Inflatable element comprising an assembly provided with at least one fabric support, at least one electronic circuit and at least one electronic component, shelter comprising such an inflatable element or such an assembly, and method for producing an electronic circuit on a fabric support

Abstract

The invention relates to an inflatable element (2) comprising an assembly provided with a fabric support (6), an electronic circuit (8) comprising a conductive track (10a, 10b) deposited on a surface of the fabric support (6), and an electronic component (12) electrically connected to the conductive track (10a, 10b), the conductive track (10a, 10b) comprising a tie sublayer made of a first metal material, and a layer made of a second metal material different from the first metal material, wherein the fabric support (6) forms an outer shell (4) of the inflatable element (2) and the electronic component (12) comprises a light source soldered to the conductive track (10a, 10b).

Description

[0001] DESCRIPTION

[0002] TITLE: Inflatable element comprising an assembly provided with at least one fabric support, at least one electronic circuit and at least one electronic component, shelter comprising such an inflatable element or such an assembly and method of producing an electronic circuit on a fabric support

[0003] Technical field

[0004] The technical field of the invention is fabric supports equipped with electronic circuits.

[0005] Previous techniques

[0006] An inflatable structure, for example an inflatable marquee, may be equipped with a plurality of electric garlands fitted with light-emitting diodes in order to illuminate the areas covered by the inflatable structure.

[0007] The electric string lights are usually installed one by one when the inflatable structure is inflated using lifting platforms, and removed before the inflatable structure is deflated.

[0008] This solution is tedious and presents risks associated with working at height on a cradle. In addition, the positioning of the electric garlands is not consistent from one position to another.

[0009] US patent 7,455,427 discloses tents equipped with light garlands having at least two layers of fabric sewn together, electrical wires extending internally to the layers of fabric, and light-emitting diodes connected to the electrical wires and protruding from the layers of fabric.

[0010] Such a solution poses problems in terms of manufacturing time, bulk and mass added to that of the structure which supports it. Furthermore, such a solution is not suitable for inflatable structures whose external envelope extends and contracts during inflation and deflation cycles of the inflatable structure, the electrical wires risking rapid deterioration.

[0011] The present invention aims to overcome all or part of the aforementioned drawbacks and to connect electronic components to a fabric support, in particular to connect electronic components to an inflatable structure.

[0012] Another objective of the invention is to provide an inflatable element with a lighting function,

[0013] A further object of the invention is to provide a shelter with a lighting function.

[0014] Statement of the invention

[0015] The invention relates to an inflatable element, in particular an elongated inflatable element of revolution, with captive air comprising an external envelope.

[0016] According to a general characteristic, the inflatable element comprises at least one assembly provided with at least one fabric support, at least one electronic circuit comprising at least one conductive track deposited on a surface of said fabric support, and at least one electronic component electrically connected to said conductive track, said conductive track of said electronic circuit comprising a bonding sub-layer deposited on said surface of said fabric support and made of a first metallic material, and a layer deposited on said bonding sub-layer and made of a second metallic material, the second metallic material being different from the first metallic material, said fabric support of said assembly forming at least in part the external envelope of the inflatable element, said electronic component comprising a light source welded to said conductive track of said electronic circuit.

[0017] The bonding underlayer of said conductive track made of a first metallic material conducts the electric current and promotes the bonding of the layer of said conductive track to said fabric support.

[0018] The layer of said conductive track made of a second metallic material conducts the electric current and promotes the electrical connection of said electronic component to said conductive track. The bonding underlayer and the layer make it possible to produce a flexible conductive track.

[0019] Such a flexible conductive track is resistant to repeated folding, unfolding and storage.

[0020] In addition, the assembly is of reduced mass, making it suitable for the production of the inflatable element.

[0021] The present invention also relates to a shelter, in particular a tent or a marquee, comprising an inflatable structure provided with a plurality of captive air inflatable elements as defined above, and at least one canvas fixed to said inflatable structure.

