Inflatable Tensioning Structure for Lower Weight and Packed Volume
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Solution Overview
Problem
Existing inflatable products face challenges in achieving a lightweight and low-cost design due to the weight and volume contributions of traditional PVC sheet or belt-based tension bands, which are necessary for maintaining shape but increase the overall weight and packed volume of the deflated structure.
Innovation Solution
The use of thin, flexible string- or wire-like strands connected via intermediate materials to form tensioning structures within inflatable products, which maintain shape while reducing weight and volume by providing high tensile strength with a lower material thickness and weight, achieving an operable area-to-weight ratio of at least 6,000 square centimeters per kilogram.
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 improved, but weight and packed volume increase
Solution Approach 1:
The patent changes the physical parameters of the tension band by transitioning from thick PVC sheets (0.36-0.8mm) to thin strands (0.01-0.5mm diameter). This parameter change maintains tensile strength while dramatically reducing weight and volume, as the strands can be loosely arranged and compressed when deflated
Solution Approach 2:
The patent uses composite construction by combining multiple thin strands together to form the tension band structure. This composite approach distributes the force requirements across many individual strands, achieving the same structural strength as thick sheets while using much less material mass
2Strength
If thick PVC sheets are used for tension bands, then force requirements are met, but packed volume increases
Solution Approach 1:
The patent segments the continuous PVC sheet into discrete, flexible strands. These segmented strands can be independently arranged and compressed, allowing the entire tension band structure to be compacted into a small volume when deflated, unlike rigid thick sheets that maintain their form factor
Solution Approach 2:
By changing from sheet geometry to strand geometry, the patent enables dramatic volume reduction in packed state while maintaining strength in inflated state. The strands can be loosely coiled and compressed to a fraction of the volume required by equivalent strength sheet structures
3Shape
If more tension bands are added, then rectangularity and shape definition are improved, but weight and complexity increase
Solution Approach 1:
The patent replaces the mechanical system of thick, heavy PVC sheets with a lighter strand-based system. The strands achieve the same shape-defining function through their arrangement and tensioning mechanism, reducing weight while maintaining or improving rectangularity
Solution Approach 2:
By using multiple thin strands in a composite arrangement, the patent achieves superior shape definition compared to individual thick sheets. The strands can be more densely arranged and provide more uniform tension distribution, improving rectangularity without the weight penalty of proportionally increasing sheet thickness
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.