Single Wall Airbeam Laminated Fabric Welding
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Solution Overview
Problem
Current inflatable airbeams with double wall construction are heavy, costly, and lack structural integrity due to material wastage and precise fabric orientation requirements, while single wall airbeams face challenges in maintaining dimensional stability and torsional strength.
Innovation Solution
A single layer of weldable and air impermeable laminated fabric is used, comprising a polyester fabric with adhesive layers and polyurethane coatings, allowing for easy manufacturing of lightweight, distortion-free airbeams with improved structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If double wall construction is used with outer sleeve and inner bladder, then airholding capability is improved, but weight increases significantly
Solution Approach 1:
The patent combines the outer sleeve and inner bladder functions into a single integrated wall construction. The single wall incorporates both structural support and airholding functions through a unified material system with exterior and interior surfaces in direct contact, eliminating the weight penalty of separate layers while maintaining airholding capability through the interior surface's low temperature melt point properties.
Solution Approach 2:
The patent uses composite material construction with an exterior surface providing structural integrity and an interior surface with low temperature melt point properties. This composite approach allows the single wall to perform both structural and airholding functions simultaneously, achieving double-wall performance with single-wall weight.
2Strength
If double wall construction with fabric sections is used, then structural integrity is improved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the manufacturing process by using pre-formed fabric sections with attached hood pieces that can be independently prepared and then assembled through welding. This segmentation allows each component to be manufactured separately with optimized processes, then joined using simple welding operations rather than complex multi-step assembly procedures.
Solution Approach 2:
The patent replaces complex mechanical sewing and alignment procedures with thermal welding processes. The weldable interior surface allows sections to be joined through heating and fusion, eliminating the need for precise mechanical alignment, sewing operations, and complex fastening systems required by traditional fabric-based constructions.
3Adaptability or versatility
If traditional fabric with bias direction stretching is used, then flexibility is improved, but pattern orientation precision requirements increase
Solution Approach 1:
The patent changes the material parameters by using a woven fabric construction with specific thread counts (e.g., 10x6 or 12x8 per inch) and controlled stretch properties (5-15% in warp and weft directions). This parameter optimization allows the fabric to provide necessary flexibility while maintaining dimensional stability, reducing the need for precise pattern orientation during manufacturing.
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 results in a lightweight, dimensionally stable, and torsion-resistant single wall airbeam that can be easily manufactured and assembled, reducing material waste and fabrication complexity while maintaining structural integrity.
Implementation Method 1
A first adhesive layer is applied to or put in contact with the first surface of the polyester fabric. A polyester film is then applied to or put in contact with the first adhesive layer. A second adhesive layer is applied to or put in contact with the second surface of the polyester fabric.
Implementation Method 2
A first, generally high melt point polyurethane layer is applied to or put in contact with the second adhesive layer. A second, generally low melt point polyurethane layer is applied to or put in contact with the first polyurethane layer. The second, generally low melt point polyurethane layer is configured for forming the interior layer or interior surface of the airbeam.
Data Source
AI summary
A single wall airbeam constructed of a single layer material including a core of polyester fabric having a coating of adhesive on each surface of the polyester layer. A thin polyester film is applied to one of the adhesive layers. First and second polyurethane layers are applied to the other adhesive layer. The first polyurethane layer is a thicker, higher melt point polyurethane layer that may or may not be coated in a fire retardant material. The second polyurethane layer is a thinner, polyurethane layer having a lower melting point. An airbeam is constructed using one or more pieces of the fabric and heat sealing or welding the one or more polyurethane layers of fabric at seams, when the one or more layers are placed in a confronting position.