formed from more than two upper or lower outer layers 12a, 12b, for example more than three upper or lower outer layers 12a, 12b.

The at least one insulating layer 16a-c is manufactured from a different material to the upper and lower outer layers 12a, 12b to insulate against radiated heat. The insulating layer may also assist in reducing heat loss from convection. In the embodiment of FIGS. 1 to 4, the at least one insulating layer is manufactured from a material to reflect radiated heat, for example a thin scrim or gauze substrate of woven or non-woven fabric coated in a metallic material, such as aluminium or titanium, for example proprietary “TILT” (Thermo Ionic Lining Technology) material. In alternative embodiments, the at least one insulating layer 16a-c may be any suitable sheet of insulating material, for example a foam material sheet if a less compact mat is acceptable when deflated.

Such insulating layers 16a, 16c are manufactured from materials that cannot be heat sealed or welded to the respective upper or lower outer layer 12a, 12b. For example, metallic coatings are typically a barrier to the fusing of layers, even if the substrate could be heat sealed. As such, the tie members 18 and strap members 20a, 20b help to suitably locate the upper, lower and intermediate insulating layers 16a-c relative to the upper and lower outer layers 12a, 12b.

In the embodiment shown in FIGS. 1 to 4, the at least one insulating layer 16a-c includes an upper insulating layer 16a held in place adjacent to the upper outer layer 12a by a plurality of upper strap members 20a, a lower insulating layer 16c held in place adjacent to the lower outer layer 12b by a plurality of lower strap members 20b, and an intermediate insulating layer 16b located between the upper insulating later 16a and the lower insulating layer 16c. Providing more than one insulating layer 16a-c helps to facilitate additional reflection of heat back to the user, and reduction of heat loss via convection, thereby reducing the amount of heat energy transferred through the inflatable mat 10 and improving thermal efficiency of the inflatable mat 10. The insulating layers 16a-c are each of substantially the same material in this embodiment, but in other embodiments, this need not be the case.

It shall be appreciated that in alternative embodiments, any suitable number of insulating layers 16a-c may be used, for example one, two or four insulating layers 16a-c. The number of insulating layers 16a-c may depend on the season during which the inflatable mat 10 is intended for use. Inflatable mats 10 for use in the summer may have fewer insulating layers 16a-c, for example one insulating layer 16a-c, and inflatable mats 10 for use in the winter may have a greater number of insulating layers 16a-c, for example three or four insulating layers 16a-c.

The insulating layers 16a-c extend over a majority of the area of the inflatable mat 10, for example over substantially an entirety of the inflatable mat 10. This helps to improve uniformity of insulation of the inflatable mat 10. The intermediate layer 16b is located approximately equidistant from the upper and lower outer layer 12a, 12b when the inflatable mat 10 is in the inflated configuration, as will be described in more detail below.

The upper and lower insulating layers 16a, 16c each include a plurality of tic apertures 22 each configured to receive a tie member 18 therethrough, as illustrated in FIGS. 2 and 3. Furthermore, in the embodiment of FIGS. 1 to 4, 5A and 5B, the upper and lower insulating layers 16a, 16c each include a plurality of strap apertures 24 configured to receive a respective strap member 20a, 20b therethough. The intermediate insulating layer 16b includes a plurality of apertures 26 configured to receive a tic member 18 therethrough. In this embodiment, the tie apertures 22 of the upper and lower insulating layers 16a, 16c are each transversely aligned, and each of the apertures 26 in the intermediate insulating layer 16b are transversely aligned with each tie aperture 22 of the upper and lower insulating layers 16a, 16c, so as to receive a vertically arranged tie member 18. In other embodiments, the tie members 18 may be angled, and in which case the apertures 22, 26 may not be aligned. The arrangement of the tie members 18 and the strap members 20a, 20b through the apertures will be described in more detail below.

