Air-Filled Sleeping Pad Structure With Weld-Through Insulation Layers
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Solution Overview
Problem
Existing sleeping pads are heavy due to the need for bulk to insulate from ground variations and moisture, and current manufacturing methods cannot efficiently attach high-volume, low-cost internal insulation layers to air-filled structures without adding weight or requiring significant heat, limiting the use of high-speed manufacturing techniques.
Innovation Solution
A method involving a multilayer structure with cut-out interior layers allows for heat welding of exterior layers to an internal baffle, reducing weight and enabling high-speed manufacturing by 'pinning' internal layers through openings, using thermoplastic polyurethane materials for the baffle and exterior layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bulk or thickness is increased to insulate from ground variations and moisture, then insulation performance is improved, but weight increases
Solution Approach 1:
The patent applies local quality by placing insulation layers selectively at the interior surfaces of the air-filled structure rather than uniformly throughout. The insulation layers are positioned only where thermal contact with the ground occurs, providing targeted insulation where needed while leaving other areas lightweight and air-filled.
Solution Approach 2:
The patent implements nesting by placing insulation layers within the interior of the air-filled structure, effectively nesting the insulation within the air chamber. This allows the insulation to be contained within the existing structural envelope without adding external bulk or weight.
2Reliability
If internal insulation layers are added to air mattresses, then insulation performance is improved, but manufacturing complexity increases due to attachment requirements
Solution Approach 1:
The patent extracts the attachment problem by providing openings in the insulation layers that allow direct access to the interior structure. This extraction of material (creating holes) eliminates the need for complex attachment mechanisms, as the interior structure can be directly bonded to the exterior layers through the openings without interfering with the insulation material.
Solution Approach 2:
The openings in the insulation layers serve as intermediaries that facilitate the bonding process. These openings allow adhesive or welding to pass through and bond the exterior layers to the interior structure, mediating the connection between components that would otherwise be blocked by the insulation material.
3Productivity
If heat welding is used to attach internal structure, then manufacturing speed is improved, but attachment is blocked by internal insulation layers requiring significant heat or power
Solution Approach 1:
The patent extracts material from the insulation layers by creating openings, which removes the barrier that would block heat welding. These openings allow the welding tool to access and bond the interior structure to the exterior layers directly, eliminating the need to generate excessive heat or power to penetrate through thick insulation material.
Solution Approach 2:
The patent replaces the mechanical barrier of continuous insulation material with an open structure featuring predetermined openings. This substitution allows thermal energy from heat welding to pass through the openings and achieve bonding without requiring excessive power, effectively replacing the solid insulation barrier with a perforated configuration.
4Reliability
If interior layers are made continuous for insulation, then insulation performance is improved, but weight increases and attachment becomes difficult
Solution Approach 1:
The patent applies local quality by making the insulation layers continuous only in the regions where insulation is needed, while providing openings in areas where attachment to the interior structure is required. This localized continuity maintains insulation performance at thermal contact points while reducing overall weight and enabling attachment.
Solution Approach 2:
The patent segments the insulation layers by introducing predetermined openings that divide the continuous material into sections. This segmentation reduces the total amount of insulation material required, lowering weight, while the openings provide access points for attachment without compromising insulation at the continuous portions.
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 approach results in a lightweight, warm sleeping pad with reduced weight by approximately one third, facilitating high-speed, low-cost manufacturing while maintaining the structural integrity and insulation of internal layers.
Implementation Method 1
The first generally planar exterior member is attached to the first external member attachment region of the plurality of internal connecting members in a plurality of attachment locations utilizing a heat attachment method. Each of the plurality of attachment locations is provided through one of the plurality of openings in the first generally planar interior layer.
Data Source
AI summary
A method for manufacturing an air-filled structure allows for ease of manufacturing utilizing plastic/vinyl/TPU laminated/urethane coated type top and bottom exterior layers as well as an internal baffle, all of which can be heat or chemically bonded together. Most if not all of the bonds or welds required to be made can be created at the same time in a high volume manufacturing step by providing one or more internal layer(s) each with a plurality of openings or cutouts which provide an opening or window through which the internal structure/baffle can be attached directly to the top and bottom layers of the air-filled structure.