Inflatable Joint Structure With Thickened Edges for Tear Resistance
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Solution Overview
Problem
Inflatable products, such as mattresses, face stress concentration and reduced durability at the base positions where the top and bottom layers are joined by high-frequency welding, leading to potential tears and a shortened service life, while increasing the overall thickness to enhance strength results in increased weight and cost.
Innovation Solution
A connection structure where the peripheral edges of the top and bottom layers, and the ends of tension members, are thickened to enhance stress distribution and tensile strength, using a calendaring roller with annular grooves to create extruded layers with varying thicknesses for improved welding and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the overall thickness of the top layer and bottom layer is uniformly increased to enhance tensile strength at base positions, then the stress-resistant strength is improved, but the weight and manufacturing cost increase
Solution Approach 1:
The patent applies local quality by creating a thickened section specifically at the peripheral edge of the material layer where the base positions are located. This localized thickening provides enhanced tensile strength at the stress-prone base positions without increasing the thickness of the entire material layer, thereby avoiding unnecessary weight increase while solving the strength problem at critical locations.
2Reliability
If the overall thickness of the top layer and bottom layer is uniformly increased to prevent tearing at base positions, then the durability is improved, but the manufacturing cost increases
Solution Approach 1:
The invention uses local quality by providing a thickened section only at the peripheral edge where base positions are formed, rather than uniformly increasing the thickness of the entire material layer. This localized approach enhances durability at the critical base positions while minimizing material consumption and manufacturing cost.
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 solution enhances the tensile strength of the base positions, reduces material costs, and maintains product lightweightness, resulting in improved durability and longer service life without increasing the overall thickness or weight.
Implementation Method 1
a first calendaring roller having a circular roller body, and a plurality of annular grooves provided in spaced-apart manner along the length of the roller body, and a second roller having a uniform smooth surface. The first roller is positioned from the second roller with a gap between the two rollers, and then a material is passed through the gap to create an extruded layer having thickened sections
Data Source
AI summary
An inflatable product has a first layer and a second layer, each layer having a peripheral edge, with the first and second layers joined together along their peripheral edges to define an internal space for receiving air or fluid. Each layer has a uniform thickness throughout except that the thickness along the peripheral edge of each layer is greater than the thickness of the rest of the layer. A plurality of tension members can also be provided inside the internal space, each tension member having a first end that is joined to an inner surface of the first layer, and a second end that is joined to an inner surface of the second layer. Each tension member has a uniform thickness throughout except that the thickness along the first and second ends is greater than the thickness of the rest of the tension member.