Each of the plurality of tie members 18 are discrete from one another. Each of the plurality of strap members 20a, 20b are discrete from one another and discrete from each of the plurality of tie members 18. Put another way, each of the plurality of tic members 18 and each of the plurality of strap members 20a, 20b is a separate body. Providing a plurality of discrete tie members 18 and strap members 20a, 20b helps to improve case of manufacture of the inflatable mat 10 compared, for example, to a continuous arrangement of tie members 18 and/or strap members 20a, 20b. This arrangement may also improve the flexibility of the construction to alter the number and position of insulating layers 16a-c, for example.

As illustrated in FIGS. 1 and 4, the plurality of tie members 18 and the plurality of strap members 20a, 20b are arranged in an array of rows. In this embodiment, each row of tie members 18 extends in a direction substantially perpendicular to the central longitudinal axis a-a of the inflatable mat 10 and the rows of strap members 20a, 20b extend longitudinally along the inflatable mat 10 in an alternating pattern. Providing an array of rows provides uniform support and helps to keep the shape of the inflatable mat 10 along each of the rows. In addition, rows are a simple configuration to manufacture. In the embodiment of FIGS. 1 to 4, 25 rows of tie members 18 are provided and five rows of strap members 20a, 20b are provided, however it shall be appreciated that any suitable number of rows with any suitable number of tie members 18 and/or strap members 20a, 20b in each row may be provided, for example depending on a length or width of the inflatable mat 10. Adjacent rows of the plurality of rows of tic members 18 are longitudinally offset. Adjacent rows of the plurality of strap members 20a, 20b are transversely offset. This helps to provide support across a larger surface area of the inflatable mat 10 for a given number of tie members 18 or strap members 20a, 20b.

Each of the plurality of strap members 20a, 20b are located in between adjacent tie members 18. Some of the strap members 20a, 20b are located between longitudinally adjacent tie members 18, and some of the strap members 20a, 20b are located between laterally adjacent tie members 18.

It shall be appreciated that the arrangement of tie members 18 and strap members 20a, 20b shown in the Figures, for example the arrangement shown in FIGS. 1 and 4, is exemplary. In alternative embodiments, each row of strap members 20a, 20b and/or tic members 18 may extend in a direction substantially parallel to the longitudinal axis a-a of the inflatable mat 10. It shall be appreciated that in alternative embodiments, the tie members 18 and/or strap members 20a, 20b may be arranged in any suitable arrangement, for example in diamonds of tic members 18 and/or strap members 20a, 20b.

The tie members 18 help to support the upper outer layer 12a with respect to the lower outer layer 12b when the inflatable mat 10 is in the inflated configuration. It shall be appreciated that the tie members 18 are located in the enclosed internal volume of the inflatable mat 10, i.e. are connected to an internal surface of the upper and lower outer layers 12a, 12b. When the inflatable mat 10 is inflated, the upper and lower outer layers 12a, 12b are forced away from one another by the pressure of the air in the enclosed volume. The tie members 18 act in tension to retain the upper outer layer 12a and the lower outer 12b at a desired spacing from each other, thereby providing a comfortable and stable shape of inflatable mat 10 for the user to lie on. As such, the tie members 18 are under tension when the inflatable mat 10 is in the inflated configuration.

The tie members 18 enable the substantially planar surfaces of the upper and lower outer layer 12a, 12b so that the user can sleep comfortably on the upper outer layer 12a and the lower outer layer 12b can be supported by the ground surface.

In this embodiment, the tie members 18 are provided as a unitary sheet of flexible heat-weldable material. This may be a plastics sheet—e.g. a thermoplastic urethane (TPU) material. The members 18 extend between the upper outer layer 12a and the lower outer layer 12b. The tie members 18 are orientated substantially transversely with respect to the strap members 20a, 20b, as illustrated in FIG. 2. In addition, the tie members 18 are orientated substantially transversely with respect to the upper and lower outer layers 12a, 12b when the mat is in an inflated configuration. Orientating the tie members 18 transversely helps to provide support and shape to the inflatable mat 10 in the direction substantially transverse to the upper and lower outer layers 12a, 12b, i.e. in an opposing direction to a direction of load exerted on the upper outer layer 12a by the user, in use. The tie members 18 may be beam members or column members, by way of example.

