Floating Mandrel for RF Welding Multi-Layer Air Mattress Baffles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing dielectric welding techniques for multi-dimensional constructions are complex and inefficient, particularly when attempting to weld multiple layers without causing unintended welds or ensuring proper bonding between layers.
Innovation Solution
The use of a non-grounded, floating mandrel in an RF welding machine allows for the fabrication of embedded baffles in an air mattress by positioning and welding pre-cut thermoplastic layers without electrical contact to the grounding plate, using a mandrel with stop blocks to control material flow and prevent over-compression during the welding cycle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If grounding plates/mandrels are inserted between layers of material to control weld occurrence, then weld control precision is improved, but device complexity increases
Solution Approach 1:
The invention extracts the grounding plate/mandrel from the traditional grounded state and uses it as a floating mandrel that is not electrically connected to the grounding plate. This allows the mandrel to control weld occurrence through its physical positioning and interaction with RF fields without requiring complex grounding connections, thereby reducing device complexity while maintaining weld control precision.
Solution Approach 2:
The floating mandrel acts as an intermediary element between the RF head and the grounding plate. It mediates the RF energy distribution and controls weld formation through its physical presence and interaction with the thermoplastic layers, eliminating the need for complex grounding plate arrangements while maintaining precise weld control.
2Adaptability or versatility
If switching machines are used to weld multiple layers, then multi-dimensional welding capability is improved, but device complexity increases
Solution Approach 1:
The invention uses a floating mandrel that can be dynamically positioned and removed during the welding process. The mandrel allows for multi-dimensional welding by enabling selective welding of different layers at different stages, providing adaptability without requiring complex switching machinery.
Solution Approach 2:
The welding process is segmented into different stages where the floating mandrel can be positioned to enable welding of specific layers. This segmentation allows multi-dimensional welding capability while keeping the device simple, as the same basic RF welding machine can perform different welding operations by repositioning the mandrel.
3Use of energy by moving object
If thermoplastic with high dielectric constant is used, then RF energy transmission is improved, but material stability deteriorates due to quick breakdown and phase change
Solution Approach 1:
The floating mandrel acts as an intermediary that controls the RF energy distribution to the thermoplastic layers. By mediating the energy transmission through its physical presence and interaction with the RF fields, it prevents excessive energy concentration that would cause quick breakdown and phase change, thereby improving material stability while maintaining RF energy transmission efficiency.
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
This method enables efficient welding of multiple layers with precise control over the weld formation, resulting in a strong, airtight inflatable mattress with controlled volume and flatness upon inflation, while simplifying the welding process by avoiding direct electrical contact and ensuring complete bonding between layers.
Implementation Method 1
using a mandrel that acts as a capacitor to control energy distribution
Implementation Method 2
transmit powerful radio frequency waves from the generator through a head plate, and subsequently to an electrode of a certain shape. The electrode then radiates the RF energy through a thermoplastic
Data Source
AI summary
A mandrel for use in welding an air mattress having a top layer, bottom layer and at least one baffle joining the top layer and bottom layer, the mandrel includes a central mounting block; a baffle locating pin on a top surface of the central mounting block for securing the baffle to the central mounting block; a conductive sealing surface positioned along an edge of the central mounting block; a stop block positioned on the top surface of the central mounting block adjacent the sealing surface; and a bumper mounted to the central mounting block.