Inflatable Tensioning Structure for Low-Weight Compact Packing
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Solution Overview
Problem
Existing inflatable products face challenges in maintaining shape while minimizing weight and packed volume due to the use of thick PVC tension bands, which increase the weight and folded volume of deflated structures.
Innovation Solution
The use of thin, flexible strands or wires connecting plastic sheets with weld strips to create a tensioning structure that maintains geometric shape with a high tensile strength, reducing the weight and volume of the inflatable product by optimizing the operable area-to-weight and area-to-volume ratios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick PVC tension bands are used to maintain shape and provide tensile strength, then the structural integrity and shape maintenance are improved, but the weight and folded volume of the deflated structure increase
Solution Approach 1:
The continuous PVC tension band is segmented into discrete plastic strips spaced apart from each other. These strips are connected by tension members (strings, wires, or rods) to form a lattice-like structure. This segmentation reduces the total amount of PVC material needed while maintaining tensile strength through the tension members, thereby reducing weight without sacrificing structural integrity.
Solution Approach 2:
The tensioning structure uses a composite approach by combining different materials: plastic strips (for welding to inflatable surfaces), tension members (for providing tensile strength), and potentially rigid rods (for additional structural support). This composite structure achieves the required strength-to-weight ratio by leveraging the advantages of each material type rather than relying on a single thick PVC band.
2Strength
If thick PVC tension bands are used to maintain shape and provide tensile strength, then the structural integrity and shape maintenance are improved, but the folded volume of the deflated structure increases
Solution Approach 1:
By dividing the continuous tension band into discrete plastic strips connected by tension members, the structure becomes more collapsible. The spaced-apart configuration allows the strips and tension members to fold and compact more efficiently, reducing the folded volume compared to a solid continuous band that maintains its cross-sectional thickness throughout folding.
Solution Approach 2:
The plastic strips are thin and flexible, allowing them to conform and compact during folding. This flexibility enables the tensioning structure to collapse into a smaller volume while maintaining its tensile strength when inflated, as the thin strips can bend and fold without breaking or creating excessive bulk.
3Manufacturing precision
If the number and spacing of tension bands are increased to achieve sharper rectangularity, then the shape precision is improved, but the weight and material usage increase
Solution Approach 1:
The segmented structure with spaced plastic strips and tension members allows for increased number of tensioning elements without proportionally increasing weight. Each strip-member assembly is lightweight, so multiple assemblies can be distributed throughout the inflatable structure to achieve sharp rectangularity and precise shape control while keeping overall weight low.
Solution Approach 2:
The invention changes the structural parameters from continuous thick bands to discrete thin strips with tension members. This parameter change allows optimization of the number and spacing of tensioning elements to achieve desired shape precision while controlling weight through the lightweight nature of individual strip-member assemblies.
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 lightweight, compact inflatable product with enhanced tensile strength and reduced material usage, allowing for efficient packing and transportation while maintaining structural integrity during inflation.
Implementation Method 1
When pulled taut, the strands provide a high tensile strength between the two opposed plastic strips
Implementation Method 2
the plastic strips facilitate a strong, long-lasting weld between the tensioning structure and the inflatable product
Data Source
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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.