Surfing Tether End Component Thermal Bonding
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Solution Overview
Problem
Existing surfing tether end components are prone to failure due to material limitations and manufacturing weaknesses, leading to lack of flexibility and aesthetic issues, with stitches causing localized weaknesses and vulnerability to snapping.
Innovation Solution
The development of a surfing tether end component with layers of polymers thermally bonded together using internal or external heat welding processes, eliminating the need for adhesives and additional affixing means, and incorporating a cushioning layer for improved comfort and shape retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple materials are assembled and stitched together to form the end component, then the component can be fabricated with various functions (fastening, connecting, cushioning), but the component lacks flexibility and has localized weaknesses that make it vulnerable to snapping
Solution Approach 1:
The patent merges multiple previously separate components (end component body, fastening means, tether connector, cushioning layer) into a single integrated structure formed from one continuous piece of webbing material. This eliminates the need for stitching multiple materials together, removing localized weaknesses while preserving all necessary functions through the unified design.
Solution Approach 2:
While using a single continuous piece of material, the patent creates functional segments (cuff portion, fastening means, tether connector) within the unified structure. Each segment is formed from the same continuous material, ensuring consistent flexibility and eliminating weak points at junctions between different materials.
2Adaptability or versatility
If multiple materials are stitched together to form the end component, then the component can provide multiple functions, but the stitching creates localized weaknesses and reduces flexibility
Solution Approach 1:
The patent combines all functional elements into one continuous piece of webbing material, eliminating stitching lines that restrict flexibility. The unified construction allows the component to bend and move freely while maintaining all necessary functions through strategic formation of fastening means and connectors within the continuous material.
3Reliability
If adhesive bonding is used to join end component elements, then the component achieves strong bonds and improved flexibility, but the use of adhesives complicates manufacturing and recycling
Solution Approach 1:
The patent extracts and eliminates the adhesive bonding process entirely by forming all component elements from one continuous piece of webbing material. This removes the complexity of adhesive application, curing, and cleanup, while also simplifying recycling by eliminating mixed materials. The strong bonds are achieved through the continuous material structure rather than chemical adhesives.
4Ease of manufacture
If traditional stitching methods are used to assemble the end component, then the component can be manufactured with standard equipment, but the stitches create vulnerability to failure and reduce component lifespan
Solution Approach 1:
The patent merges all component elements into a single continuous piece of webbing, eliminating stitching entirely. This extends component lifespan by removing the weak points where stitches create vulnerability, while manufacturing remains simple through cutting and folding the continuous material into the desired configuration.
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 enhances the durability and flexibility of the tether end component, reducing the likelihood of failure and improving aesthetic appeal by using a single polymer class for bonding, which also simplifies recycling and production efficiency.
Implementation Method 1
the contacting surface is thermally bonded to the contacting portion
Implementation Method 2
the contacting surface is welded to the contacting portion
Implementation Method 3
the thermal bond is at least partially formed via internal heat welding process, and the internal heat welding process is either an electromagnetic welding process or a mechanical welding process
Implementation Method 4
the thermal bond is at least partially formed via external heat welding process and the external heat welding process is a thermal welding process
Data Source
AI summary
The present invention relates to, in a first aspect, a surfing tether end component comprising an end component body having one or more end component body layers, a tether connector for connecting the surfing tether end component to a surfing device tether, and a fastening means. A second and third aspect, comprising methods of forming a surfing tether end component, are also provided.