Manufacturing of an inflatable structure
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Solution Overview
Problem
The manufacturing process of inflatable drop stitch products is time-consuming and costly due to the need for complex welding and sealing of edges to make the structure airtight and gas-proof.
Innovation Solution
A method involving a control system that determines contours of the inflatable structure, provides a drop stitch fabric with fixation lines corresponding to these contours, and coats the fabric, eliminating the need for subsequent patching and sealing by defining and bonding the edges during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional welding and sealing processes are used to make the inflatable structure airtight, then the structure achieves gas-proof properties, but the manufacturing process becomes time-consuming and complex
Solution Approach 1:
The coating is applied to the drop stitch fabric before the welding and sealing steps, creating a gas-proof barrier in advance. This preliminary coating action eliminates the need for subsequent patching and sealing operations, as the coating itself provides the airtight seal along the contours of the structure.
Solution Approach 2:
The invention combines the coating process with the contour definition process. The same coating that provides gas-proof properties also defines and seals the contours of the inflatable structure, merging two functions (protection and shape definition) into a single integrated process step.
2Reliability
If traditional welding and sealing processes are used to make the inflatable structure airtight, then the structure achieves gas-proof properties, but the manufacturing cost increases
Solution Approach 1:
The coating is applied to the drop stitch fabric before the welding and sealing steps, creating a gas-proof barrier in advance. This preliminary coating action eliminates the need for subsequent patching and sealing operations, as the coating itself provides the airtight seal along the contours of the structure.
Solution Approach 2:
The invention combines the coating process with the contour definition process. The same coating that provides gas-proof properties also defines and seals the contours of the inflatable structure, merging two functions (protection and shape definition) into a single integrated process step.
3Productivity
If fixation lines are provided along the drop stitch fabric corresponding to the contours, then the edges are defined and bonded during manufacturing, but additional coating steps are required
Solution Approach 1:
The invention combines the coating process with the contour definition process. The same coating that provides gas-proof properties also defines and seals the contours of the inflatable structure, merging two functions (protection and shape definition) into a single integrated process step.
Data Source
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AI summary
The present disclosure relates to manufacturing an inflatable structure (1). There is determined one or more contours (2) of at least a portion of an inflatable structure to be manufactured. There is further provided a drop stitch fabric (3) having a first layer (31) and a second layer (32) tethered by drop stitches (4). Moreover, there is provided along at least a portion of the drop stitch fabric one or more fixation lines (5) comprising coupling means (51) fixating the first layer to the second layer, the one or more fixation lines corresponding to the one or more contours. Furthermore, the drop stitch fabric is coated, wherein one or more coating layers cover at least the one or more fixation lines. The disclosure also relates to an inflatable structure manufactured according to the foregoing, and a control system (10) for controlling said manufacturing.