[0022] Advantageously, the shelter may comprise an additional assembly as defined previously, the fabric support of which at least partly forms said canvas.

[0023] The present invention also relates to a shelter, in particular a tent or a marquee, comprising a structure and at least one canvas fixed to said structure.

[0024] According to a general characteristic, the shelter comprises at least one assembly provided with at least one fabric support, at least one electronic circuit comprising at least one conductive track deposited on a surface of said fabric support, and at least one electronic component electrically connected to said conductive track, said conductive track of said electronic circuit comprising a bonding sub-layer deposited on said surface of said fabric support and made of a first metallic material, and a layer deposited on said bonding sub-layer and made of a second metallic material, the second metallic material being different from the first metallic material, said fabric support of said assembly at least partly forming said canvas, said electronic component comprising a light source welded to said conductive track of said electronic circuit.

[0025] Preferably, said conductive track of said electronic circuit is deposited on an outer surface of said fabric support. Alternatively or in combination, said conductive track of said electronic circuit may be deposited on an inner surface of said fabric support.

[0026] The bonding undercoat of said conductive track may be deposited by a flame-wire spraying type coating process. Alternatively, the bonding undercoat may be deposited by an electric arc spraying type coating process.

[0027] The layer of said conductive track can also be deposited by a flame-wire spraying type coating process, or by an electric arc spraying type.

[0028] These coating methods allow precise control of the positioning of said conductive track on said surface of said fabric support. In addition, these coating methods are compatible with the limited thermal resistance of said fabric support, in particular degradation of said fabric support from 210°C.

[0029] Optionally, another coating process can be used, such as a plasma spraying process or an HVOF spraying process for “High Velocity Oxy Fuel” in Anglo-Saxon terms.

[0030] The first metallic material may comprise zinc, or aluminum, or an alloy of aluminum and zinc, or molybdenum or an alloy of nickel, chromium and aluminum.

[0031] Preferably, the second metallic material may comprise copper-aluminum. Alternatively, the second metallic material may comprise bronze, or brass, or a copper alloy, or an aluminum alloy.

[0032] The thickness of the bonding sub-layer of said conductive track may be between 30 μm and 50 μm.

[0033] The thickness of the layer of said conductive track may be between 50 pm and 150 pm.

[0034] These thicknesses provide sufficient electrical conductivity to said conductive track using a small amount of material, contributing to the lightness of the assembly, and allow said conductive track to retain its electrical conductivity performance during numerous crumpling cycles of said fabric support of the assembly.

[0035] Said electronic component may comprise a light-emitting diode.

[0036] Said light-emitting diode can be soldered to said conductive track of said electronic circuit.

[0037] The assembly may further comprise at least two electrical connection tabs connected to said electronic circuit.

[0038] The assembly may further comprise a power source connected to said two electrical connection tabs.

[0039] The present invention also relates to a method for producing an electronic circuit on a fabric support, comprising at least the following steps:

[0040] - a preliminary step of preparing said surface of the fabric support;

[0041] - a step of positioning a mask opposite a surface of the fabric support;

[0042] - a first step of projecting a first metallic material onto said surface of the fabric support through the mask to form a bonding underlayer;

[0043] - a second step of projecting a second metallic material onto said bonding sub-layer through said mask to form a layer; and

[0044] - a step of electrically connecting at least one electronic component to said layer.

[0045] The step of preparing said surface of the fabric support ensures good adhesion of the electronic circuit, in particular by removing contaminants such as grease or dirt.

[0046] The preparation step can be carried out with compressed air or ethanol.

[0047] The step of connecting said electrical component may comprise soldering at least one light source to said layer. The step of connecting said electrical component may comprise soldering at least one light-emitting diode to said layer.

[0048] The first spraying step can be implemented by a flame-wire spraying type coating process.

[0049] The first spraying step can be implemented by an electric arc spraying type coating process.

