Inflatable Pad Welding Structure to Reduce Tearing at Line Ends
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Solution Overview
Problem
Existing inflatable pads are prone to tearing at the ends of the welding lines, compromising their flatness and overall usability due to weak welds.
Innovation Solution
The welding points are positioned a predetermined distance from the ends of the welding lines and have a larger diameter than the lines, with a matrix arrangement in the central region and parallel lines in the edge regions, using thermoplastic polyurethane elastomer materials, and optionally incorporating a thermal insulation layer for enhanced durability and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If welding lines are used to connect the top piece and bottom piece, then the pad maintains flatness when inflated, but the ends of the welding lines are easily torn off
Solution Approach 1:
The welding structure is segmented into two distinct components: continuous welding lines that maintain flatness and discrete welding points with enlarged diameters positioned at critical locations to prevent tearing. This segmentation allows each component to fulfill its specific function without compromising the other.
Solution Approach 2:
The welding points are designed with locally enhanced properties - specifically, their diameters are enlarged to be greater than the width of the welding lines. This local quality enhancement provides extra strength at the vulnerable ends of welding lines without affecting the overall flatness maintained by the continuous welding lines.
2Strength
If welding points are added to reinforce welding lines, then tearing resistance is improved, but the manufacturing complexity increases
Solution Approach 1:
The welding points are pre-positioned at predetermined distances from the ends of the welding lines, and their diameters are predetermined to be larger than the welding line width. This preliminary design of welding parameters simplifies the manufacturing process by providing clear, standardized specifications for welding operations.
Solution Approach 2:
The welding points are designed with specific parameter changes - their diameters are set to be greater than the welding line width, and their positions are set at predetermined distances from the ends. These parameter changes create a standardized welding pattern that is easier to manufacture while providing enhanced tearing resistance.
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 design enhances the pad's resistance to tearing, maintains flatness, and improves user comfort and warmth, particularly when used outdoors.
Implementation Method 1
Each of the top piece and the bottom piece may be made of thermoplastic polyurethane elastomer
Implementation Method 2
an outer periphery of the top piece of material and an outer periphery of the bottom piece of material are welded to each other
Data Source
Figure 1~3a
Figure 2~3
Figure 4
AI summary
An inflatable pad is provided including a top piece and a bottom piece comprising an outer periphery welded to an outer periphery of the top piece, thereby defining an inflatable chamber between the top piece and the bottom piece. The inflatable pad further includes a plurality of welding points at which the top piece and the bottom piece are welded to each other and a plurality of welding lines along which the top piece and the bottom piece are welded to each other. One of the plurality of welding points is disposed as predetermined distance from each end of each of the plurality of welding lines.