Inflatable Product Pull Strap Fusing for One-Step Manufacturing
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Solution Overview
Problem
The conventional inflatable product fusing process is tedious and low-efficiency due to the need for two separate fusing processes to connect pull straps with the upper and lower sheets.
Innovation Solution
The process involves using upper and lower pull strap sheets made from porous materials, with upper and lower fixing sheets placed between them, allowing for simultaneous hot fusing or high-frequency operation to fuse the sheets in one step, eliminating the need for a separating sheet and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two separate fusing processes are used to connect pull straps with upper and lower sheets, then the connection reliability is improved, but the manufacturing complexity and production time increase
Solution Approach 1:
The patent combines two separate fusing processes into a single integrated process by using a pull strap assembly that pre-connects the upper and lower pull strap sheets. This allows both the upper sheet-pull strap and pull strap-lower sheet connections to be established simultaneously in one fusing operation, reducing manufacturing complexity while maintaining connection reliability
Solution Approach 2:
The pull strap assembly is prepared in advance with the upper and lower pull strap sheets already connected through preliminary fusing or bonding. This preliminary action enables the final assembly process to complete both connections in one step, eliminating the need for sequential operations and reducing overall manufacturing complexity
2Reliability
If two separate fusing processes are used to connect pull straps with upper and lower sheets, then the connection reliability is improved, but the production time increases
Solution Approach 1:
The patent merges two sequential fusing operations into a single simultaneous operation by designing the pull strap assembly to enable both connections to be made at the same time. This reduces production time from two separate process cycles to one, while the pre-designed assembly structure ensures that connection reliability is maintained
Solution Approach 2:
The invention enables continuous productive action by eliminating the idle time between two separate fusing processes. The single integrated fusing process allows the useful action of connecting components to continue without interruption, thereby reducing total production time while maintaining the necessary connection quality
3Ease of manufacture
If conventional fusing process is used with separating sheet, then the manufacturing process is established, but the product weight increases and efficiency decreases
Solution Approach 1:
The patent extracts and eliminates the separating sheet from the manufacturing process. By removing this unnecessary component, the product weight is reduced while the simplified process using only the pull strap assembly maintains ease of manufacture through the single-step fusing operation
4Ease of manufacture
If conventional fusing process is used with separating sheet, then the manufacturing process is established, but the productivity decreases
Solution Approach 1:
The patent merges multiple manufacturing steps into a single integrated process. By combining the connection of upper and lower pull strap sheets to their respective sheets into one simultaneous fusing operation, productivity is doubled while the established manufacturing principles are maintained through the systematic design of the pull strap assembly
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 approach reduces the weight of the inflatable product by using lightweight materials and streamlines the production process, enabling the formation of inflatable products in a single step with improved efficiency.
Implementation Method 1
the upper pull strap sheet and the lower pull strap sheet are made from a porous material
Implementation Method 2
performing a hot fusing or high-frequency operation, to fuse the upper pull strap sheets with the upper fixing sheets and the lower fixing sheets with the lower pull strap sheets together at the same time
Implementation Method 3
performing a hot fusing or high-frequency operation, to fuse the upper pull strap sheets with the upper fixing sheets and the lower fixing sheets with the lower pull strap sheets together at the same time
Data Source
AI summary
Provided are an inflatable product and an inflatable product fusing process. The inflatable product comprises an upper sheet, a lower sheet, pull straps provided therebetween, and upper and lower fixing sheets having one faces away from each other respectively joined with inner surfaces of the upper and lower sheets and one faces facing towards each other not joined. The pull strap has oppositely-provided upper and lower pull strap sheets of porous material. The upper sheet, upper pull strap sheet, upper fixing sheet, lower fixing sheet, lower pull strap sheet and lower sheet are successively provided. When processing using a hot-fusing machine or high-frequency machine, the upper and lower pull strap sheets are simultaneously jointed with the upper and lower fixing sheets, therefore the inflatable product can be one-step formed and no separating sheet needs to be provided in the pull strap, thus simplifying manufacturing process and improving production efficiency.