[0050] The second spraying step can be implemented by a flame-wire spraying type coating process.

[0051] The second spraying step can be implemented by an electric arc spraying type coating process.

[0052] Brief description of the drawings

[0053] The present invention will be better understood upon studying the detailed description of embodiments, taken as non-limiting examples and illustrated by the appended drawings in which:

[0054] [Fig 1] is a schematic view of an elongated inflatable element of revolution with captive air according to an exemplary embodiment of the invention;

[0055] [Fig 2] is a schematic section of a fabric support of the captive air inflatable elongated revolution element of Figure 1 on which are deposited a bonding underlayer and a layer;

[0056] [Fig 3] is a schematic view of the elongate member of Fig. 1 in the folded state;

[0057] [Fig 4] is a schematic view of the inflatable structure of a shelter according to an exemplary embodiment of the invention;

[0058] [Fig 5] is a schematic view of the shelter according to an exemplary embodiment of the invention; and

[0059] [Fig 6] schematically illustrates a method of producing an electronic circuit on a fabric support according to an exemplary embodiment of the invention.

[0060] Detailed description Figure 1 represents an elongated inflatable element of revolution 2 with captive air or inflatable sausage in the form of an elongated cylindrical element with circular section.

[0061] The inflatable elongated element 2 is composed of a plurality of internal air chambers (not shown) and an external envelope 4 inside which the internal air chambers are housed.

[0062] The outer casing 4 of the inflatable elongated element 2 is formed from a fabric body or support 6, for example a polyester or DACRON® support.

[0063] Each internal air chamber of the inflatable elongated member 2 is formed of an expandable material, for example polyurethane. The internal air chambers form the framework of the inflatable elongated member 2.

[0064] The inflatable elongated element 2 comprises one or more inflation points (not shown), in particular an inflation valve allowing the internal air chambers of the inflatable elongated element 2 to be inflated simultaneously or several inflation valves allowing the internal air chambers of the inflatable elongated element 2 to be inflated independently.

[0065] The inflatable elongated element 2 comprises an electronic circuit 8 arranged on the outer surface of the fabric support 6 of the outer casing 4.

[0066] The electronic circuit 8 of the inflatable elongate element 2 comprises a plurality of longitudinal conductive tracks 10a extending longitudinally on the outer surface of the fabric support 6 of the outer casing 4, and a plurality of circumferential conductive tracks 10b extending in the circumferential direction on the outer surface of the fabric support 6 of the outer casing 4 and connected to the longitudinal conductive tracks 10a.

[0067] The inflatable elongated element 2 comprises a plurality of electronic components 12, here a plurality of light sources, in particular a plurality of light-emitting diodes, electrically connected to the conductive tracks 10a, 10b of the electronic circuit 8. Each electronic component 12 of the inflatable elongated element 2 is connected, in particular welded, between two adjacent longitudinal conductive tracks 10a of the electronic circuit 8, each electronic component 12 thus being arranged in the circumferential direction between two adjacent longitudinal conductive tracks 10a of the electronic circuit 8.

[0068] The inflatable elongated element 2 further comprises two electrical connection tabs 14 each connected to a circumferential conductive track 10b of the electronic circuit 8, and a power source 16 connected to the two electrical connection tabs 14 of the elongated element. The power source 16 is preferably a very low voltage direct current source.

[0069] The inflatable elongated element 2 thus includes directly integrated lighting.

[0070] The arrangement of the electronic circuit 8 in longitudinal conductive tracks 10a and in circumferential conductive tracks 10b, and of the electronic components 12 is given solely for illustrative purposes. Alternatively, other arrangements of the electronic circuit 8 and of the electronic components 12 may be provided.

[0071] As illustrated more visibly in Figure 2, each longitudinal or circumferential conductive track 10a, 10b of the electronic circuit 8 comprises a bonding sub-layer 18 deposited on the outer surface of the fabric support 6 of the outer envelope 4, and a layer 20 deposited on the bonding sub-layer 18 of the conductive track 10a, 10b.

