Masked Multi-Layer Bladder Fabrication for Cost-Effective Bonding
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Solution Overview
Problem
Creating complex multi-layer bladders with efficient and cost-effective manufacturing processes is challenging, especially when using perimeter sealing methods like ultrasonic welding, which can be costly or impractical.
Innovation Solution
The development of masked multi-layer bladders involves using a mask with apertures between bladder layers to prevent bonding, allowing gas flow and distribution, and employing a heat press to bond the layers at specific locations, enabling efficient and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If perimeter sealing methods like ultrasonic welding are used to bond bladder layers, then bonding strength is improved, but manufacturing cost increases and manufacturing complexity increases
Solution Approach 1:
A mask layer is introduced as an intermediary between the first and second bladder layers. The mask has apertures that allow selective bonding - the bladder layers bond to each other where the mask has apertures, but remain unbonded where the mask material is present. This intermediary approach enables cost-effective manufacturing while maintaining necessary bonding strength at critical locations.
Solution Approach 2:
Instead of uniformly bonding the entire perimeter of the bladder layers, the invention applies bonding only at specific locations where structural strength is needed. The mask creates regions of bonded and unbonded areas, providing local quality - full bonding strength where required and flexibility where required. This reduces manufacturing cost and complexity while maintaining adequate bonding strength.
2Strength
If perimeter sealing methods like ultrasonic welding are used to bond bladder layers, then bonding strength is improved, but device complexity increases
Solution Approach 1:
The mask serves as a simple intermediary component that simplifies the manufacturing process. Instead of using complex ultrasonic welding fixtures and processes to achieve selective bonding, the mask provides a straightforward solution - place the mask between layers, apply heat and pressure, and bonding occurs automatically at the desired locations. This reduces device complexity while maintaining bonding strength.
Solution Approach 2:
The invention changes the bonding parameters from requiring complex ultrasonic welding to simple heat and pressure application. By using a mask to control the bonding interface, the process parameters become much simpler - standard heat pressing conditions suffice, eliminating the need for complex ultrasonic welding equipment and procedures.
3Quantity of substance
If mask with apertures is used to prevent bonding between bladder layers, then gas flow distribution is improved, but manufacturing precision requirements increase
Solution Approach 1:
The mask is positioned and secured to the first bladder layer before the second bladder layer is applied. This preliminary action ensures proper alignment and positioning is established early in the manufacturing process, making the subsequent bonding process more forgiving and reducing the overall manufacturing precision requirements.
Solution Approach 2:
The mask serves multiple functions simultaneously: it prevents bonding in regions where flexibility is needed, it distributes gas flow through its apertures, and it provides alignment references for the bladder layers. This multi-functionality reduces the need for separate alignment features and reduces overall manufacturing precision requirements.
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 method allows for the efficient and cost-effective manufacturing of multi-layer bladders that can be used in various applications, such as HVAC systems and seatback pockets, by evenly distributing gas flow and enabling flexible expansion and deformation.
Implementation Method 1
a second bladder layer that is adhesively bonded to the first bladder layer within the apertures in the mask
Implementation Method 2
employing a heat press to bond the layers at specific locations
Data Source
AI summary
A multi-layer bladder includes: a first bladder layer; a mask including a plurality of apertures; a second bladder layer bonded to the first bladder layer within the apertures in the mask and where the mask is not present between the first and second bladder layers, where the mask is configured to prevent bonding of the second bladder layer to the first bladder layer where the mask is present; and a fluid channel that is located between the first and second bladder layers and that extends to the mask from an outer edge of the multi-layer bladder.