Inflatable Internal Tensioning Structure for Lower Packed Volume
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Solution Overview
Problem
Conventional inflatable products face challenges with weight and packed volume due to the use of thick PVC sheets for tension bands, which increase the weight and folded volume of deflated structures.
Innovation Solution
The use of thin, flexible string- or wire-like strands joined by intermediate materials like strips or sheets, which provide tensile strength while minimizing weight and volume, replacing traditional PVC sheets with a more efficient and lightweight tensioning structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick PVC sheets are used for tension bands, then force requirements are met, but weight increases
Solution Approach 1:
The continuous PVC sheet tension band is segmented into discrete strands spaced at intervals. Each strand is individually connected to the first and second sheets, distributing the force requirement across multiple discrete elements rather than requiring a single continuous thick sheet. This segmentation allows weight reduction while maintaining overall structural strength.
Solution Approach 2:
The invention changes the parameter of tension band thickness from conventional thick PVC sheets to thin strands with diameter between 0.01-2mm. By changing this dimensional parameter and using multiple spaced strands instead of a single thick sheet, the force requirements are met through distributed tension while significantly reducing the weight of the inflatable product.
2Strength
If thick PVC sheets are used for tension bands, then force requirements are met, but folded volume increases
Solution Approach 1:
Segmenting the tension band into discrete spaced strands allows the deflated structure to collapse more efficiently. The gaps between strands create void spaces that facilitate compact folding, reducing the overall folded volume compared to a continuous thick sheet that must maintain its structural form during compression.
Solution Approach 2:
By changing the thickness parameter from conventional sheets to thin strands (0.01-2mm diameter), the folded volume is significantly reduced. The thin strands can be compressed into much smaller spaces within the deflated product, decreasing the packed/folded volume for storage and transport.
3Strength
If continuous plastic strips are used for tension bands, then force requirements are met, but weight increases
Solution Approach 1:
The continuous plastic strip is divided into multiple discrete strands spaced at specific intervals. This segmentation maintains the force-bearing capability through distributed tension across multiple elements while reducing the total material quantity required, thereby decreasing weight.
Solution Approach 2:
Material is extracted from the continuous strip by creating gaps between individual strands. Only the necessary portions of material are retained at strategic locations where force transmission is needed, while removing excess material between strands that would contribute to weight without providing proportional strength benefits.
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 solution results in a strong, lightweight, and compact inflatable product with reduced weight and deflated volume, maintaining structural integrity and shape upon inflation.
Implementation Method 1
strands spanning a gap between a first sheet and a second sheet of the adjacent material. The strands are firmly connected to the adjacent fabric via an intermediate material, such as a strip or sheet, and the intermediate material is in turn firmly connected to the fabric
Data Source
AI summary
An inflatable product with an internal tensioning structure (3) wherein the internal tensioning structure (3) fulfills the basic function of maintaining two adjacent inflatable surfaces (1, 2) in a desired geometric arrangement when the inflatable product is pressurized. The tensioning structure (3) is formed by connecting a pair of plastic strips sheets (31), via spaced-apart strands (32), such as strings or wires. When pulled taut, the strands provide a high tensile strength between the two opposed plastic strips (31). At the same time, the plastic strips (31) facilitate a strong, long-lasting weld between the tensioning structure (3) and the inflatable product.