[0072] The bonding sub-layer 18 of each longitudinal or circumferential conductive track 10a, 10b is made of a first metallic material, for example an alloy composed of 85% zinc and 15% aluminum.

[0073] The layer 20 of each longitudinal or circumferential conductive track 10a, 10b is made of a second metallic material different from the first metallic material, for example copper-aluminum. The thickness of the bonding sub-layer 18 of each longitudinal or circumferential conductive track 10a, 10b is here between 30 μm and 50 μm.

[0074] The thickness of the layer 20 of each longitudinal or circumferential conductive track 10a, 10b is here between 50 pm and 150 pm.

[0075] Advantageously, the total thickness of the bonding sub-layer 18 and of the layer 20 of each longitudinal or circumferential conductive track 10a, 10b is between 100 μm and 200 μm.

[0076] Figure 3 shows the inflatable elongated element 2 folded, in particular so as to form an inflatable arch provided with integrated lighting.

[0077] In the example shown, the inflatable element 2 is an elongated inflatable element of revolution 2. Alternatively, the inflatable element 2 may be of another shape.

[0078] Furthermore, it is also possible, without departing from the scope of the invention, to provide in another application that the element 2 is not inflatable and that it comprises the fabric support 6, the electronic circuit 8, and the electronic components 12.

[0079] In the example shown, the inflatable element 2 comprises a single electronic circuit 8. Alternatively, the inflatable element 2 may comprise several electronic circuits 8, in particular several electronic circuits 8 depending on the shape of the inflatable element 2 and the need.

[0080] In the example shown, the inflatable element 2 comprises several light sources. Alternatively, the inflatable element 2 may comprise other types of electronic components 12, for example an electronic component operating at very low voltage, a digital display, a photovoltaic module, a GPS beacon for "Global Positioning System" in English terms, a sensor such as an anemometer or a thermometer, or any other electronic component. Figures 4 and 5 show a shelter 22, for example a tent or a marquee, comprising an inflatable structure 24 and a canvas 26 fixed to the inflatable structure 24.

[0081] The inflatable structure 24 comprises a plurality of masts 28 or legs, a plurality of stringers 30 and a roof 32, each formed from inflatable elongated elements 2.

[0082] The inflatable structure 24 here comprises four masts 28, each mast 28 being formed from an elongated inflatable element 2 arranged vertically, and two rails 30 each extending horizontally between two masts 28 in order to reinforce the inflatable structure 24.

[0083] The roof 32 of the inflatable structure 24 comprises a plurality of hoops, in particular two main hoops 34 each connecting two masts 28 and five additional intersecting hoops 36 extending between the main hoops 34.

[0084] Electronic components 12, in particular light-emitting diodes, are electrically connected to electronic circuits 8 formed on the fabric support 6 of the external envelope 4 of the main arches 34 of the roof 32 and the masts 28 of the inflatable structure 24. Thus, the inflatable structure 24 is provided with integrated lighting. Alternatively, other parts of the inflatable structure 24 may be provided with electronic circuits 8 and electronic components 12, in particular the canvas 26 could be provided with electronic circuits 8 and electronic components 12. When the canvas 26 is provided with electronic circuits 8 and electronic components 12, all or part of the inflatable elongated elements 2 of the shelter 22 may each comprise an airtight envelope, for example formed of a coated fabric. In this case, each inflatable elongated element concerned may be assembled by heat welding and may be devoid of an internal air chamber.

[0085] Although illustrated by the construction of shelter 22, the invention applies to other structures equipped with fabric supports. For example, in the naval field, the invention finds applications for the construction of an inflatable VHF antenna for "Very High Frequency" in Anglo-Saxon terms, or for the construction of a boat sail allowing the electrical connection of solar panels.

