Inflatable Internal Tensioning Structure for Low Packed Volume
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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
A tensioning structure formed by connecting plastic strips with spaced-apart strands, such as strings or wires, providing high tensile strength while reducing the thickness and weight of the inflatable product, and allowing for a strong weld between the strands and the inflatable product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick PVC tension bands are used to maintain shape and provide tensile strength, then the strength and shape stability are improved, but the weight and folded volume of the deflated structure increase
Solution Approach 1:
The tension band is segmented into multiple discrete strands (e.g., 7-13 strands per tension band) rather than using a single thick PVC sheet. Each strand has a diameter of 0.25-0.75 mm, and multiple strands collectively provide the required tensile strength while significantly reducing weight and packed volume compared to traditional thick PVC tension bands
Solution Approach 2:
The invention uses composite construction by combining multiple material components: plastic strips (0.15-0.38 mm thick) for structural support, strands (0.25-0.75 mm diameter) for tensile strength, and adhesive layers for bonding. This composite approach achieves the required mechanical properties with reduced overall thickness and weight
2Reliability
If thick PVC tension bands are used to ensure force distribution and stress reduction, then the reliability is improved, but the packed volume of the deflated structure increases
Solution Approach 1:
The tension band is divided into multiple discrete strands (7-13 per tension band) that collectively distribute forces across the structure. Each strand has a diameter of 0.25-0.75 mm, and the segmented configuration maintains force distribution reliability while reducing the overall packed volume compared to solid thick PVC sheets
Solution Approach 2:
The invention uses thin plastic strips (0.15-0.38 mm thick) instead of thick rigid PVC sheets. These thin flexible strips maintain the necessary structural integrity and force distribution while occupying significantly less volume when deflated and packed
3Strength
If the thickness of tension bands is increased to meet force requirements, then the strength is improved, but the weight and material cost increase
Solution Approach 1:
Instead of using fewer thick strands, the invention uses multiple thinner strands (0.25-0.75 mm diameter) arranged in groups of 7-13 per tension band. This segmentation provides the required force bearing capacity through collective strength while significantly reducing the weight compared to equivalent single thick PVC sheets
Solution Approach 2:
The invention changes the dimensional parameters of the tension band components: using plastic strips with thickness of 0.15-0.38 mm (thinner than traditional PVC sheets) and strands with diameter of 0.25-0.75 mm. These parameter changes maintain structural strength while reducing weight and material usage
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 achieves a lightweight, compact inflatable product with high tensile strength and a low packed volume, maintaining desired geometric arrangements when inflated, and reducing material costs by using thinner strands instead of thick PVC sheets.
Implementation Method 1
a plurality of strands extending between and connecting the plastic strips to one another, with the strands substantially parallel to one another and substantially perpendicular to the plastic strips
Implementation Method 2
either weld strips or weld sheets, and either hot roll or high frequency weld the weld strips or weld sheets to the plurality of strands
Data Source
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AI summary
An internal tensioning structure for use in an inflatable product fulfills the basic function of maintaining two adjacent inflatable surfaces in a desired geometric arrangement when the inflatable product is pressurized. The tensioning structure is formed by connecting a pair of plastic strips sheets via spaced-apart strands, such as strings or wires. When pulled taut, the strands provide a high tensile strength between the two opposed plastic strips. At the same time, the plastic strips facilitate a strong, long-lasting weld between the tensioning structure and the inflatable product.