Trampoline Fabric Clamp Ultrasonic Welding and T-Joint Design
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Solution Overview
Problem
Traditional trampolines face issues with twisting arc-shaped rods affecting stability, inefficient processing methods, high labor costs in fabric attachment, and complex protective net installations, leading to safety hazards and production inefficiencies.
Innovation Solution
A trampoline design featuring T-shaped long iron joints and arc-shaped rods connected to form a circular ring, with a fabric clamp system using high-frequency welding and concave-convex stripes for enhanced strength and safety, and a simplified protective net installation mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If arc-shaped rods are connected using traditional iron joints with retracted-head shape, then the connection is achieved, but the processing time is increased and labor cost is high
Solution Approach 1:
The iron joint is segmented into a standardized T-shaped structure with perpendicular arms, eliminating the need for complex retracted-head shaping. Each arc-shaped rod connects to adjacent rods through the orthogonal arms, allowing independent fabrication and assembly of standardized components, thus reducing processing time and labor costs while maintaining connection integrity.
2Ease of manufacture
If arc-shaped rods are connected using traditional iron joints, then the connection is achieved, but the rods exhibit twisting phenomenon affecting stability
Solution Approach 1:
Grooves are pre-formed on the outer surfaces of arc-shaped rods at specific positions, and corresponding protrusions are pre-formed on the T-shaped iron joint arms. These preliminary structural features ensure that when components are assembled, the grooves and protrusions mate precisely to prevent relative rotation and twisting, thereby maintaining structural stability without requiring complex post-assembly adjustments.
3Ease of manufacture
If fabric strip is sewn onto trampoline fabric edge using traditional method, then the attachment is achieved, but the processing efficiency is low and labor cost is high
Solution Approach 1:
The traditional mechanical sewing process is replaced with ultrasonic welding technology. The fabric clamp assembly includes a clamping plate that holds the fabric edge, and an ultrasonic welding head that applies high-frequency vibrations to melt and fuse the fabric layers together with the clamp. This substitution eliminates the need for needles, threads, and manual sewing operations, dramatically increasing processing speed and reducing labor costs while ensuring consistent attachment quality.
4Strength
If fabric clamp is used to attach trampoline fabric, then the attachment strength is improved, but the complexity of the attachment structure is increased
Solution Approach 1:
The fabric clamp assembly utilizes flexible fabric layers combined with a thin plate-like clamp structure. The clamp plate is designed with sufficient flexibility to accommodate the curved surface of the trampoline frame while maintaining clamping force. The fabric layers themselves act as flexible elements that distribute stress evenly across the attachment area, providing strong attachment without requiring complex rigid support structures or multiple fastening components.
5Ease of manufacture
If spring hooks are hung into small spring holes, then the spring attachment is achieved, but it is difficult to operate and wastes time
Solution Approach 1:
Instead of attempting to insert spring hooks directly into small holes from a single direction, the installation process utilizes multiple dimensions of access. The frame structure allows approach from different angles, and the spring hooks are designed to be inserted through the fabric and fabric clamp assembly rather than directly into tight holes in the frame. This dimensional approach to installation significantly eases the operation and reduces installation time.
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 design improves flex resistance, prevents rod rotation, reduces labor in spring attachment, enhances user safety by closing fabric intervals, and facilitates faster installation and use with improved processing efficiency and effective protective net installation.
Implementation Method 1
The fabric clamp outer sheet and the clamping sheet are processed on a surface of the trampoline fabric by hot-pressing with a high-frequency welding machine
Data Source
AI summary
A trampoline includes a plurality of arc-shaped rods and a plurality of long iron joints. The long iron joints are T-shaped. The arc-shaped rods and the long iron joints are insertedly connected to each other successively and alternatively to form a circular ring. Lower ends of the long iron joints are insertedly connected to straight tubes. Lower ends of two adjacent straight tubes are insertedly connected to a foot tube. The foot tube is U-shaped with an opening upward. The arc-shaped rods are connected to a fabric clamp through arc-shaped hook springs. The fabric clamp inner end is connected to an edge of the trampoline fabric. Grooves are insertedly connected in the inward protrusions, preventing the arc-shaped rods from rotating relative to the horizontal tube. The fabric clamp outer sheet closes the interval between the tension spring and the trampoline fabric, preventing users from stepping into the interval.