[0086] Figure 6 represents a method of producing an electronic circuit 8 on a fabric support 6.

[0087] Preferably, a step 38 of preparing a surface of the fabric support 6 is started to ensure good adhesion of the electronic circuit 8, in particular to remove contaminants such as grease or dirt. The preparation step 38 is, for example, carried out with compressed air or ethanol.

[0088] Then, a step 40 is carried out for positioning a mask opposite the surface of the fabric support 6. The mask is, for example, produced beforehand by an additive manufacturing process, by laser cutting or by cutting an adhesive tape, by a refractory paint applied to the surface of the fabric support 6, by a cut metal sheet or by lithography.

[0089] Then, a first step 42 of projection of the first metallic material is carried out onto the surface of the fabric support 6 through the mask to form the bonding sub-layer 18.

[0090] The first projection step 42 is, for example, implemented by a flame-wire projection type coating process or an electric arc projection type coating process.

[0091] In this case, the first metallic material is prepared so that the first metallic material is in the form of a wire. A projection system is then used which is capable of melting the wire of the first metallic material into droplets and of emitting a jet of compressed air or nitrogen in order to propel the droplets of the first metallic material towards the surface of the fabric support 6. The jet of compressed air or nitrogen is, for example, carried out under a pressure of between 4 bars and 6 bars. The droplets of the first metallic material thus projected solidify on the fabric support 6 while cooling to form the bonding sub-layer 18. The cooling of the droplets of the first metallic material can be carried out inertially, in air, or by contact with water.When the coating process is of the flame-wire spraying type, the spraying system comprises a torch powered by a combustible gas mixture in order to generate a flame to melt the wire of the first metallic material. The combustible gas mixture is, for example, a mixture of acetylene under a pressure of between 1 bar and 1.4 bar and sprayed at a flow rate of between 40 liters and 75 liters per minute, with dioxygen under a pressure of between 3.5 bar and 4.2 bar and sprayed at a flow rate of between 40 liters and 75 liters per minute.

[0092] When the coating process is of the electric arc projection type, the projection system comprises an electrode and is capable of creating an electric arc between the electrode and the wire of the first electrical material to melt the wire of the first metallic material.

[0093] Preferably, several passes are made with the projection system, in particular four passes, in order to form the thickness of between 30 μm and 50 μm of the bonding sub-layer 18.

[0094] After having carried out this first projection step 42, a second projection step 44 of the second metallic material is then carried out on the bonding sub-layer 18 to form the layer 20. For example, the procedure is the same as during the first projection step 42 of the first metallic material and several passes are carried out with the projection system, in particular four passes, in order to form the thickness of between 50 μm and 150 μm of the layer 20.

[0095] The bonding sub-layer 18 and the layer 20 thus form conductive tracks 10a, 10b of the electronic circuit 8, the arrangement of which depends on the shape of the mask used.

[0096] Advantageously, the droplets of the first metallic material and / or the second metallic material are projected with at least one of the following properties: a mass flow rate of projection of the metallic material of between 40 grams per minute and 100 grams per minute, a projection speed of the metallic material of between 200 millimeters per second and 1000 millimeters per second, a projection along a trajectory forming with the surface of the fabric support 6 an angle of between 60 degrees and 120 degrees, a projection from a distance of between 100 millimeters and 300 millimeters.

[0097] Advantageously, the tolerance concerning the total thickness of the bonding sub-layer 18 and of the layer 20 of each conductive track 10a, 10b is plus or minus 50 μm for the coating process.

[0098] Advantageously, the tolerance of the width of each conductive track 10a, 10b is plus or minus 500 pm for the coating process.

[0099] Finally, a step 46 of electrical connection of an electronic component 12 to the layer 20 is carried out. For example, a light source, in particular a light-emitting diode, is soldered to the layer 20 of a conductive track 10a, 10b.

