Sheet and inflatable product
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Solution Overview
Problem
Existing inflatable pad manufacturing processes face challenges in achieving precise control over welding temperature and time due to equipment limitations, environmental variations, and manual operation, leading to issues like gas leakage and product defects.
Innovation Solution
A sheet comprising a fabric layer, an adhesive layer, and a substrate layer with a first layer of a high-melting-point polymer material and a second layer of a low-melting-point polymer material, allowing for controlled welding within a specific temperature range to ensure airtightness and reduce sensitivity to temperature deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-temperature TPU film is used for welding, then the manufacturing process can be simplified, but the welding temperature and time control becomes highly sensitive to deviations leading to gas leakage or insufficient bonding
Solution Approach 1:
The substrate layer is divided into two distinct polymer layers: a first layer with high melting point (140-160°C) and a second layer with low melting point (110-130°C). This segmentation allows the welding process to occur at a lower temperature range while the higher melting point layer maintains structural integrity, reducing sensitivity to temperature deviations and preventing both over-melting and under-bonding issues
Solution Approach 2:
The invention uses a composite structure combining two different polymer materials with distinct melting points in the substrate layer. This composite material approach enables the welding process to benefit from the low melting point material (easier welding) while being protected by the high melting point material (prevents overheating), thereby improving welding quality consistency without significantly complicating the manufacturing process
2Strength
If higher welding temperature or longer welding time is used to ensure adequate bonding, then bonding strength improves, but over-melting occurs causing small holes or void areas that lead to gas leakage
Solution Approach 1:
The high melting point first layer acts as a protective barrier that prevents over-melting before it can occur. During welding, even if temperature or time exceeds the optimal range, the second layer may melt excessively but the first layer maintains its structural integrity, cushioning against the harmful effect of over-melting and preventing gas leakage from void formation
3Object-generated harmful factors
If lower welding temperature or shorter welding time is used to avoid over-melting, then gas leakage from over-melting is prevented, but insufficient melting occurs leading to inadequate adhesion or poor bonding
Solution Approach 1:
Different regions of the substrate layer have different melting points tailored to specific functions: the second layer (low melting point) is optimized for welding bonding, while the first layer (high melting point) is optimized for structural stability. This local quality differentiation ensures that during welding, the second layer melts adequately for bonding without requiring excessive temperature that would cause over-melting, while the first layer remains intact to prevent gas leakage
4Manufacturing precision
If high precision is required for production equipment and process to control welding temperature, then welding quality can be maintained, but production complexity and costs increase
Solution Approach 1:
The invention changes the material parameters (melting points) of the substrate layer polymers to create a wider acceptable welding temperature range. By using polymers with melting points of 110-130°C and 140-160°C, the welding process can tolerate greater temperature fluctuations and deviations without producing defects, thereby reducing the precision requirements for welding equipment and simplifying production processes
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 proposed solution significantly reduces the impact of welding temperature and time deviations on product quality, enhancing gas tightness, increasing yield rate, reducing production costs, and simplifying the welding operation.
Implementation Method 1
the first polymer material having a melting point higher than a melting point of the second polymer material... the second layer with a lower melting point can be melted for welding, while the first layer with a higher melting point remains structurally intact
Implementation Method 2
the heat of the welding apparatus is transferred to the dies, which in turn transfer the heat to the single-temperature TPU films, thus welding the single-temperature TPU films of the top sheet and the bottom sheet
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
Provided is a sheet (200) comprising: a fabric layer (202); an adhesive layer (204); and a substrate layer (206) having a first layer (208) comprising a first polymer material and a second layer (210) comprising a second polymer material, the first polymer material having a melting point higher than a melting point of the second polymer material, wherein the substrate layer (206) is formed by converging the first polymer material in a flowable state and the second polymer material in a flowable state, and the fabric layer (202) is laminated to the first layer (208) through the adhesive layer (204). Further provided is an inflatable product, wherein at least a portion of the inflatable product is made of the sheet (200). The inflatable product may be an inflatable pad (100) comprising a top sheet (102) and a bottom sheet (104) connected to each other to jointly define an inflatable chamber (106), the top sheet (102) and the bottom sheet (104) being made of the sheet (200).