Manufacturing of an inflatable structure
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Solution Overview
Problem
The manufacturing process of inflatable drop stitch products is time-consuming and complex, leading to high production costs due to the need for additional welding and sealing of edges to ensure airtightness.
Innovation Solution
A method involving determining contours of the inflatable structure, providing a drop stitch fabric with tethered layers and fixation lines that correspond to these contours, and coating the fixation lines to seal the edges, eliminating the need for subsequent welding and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the traditional manufacturing process is used with coating and impregnation before cutting contours, then the fabric is properly prepared, but the process becomes time-consuming and complex requiring additional welding and sealing
Solution Approach 1:
The invention applies preliminary action by providing fixation lines that define the contours of the inflatable structure before cutting occurs. These fixation lines are created during the coating process itself, so that when the fabric is later cut along these lines, the edges are already sealed and ready for use, eliminating the need for subsequent welding or sealing operations.
Solution Approach 2:
The invention merges the contour definition function and the sealing function into a single integrated feature - the fixation line. Rather than having separate steps for defining contours and separate steps for sealing edges, the fixation line simultaneously performs both functions, reducing process complexity and time.
2Reliability
If additional welding and sealing steps are performed to ensure airtightness, then the product becomes airtight, but the production cost increases
Solution Approach 1:
The invention ensures airtightness through preliminary action by creating fixation lines during the initial coating process. These fixation lines are formed by applying coating material along predetermined paths that will become the contours of the inflatable structure. The coating material itself acts as the seal, eliminating the need for additional welding or sealing steps that would increase production cost.
3Shape
If contours are determined and fixation lines are provided corresponding to these contours, then the geometry is fixed and edges are defined, but the process requires precise coordination
Solution Approach 1:
The invention applies local quality by creating fixation lines with different properties at different locations. The coating material is applied along specific paths (the fixation lines) rather than uniformly across the entire fabric. This allows the fixation lines to have the sealing and defining properties exactly where needed - along the future contours of the inflatable structure - while the rest of the fabric maintains its standard properties.
Data Source
AI summary
The present disclosure relates to manufacturing an inflatable structure. There is determined one or more contours of at least a portion of an inflatable structure to be manufactured. There is further provided a drop stitch fabric having a first layer and a second layer tethered by drop stitches. Moreover, there is provided along at least a portion of the drop stitch fabric one or more fixation lines comprising coupling means 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 for controlling said manufacturing.