Claims

CLAIMS 1. Inflatable element (2), in particular an elongated inflatable element of revolution, with captive air comprising an external envelope (4), characterized in that it comprises at least one assembly provided with at least one fabric support (6), at least one electronic circuit (8) comprising at least one conductive track (10a, 10b) deposited on a surface of said fabric support (6), and at least one electronic component (12) electrically connected to said conductive track (10a, 10b), said conductive track (10a, 10b) of said electronic circuit (8) comprising a bonding sub-layer (18) deposited on said surface of said fabric support (6) and made of a first metallic material, and a layer (20) deposited on said bonding sub-layer (18) and made of a second metallic material, the second metallic material being different from the first metallic material,said fabric support (6) of said assembly forming at least in part the external envelope (4) of the inflatable element (2), said electronic component (12) comprising a light source welded to said conductive track (10a, 10b) of said electronic circuit (8), in particular a light-emitting diode., 2. Shelter (22) comprising an inflatable structure (24) provided with a plurality of inflatable elements (2) with captive air according to claim 1, and at least one canvas (26) fixed to said inflatable structure (24).

3. Shelter (22) comprising a structure and at least one canvas (26) fixed to said structure, characterized in that it comprises at least one assembly provided with at least one fabric support (6), at least one electronic circuit (8) comprising at least one conductive track (10a, 10b) deposited on a surface of said fabric support (6), and at least one electronic component (12) electrically connected to said conductive track (10a, 10b), said conductive track (10a, 10b) of said electronic circuit (8) comprising a bonding sub-layer (18) deposited on said surface of said fabric support (6) and made of a first metallic material, and a layer (20) deposited on said sub-layer hanging (18) and made of a second metallic material, the second metallic material being different from the first metallic material, said fabric support (6) of said assembly at least partly forming said canvas (26), said electronic component (12) comprising a light source welded to said conductive track (10a, 10b) of said electronic circuit (8), in particular a light-emitting diode.

4. Inflatable element (2) according to claim 1, or shelter (22) according to claim 2 or 3, in which the bonding sub-layer (18) of said conductive track (10a, 10b) and / or the layer (20) of said conductive track (10a, 10b) is deposited by a flame-wire spraying type coating process or an electric arc spraying type coating process.

5. Inflatable element (2) according to claim 1 or 4, or shelter (22) according to any one of claims 2 to 4, in which the second metallic material comprises cupro-aluminium.

6. Inflatable element (2) according to any one of claims 1, 4 and 5, or shelter (22) according to any one of claims 2 to 5, in which the thickness of the bonding sub-layer (18) of said conductive track (10a, 10b) is between 30 pm and 50 pm and / or in which the thickness of the layer (20) of said conductive track (10a, 10b) is between 50 pm and 150 pm.

7. Inflatable element (2) according to any one of claims 1 and 4 to 6, or shelter (22) according to any one of claims 2 to 6, further comprising at least two electrical connection tabs (14) connected to said electronic circuit (8), and a power source (16) connected to said two electrical connection tabs (14).

8. Method for producing an electronic circuit (8) on a fabric support (6), characterized in that it comprises the following steps: - a step of positioning (40) a mask opposite a surface of the fabric support (6); a first step of projecting (42) a first metallic material onto said surface of the fabric support (6) through the mask to form a bonding undercoat (18); - a second step of projection (44) of a second metallic material onto said bonding sub-layer (18) through said mask to form a layer (20) - a step of electrically connecting (46) at least one electronic component (12) to said layer (20); and - a preliminary step of preparation (38) of said surface of the fabric support (6).

9. Method according to claim 8, wherein the step of connecting (46) said electrical component (12) comprises soldering at least one light source to said layer (20), in particular soldering at least one light-emitting diode to said layer (20).

10. Method according to claim 8 or 9, wherein the first spraying step (42) and / or the second spraying step (44) is implemented by a flame-wire spraying type or electric arc spraying type coating method.

Images