Inflatable Internal Tensioning Structure With Lightweight Strand Support
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Solution Overview
Problem
Conventional inflatable products face challenges in achieving a lightweight and compact internal tensioning structure that maintains shape and durability while minimizing weight and volume, especially when deflated, due to the use of thick PVC sheets or continuous plastic strips which increase weight and folded volume.
Innovation Solution
The use of thin, flexible string- or wire-like strands joined by intermediate materials like strips or sheets, which are connected to the fabric to provide tensile strength and maintain shape, reducing the thickness and weight of the tensioning structure while maintaining high tensile strength and operable area-to-volume ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick PVC sheets are used for tension bands, then force requirements are met and structural strength is ensured, but weight and compressed volume increase
Solution Approach 1:
The continuous PVC sheet is segmented into discrete tension bands with specific spacing and dimensions. Each tension band is a separate element that can be optimized independently, allowing the use of thinner material while maintaining overall structural strength through proper distribution and anchoring to the inflatable structure.
Solution Approach 2:
The invention changes the parameters of the tension bands by reducing thickness from conventional values (0.36-0.8mm) to thinner gauges (0.15-0.3mm), while compensating for the reduced individual strength through increased surface area coverage and optimized spacing patterns to maintain the required tensile strength.
2Strength
If continuous plastic strips or belts are utilized for tension bands, then force distribution is improved, but weight of the inflatable product increases
Solution Approach 1:
The continuous strip is divided into multiple discrete tension bands of specific width and length, spaced at optimized intervals. This segmentation allows each band to be thinner and lighter while the collective arrangement maintains force distribution across the inflatable structure surface.
Solution Approach 2:
Different regions of the inflatable structure have tension bands with locally optimized properties - bands in high-stress areas are more numerous or larger, while bands in lower-stress areas can be smaller or more sparsely distributed, allowing weight reduction without compromising overall structural integrity.
3Strength
If thickness and spatial density of solid-strip tension bands are increased, then force requirements are met, but compressed volume of the deflated structure increases
Solution Approach 1:
The segmented tension band design allows each individual band to be thin and flexible, enabling them to fold and compress efficiently. When deflated, the thin bands can be packed into small volumes without the rigidity constraints of thicker solid strips, dramatically reducing the compressed volume of the entire structure.
Solution Approach 2:
The tension bands are designed with dynamic characteristics - thin and flexible when deflated for compact storage, yet capable of spanning and tensioning effectively when inflated. This dynamic adaptability allows the same structure to achieve both compactness in storage and structural strength in use.
4Shape
If greater number and linear extent of tension bands are used, then rectangularity and shape definition are improved, but weight and complexity increase
Solution Approach 1:
The invention optimizes the parameters of tension bands including their width, length, spacing, and thickness to achieve the desired rectangularity with minimal weight. By carefully selecting these parameters, the design achieves sharp geometric definition without requiring excessive material or an overly dense arrangement of bands.
Solution Approach 2:
Different regions of the inflatable structure have tension bands with locally optimized properties - bands near corners or edges that require sharp definition may be more numerous or larger, while central areas with lower geometric demands can have sparser band arrangements, reducing overall weight while maintaining shape integrity.
Data Source
AI summary
An internal tensioning structure (3) for use in an inflatable product 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 (32) 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 and the inflatable product.