Each of the tie members 18 is directly connected to the upper outer layer 12a at an upper connection point 28a, and directly to the lower outer layer 12b at a lower connection point 28b, illustrated in FIG. 3. The upper and lower connection points 28a, 28b are formed in a folded lip or flange 29a, 29b at the free ends of the tie members 18, which are brought into a face-contacting relationship with an inner face of the respective outer layers 12a, 12b.

As such, the upper and lower connection points 28a, 28b connect opposing upper and lower ends of the tie member 18 to the respective upper or lower outer layer 12a, 12b. The tie members 18 are heat sealed or welded at the upper and lower connection points 28a, 28b. The upper and lower connections points 28a, 28b may be a strip or a linear connection point, as illustrated in the Figures.

The upper connection point 28a and the lower connection point 28b are transversely aligned when the inflatable mat 10 is inflated. The upper and lower connection points 28a, 28b are aligned with the tie apertures 22 of the upper and lower insulating layers 16a, 16c, and with the aperture 26 of the intermediate insulating layer 16b. As such, each tic member 18 extends from the upper connection point 28a, transversely through the tie aperture 22 of the upper insulating layer 16a, through the aperture 26 of the intermediate insulating layer 16b and through the tie aperture 22 of the lower insulating layer 16c to the second connection point 18b. The tie apertures 22 are dimensioned to provide a suitable clearance around the lips 29a for assembly, but not so large as to impair the insulating qualities.

It shall be appreciated that in embodiments where the upper and lower insulating layers 16a, 16c are omitted, each tie member 18 may extend from the upper connection point 28a transversely through the aperture 26 of the intermediate insulating layer 16b and to the lower connection point 28b.

As illustrated in FIG. 3, in this embodiment, each of the plurality of tie members 18 includes a neck portion 30. The neck portion 30 defines a minimum width of the respective tie member 18, and the minimum width is located spaced apart from upper and lower ends of the tic member 18. In the embodiment of FIG. 3, the minimum width is located substantially centrally on the tie member 18 in the transverse direction. Put another way, the minimum width is equidistant from the upper and lower ends of the tie member 18, or equidistant from the upper and lower outer layers 12a, 12b. The tie member 18 is substantially planar. In this embodiment, the tie member 18 has a substantially hourglass shape defining the neck portion 30. Put another way, the tie member 18 tapers inward from both the upper end (or upper connection point 28a) and lower end (or lower connection point 28b) towards the neck portion 30. The tapers are substantially linear.

It shall be appreciated that in alternative embodiments, the tie member 18 may be any suitable shape defining a neck portion 30, from example curved or stepped. In some embodiments, the tie member 18 may include more than one neck portion 30 for transversely locating more than one intermediate insulating layer 16b. The tie member 18 may taper inwards and outwards to define more than one neck portion 30. It shall be appreciated that the tic member 18 may be provided in more than one piece, for example in two pieces. The two pieces may be heat sealed or welded together e.g. at the neck portion 30.

The aperture 26 of the intermediate insulating layer 16b is dimensioned to be held around the neck portion 30 so as to locate the intermediate layer 16b with respect to the tie member 18 in a direction substantially transverse to the upper and lower outer layers 12a, 12b when the inflatable mat 10 is in the inflated configuration. It shall be appreciated that in embodiments where only the intermediate insulating layer 16b is provided, the intermediate insulating layer 16b may instead be referred to as the insulating layer 16b. The aperture 26 defines a width, and the minimum width of the neck portion 30 is substantially equal to the width of the aperture 26. Substantially may be taken to mean that the width of the aperture 26 is up to 20% greater than the minimum width of the neck portion 30, for example up to 10% greater than the minimum width of the neck portion 30. As the minimum width of the neck portion 30 is located spaced apart from the upper and lower ends of the tic member 18, the intermediate layer 16b is located with respect to the tie member 18 regardless of the orientation of the inflatable mat 10 (i.e. regardless of whether the upper and lower outer layers 12a, 12b are upside down).

