Inflatable Mat

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.

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

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.

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.