System for producing an inflatable product
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Solution Overview
Problem
Current inflatable products, such as mattresses, are produced manually, which is time-consuming, expensive, and prone to human error due to the manual welding of tensioning structures to upper and lower sheets.
Innovation Solution
An automated system and method for producing inflatable products that includes an upstream tensioning structure production subsystem and a downstream preassembly production subsystem, allowing simultaneous alignment and welding of tensioning structures to sheets, with the system comprising conveyors, molds, and welders to automate the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual welding of tensioning structures to sheets is used, then flexibility and customization are maintained, but production time increases and productivity decreases
Solution Approach 1:
The patent replaces manual mechanical welding operations with an automated welding system that uses heat-generating electrodes to join tensioning structures to sheets. The system automatically positions and welds multiple tensioning structures simultaneously, eliminating manual labor while maintaining weld quality.
Solution Approach 2:
The patent employs preliminary positioning mechanisms that pre-align tensioning structures with the sheets before welding occurs. This preliminary action ensures accurate placement and enables automated welding without requiring manual adjustment during the welding process.
2Ease of manufacture
If manual welding processes are used, then adaptability to different designs is maintained, but production cost increases
Solution Approach 1:
The patent implements a continuous production process where sheets and tensioning structures move continuously through the welding station. Multiple welding operations occur simultaneously and continuously without interruption, maximizing equipment utilization and reducing production time while lowering per-unit costs.
Solution Approach 2:
The patent combines multiple welding operations into a single integrated process. Several tensioning structures are welded to sheets simultaneously in one operation rather than sequentially, reducing total production time and enabling cost-effective manufacturing.
3Reliability
If manual welding is performed, then error correction is possible, but reliability decreases due to human error
Solution Approach 1:
The patent incorporates feedback mechanisms that monitor the welding process in real-time. Sensors detect parameters such as welding temperature, pressure, and position, and automatically adjust process variables to maintain consistent weld quality. This feedback control ensures high reliability by eliminating human error while managing system complexity through automated control.
4Productivity
If simultaneous welding of multiple tensioning structures is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The patent divides the welding system into modular segments, each handling specific welding operations. Multiple welding stations or welding heads are arranged to work in parallel on different tensioning structures simultaneously. This segmentation enables high productivity while managing complexity through modular, maintainable components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The automated system enables efficient and repeatable production of inflatable products by simultaneously aligning and welding tensioning structures to sheets, reducing production time and minimizing human error.
Implementation Method 1
The welding position is agreed with the upper electrode. The upper electrode is pressed down to generate heat from the resins of the sheet members and crosslinking member
Implementation Method 2
simultaneously welding the leading end of the first tensioning structure to the first sheet and the trailing end of the first tensioning structure to the second sheet by simultaneously operating the first and second welders
Data Source
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AI summary
An automated system and method are disclosed for producing an inflatable product having a first sheet, a second sheet, and a plurality of tensioning structures between the first and second sheets. The system includes an upstream tensioning structure production subsystem that produces the tensioning structures and a downstream preassembly production subsystem that couples the tensioning structures to the first and second sheets. The subsystems may operate simultaneously to produce the inflatable product in an automated, efficient, and repeatable manner.