It shall be appreciated that in embodiments where the upper and/or lower insulating layers 16a, 16c are omitted, only the upper strap members 20a, only the lower strap members 20b or both of the upper and lower strap members 20a, 20b may be omitted. As such, there may be embodiments of the inflatable mat 10 where only the tie members 18 are included. The upper and lower strap members 20a, 20b are of substantially the same configuration. The term “strap members” will therefore be used hereafter in reference to both the upper and lower strap members 20a, 20b.

The strap members 20a, 20b help to support the upper and lower insulating layer 16a, 16c with respect to the upper and lower outer layer 12a, 12b when the inflatable mat 10 is in the inflated configuration. It shall be appreciated that the strap members 20a, 20b are located in the enclosed internal volume of the inflatable mat 10, i.e. are connected to the internal surface of the upper and lower outer layers 12a, 12b. Each of the plurality of strap members 20a, 20b extends from the respective upper or lower outer layer 12a, 12b, through the at least one insulating layer 16a, 16c and back towards the same of the respective upper or lower layer 16a, 16c to connect the upper or lower insulating layer 16a, 16c to the respective upper or lower outer layer 12a, 12b. It shall be appreciated that when the inflatable mat 10 is in the inflated configuration, the strap members 20a, 20b extend generally in a shallow U-shape from the upper or lower outer layer 12a, 12b and through the upper or lower insulating layer 16a, 16c and thus retain the respective insulating layer at its desired position.

The plurality of strap members 20a, 20b are each orientated substantially parallel to the central longitudinal axis a-a of the inflatable mat 10 when the inflatable mat 10 is in the inflated configuration.

The plurality of strap members 20a, 20b are each formed from a flexible sheet and define opposing planar surfaces. One of the planar surface faces the upper outer layer 12a, and one of the planar surface face the lower outer layer 12b. As illustrated in FIG. 4, each of the plurality of strap members 20a, 20b is substantially linear when viewed in plain view.

The plurality of strap members 20a, 20b are directly connected to the respective upper outer layer 12a or lower outer layer 12b at a first connection point 32a and a second connection point 32b spaced apart from the first connection point 32a. The first connection point 32a may be axially aligned with the second connection point 32b when the inflatable mat 10 is configured for use, as illustrated in FIG. 4. The first and second connection points 32a, 32b may be dots or dashes. In alternative embodiments, the first and second connection points 32a, 32b may be aligned in any suitable orientated, for example laterally. The first and second connection points 32a, 32b are located at opposing ends of each of the strap members 20a, 20b. Put another way, it is the ends of the strap members 20a, 20b which are connected to the upper and lower outer layers 12a, 12b.

The strap members 20a, 20b are heat sealed or welded at the first and second connection points 32a, 32b to the respective upper or lower outer layer 12a, 12b. As such, the first and second connection points 32a, 32b securely hold the upper and lower insulating layers 16a, 16c to the respective upper and lower outer layers 12a, 12b without the need to heat seal or weld the upper or lower insulating layers 16a, 16c to the upper or lower outer layer 12a, 12b.

The first and second connection points 32a, 32b are at least partially transversely aligned with the strap aperture 24 of the respective upper or lower insulating layer 16a, 16c. This helps to improve case of manufacture because the strap members 20a, 20b can be heat sealed or welded to the upper or lower outer layer 12a, 12b via the strap apertures 24, thereby connecting the upper or lower insulating layer 16a, 16c to the respective upper or lower outer layer 12a, 12b via the strap members 20a, 20b.

Each strap member 20a, 20b extends through more than one of the plurality of strap apertures 24 of the respective upper or lower insulating layer 16a, 16c. For example, each strap member 20a, 20b may extend through adjacent strap apertures 24. As such, each strap member 20a, 20b extends from the first connection point 32a, through a strap aperture 24 and underneath the respective upper or lower insulating layer 16a, 16c, back through an adjacent aperture 24 of the upper or lower insulating layer 16a, 16c and to the second connection point 32b. It shall be appreciated that in some embodiments, the strap member 24 may extend through more than two strap apertures 24. Each strap members 20a, 20b extends only through the upper or lower insulating layer 16a, 16b. This is different to the tie members 18, which may extend through more than one of the insulating layers 16a-c.

