3D Reinforced Membrane Dropstitch Urethane Coating
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Solution Overview
Problem
Conventional three-dimensional reinforced membranes used in inflatable products lack sufficient tensile strength and puncture resistance, and existing manufacturing methods do not effectively provide the necessary reinforcement for structural applications.
Innovation Solution
A three-dimensional reinforced membrane is created using a dropstitch fabric with a urethane-based coating and a laminated substrate, comprising extruded films and fabric layers, which are applied using methods such as extrusion coating and lamination to enhance strength and air retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional three-dimensional reinforced membranes are used in inflatable products, then the basic structural function is provided, but the tensile strength and puncture resistance are insufficient
Solution Approach 1:
The patent applies composite materials by combining dropstitch fabric with multiple coating layers (urethane-based coating, laminated substrate with extruded films). This multi-layer composite structure significantly enhances tensile strength and puncture resistance compared to conventional single-material membranes, directly resolving the strength deficiency while maintaining structural reliability under high pressure conditions.
Solution Approach 2:
The patent transitions from conventional two-dimensional membrane structures to a three-dimensional reinforced structure by incorporating the dropstitch fabric's vertical stitching dimension and adding multiple coating layers. This dimensional enhancement provides superior mechanical properties including enhanced tensile strength and puncture resistance, directly addressing the strength and reliability contradiction.
2Strength
If existing manufacturing methods are used, then basic membrane production is achieved, but effective reinforcement for structural applications is not provided
Solution Approach 1:
The patent applies preliminary action by pre-coating the dropstitch fabric with urethane-based material and laminated substrates before final assembly. This pre-reinforcement approach ensures that the structural strength requirements are met before the membrane is integrated into the inflatable product, facilitating easier manufacturing while achieving the required structural reinforcement.
Solution Approach 2:
The manufacturing process creates composite materials by applying multiple coating layers (urethane-based coating, laminated substrate with extruded films) to the dropstitch fabric. This composite construction provides effective structural reinforcement while using established coating and lamination technologies, balancing manufacturing feasibility with enhanced structural performance.
3Reliability
If multi-layer coating and lamination are applied, then superior tensile strength and puncture resistance are achieved, but manufacturing process complexity increases
Solution Approach 1:
The patent applies parameter changes by optimizing the thickness, material composition, and bonding properties of each coating layer and lamination. By carefully controlling these parameters, the multi-layer structure achieves superior pressure withstanding capability (withstanding pressures up to 45 psi) while managing the manufacturing process complexity through standardized material specifications and process parameters.
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 resulting membrane exhibits superior tensile strength and puncture resistance, enabling the production of inflatable articles that can withstand pressures up to 45 psi and are suitable for various structural applications, including watercraft and military uses.
Implementation Method 1
a first coating applied to at least one of the first and second sides of the dropstitch fabric. In some embodiments, the first coating includes a urethane-based material
Implementation Method 2
a laminated substrate is applied to the second coating. In some embodiments, the laminated substrate includes a first extruded film; a second extruded film; and a fabric layer between the first extruded film and the second extruded film
Implementation Method 3
forming the laminated substrate includes providing a fabric layer; coating a first side of the fabric layer and with a solvent based reactive urethane coating to form a coated first side of the fabric layer; extruding a first film; applying the first film to the coated first side of the fabric layer
Data Source
AI summary
A three-dimensional reinforced membrane is designed to be inflated and used in various structural applications. A dropstitch or double wall fabric may be reinforced with one or more coatings, such as urethane-based coatings, and may also be laminated in accordance with various disclosed embodiments.