Inflatable Lounge Chair Folding Structure for Fewer Welds
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Solution Overview
Problem
The manufacture of inflatable lounge chairs requires numerous welding steps, making the process complex and time-consuming, with some methods needing over 20 welds and a custom welding table.
Innovation Solution
A method involving two planar sheets with cut-out portions and notches that are folded and secured to form a cup-like configuration with fewer welding steps, using a peripheral seam and interior seam to create fluidically isolated inflatable regions, reducing the number of welds required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manufacturing methods are used with multiple welding steps, then structural integrity is maintained, but manufacturing complexity and time increase significantly
Solution Approach 1:
The planar sheet is divided into multiple sections with cut-out portions that create notches. These segmented sections are folded and secured to each other, reducing the need for numerous welds while maintaining structural integrity through the distributed segmentation of the chair structure.
Solution Approach 2:
The planar sheet is folded into a three-dimensional cup-like configuration, transforming a two-dimensional structure into a 3D form. This dimensional transformation allows the sheet to form armrests, backrest, and seat portions without requiring multiple separate welded components.
2Reliability
If traditional manufacturing methods with over 20 welds are used, then structural integrity is ensured, but manufacturing time and cost increase
Solution Approach 1:
Cut-out portions are pre-formed in the planar sheet before assembly. These notches are prepared in advance to receive corresponding edges during folding, eliminating the need for complex on-site welding operations and reducing manufacturing steps.
Solution Approach 2:
Multiple structural elements (armrests, backrest, seat) are merged into a single continuous planar sheet that is folded into place. This consolidation reduces the number of separate components and welds needed compared to traditional multi-piece construction methods.
3Manufacturing precision
If custom welding tables and equipment are used, then precise welding is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The planar sheet's own geometry, with its cut-out portions and notches, provides the alignment and positioning features needed for assembly. The structure is self-aligning during folding, eliminating the need for external welding tables or specialized positioning equipment.
Solution Approach 2:
Instead of using complex equipment to achieve precision welding, the invention inverts the approach by designing the sheet geometry itself to provide alignment features. The cut-out portions and notches create inherent positioning that guides accurate assembly without specialized tools.
Data Source
AI summary
This invention relates to recreational flotation devices, and particularly to inflatable lounge chairs, and to methods for manufacturing same.