A method of manufacturing an inflatable mat 10 will be described hereafter. An upper outer layer 12a and a lower outer layer 12b are provided. As described above, the upper outer layer 12a and the lower outer layer 12b may be formed from more than one layer. At least one insulating layer 16a-c is provided, for example an upper insulating layer 16a, a lower insulating layer 16c and an intermediate insulating layer 16b. A plurality of tie members 18 and a plurality of strap members 20a, 20b, for example upper and lower strap members 20a, 20b, are provided of substantially the same configuration as described.

The upper insulating layer 16a is held to the upper outer layer 12a by the plurality of upper strap members 20a. The lower insulating layer 16b is held to the lower outer layer 12b by the lower strap members 20b. The strap members 20a, 20b are located in the strap apertures 24, and the strap members 20a, 20b are heat sealed or welded at the first and second connection points 32a, 32b to the upper or lower outer layer 12a, 12b. The intermediate insulating layer 16b is located on the neck portion 30 such that the apertures 26 receive one neck portion 30 of the tie members 18. Each of the tie members 18 is connected to the upper outer layer 12a and the lower outer layer 12b such that each of the tie members 18 extend between the upper outer layer 12a and the lower outer layer 12b, and the insulating layer 16b is located between the upper outer layer 12a and the lower outer layer 12b. The tie member 18 is heat sealed or welded at the upper and lower connection points 28a, 28b. The upper outer layer 12a and the lower outer layer 12b may then be secured, for example using heat scaling, welding or an adhesive around their perimeter edges, to form the inflatable mat 10.

FIGS. 5A to 5C show alternative embodiment of inflatable mat 10 with alternative numbers of insulating layers 16a-c. In the embodiment of FIG. 5A, the upper insulating layer 16a and the lower insulating layer 16b are provided (i.e. there are two insulating layers 16a, 16c). In this embodiment there is not, therefore, an insulating layer 16b located around the neck portion 30. It is therefore conceivable that the neck portion 30 may be omitted.

In the embodiment of FIG. 5B, an upper insulating layer 16a and an intermediate insulating layer 16b are provided. In this embodiment, intermediate is taken to mean that the insulating layer 16b is located on the neck portion 30, or does not include strap members 20a, 20b extending therethrough. In this embodiment, the lower strap members 20b are therefore omitted. It shall be appreciated that in a further alternative embodiment, only the intermediate insulating layer 16b and the lower insulating layer 16c may be provided, and the upper strap members 20b may be omitted.

FIG. 5C shows an alternative embodiment where only one insulating layer 16a is provided. As described above, this embodiment of inflatable mat 10 may be used in the summer/in higher temperature climates. The embodiment of FIG. 5C includes an upper outer layer 12a and a lower outer layer 12b defining a substantially enclosed internal volume, at least one valve in selectable fluid communication with the internal volume, at least one insulating layer 16b disposed between the upper outer layer 12a and the lower outer layer 12b, and a plurality of tic members 18 each extending between and directly connected to the upper outer layer 12a and the lower outer layer 12b, wherein each of the tie members 18 comprises a neck portion 30, and wherein the at least one insulating layer 16b comprises an aperture 24 dimensioned to be held around the neck portion 30 so as to locate the insulating layer 16b with respect to the tie member 18 in a direction substantially transverse to the upper and lower outer layers 12a, 12b when the inflatable mat 10 is configured for use.

It shall be appreciated that the teachings described above in relation to FIGS. 1 to 4 are applicable to the embodiments of FIGS. 5A to 5C.

Although the teachings have been described above with reference to one or more preferred embodiments, it will be appreciated that various changes or modifications may be made without departing from the scope as defined in the appended claims. For example, the tie members may not be of equal length. E.g. the tie members at lateral edges may be longer than those in the middle. This makes the sides of the mat thicker than the middle and therefore help to locate the user on the mat during their sleep. Although described in relation to a sleep mat, the construction described above may also be used for other articles such as pillows or cushions, which should also be understood to be encompassed by the term inflatable mat.