Woven inflatable devices and method of making the same

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Solution Overview

Problem

Inflatable structures face limitations in rigidity, shape complexity, and material sustainability due to their reliance on non-renewable and toxic materials, requiring additional rigid supports and being restricted to simple shapes.

Innovation Solution

The development of woven inflatable devices with laminated sheets that include inflatable regions, flaps, and seam-crossing passages, allowing for transformation into three-dimensional shapes under controlled pressure, using environmentally friendly materials and anchoring yarns for enhanced stiffness and structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional inflatable structures are used to provide rigidity, then structural support is achieved, but weight increases and foldability decreases

Engineering Contradiction:

Improvestructural rigidityVSAvoidproduct weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent uses a woven mesh structure as a flexible shell that can be inflated to provide rigidity. The mesh is made from continuous polymer chains that form a network structure, allowing the material to transition from flexible (deflated) to rigid (inflated) state without adding significant weight. This resolves the contradiction by using the inflatable structure itself as both the weight-saving element and the rigidity-providing element.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent changes the physical state and pressure parameters of the inflatable bladder to achieve different rigidity levels. By controlling internal pressure and the molecular structure of the polymer (amorphous vs. crystalline regions), the structure can transition between soft/foldable and rigid/supportive states, resolving the contradiction between weight and structural strength.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If non-renewable and toxic materials are used in inflatable structures, then manufacturing feasibility is maintained, but environmental harm increases

Engineering Contradiction:

Improvemanufacturing feasibilityVSAvoidenvironmental toxicity

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent uses composite materials consisting of polymer blends with specific ratios of amorphous and crystalline regions. These composite structures maintain the manufacturability and structural properties of traditional materials while using environmentally friendly polymer compositions that are non-toxic and potentially biodegradable, resolving the contradiction between ease of manufacture and environmental harm.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If simple shapes are used in inflatable structures with internal bladders, then manufacturing simplicity is maintained, but shape complexity is limited

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidshape complexity

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The patent divides the inflatable structure into multiple independent inflatable regions or cells within the woven mesh. Each cell can be inflated to different pressure levels, allowing the creation of complex three-dimensional shapes while maintaining relatively simple manufacturing processes for each individual cell. This segmentation approach resolves the contradiction by enabling shape complexity through modular design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent utilizes the third dimension (internal pressure volume) to create complex shapes. By varying the pressure and volume of different regions within the woven mesh structure, complex three-dimensional forms can be achieved without complicating the two-dimensional manufacturing process of the mesh itself, resolving the contradiction between manufacturing simplicity and shape complexity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 woven inflatable devices achieve greater rigidity, lightness, and structural soundness, enabling complex shapes while reducing material waste and environmental impact, with the ability to support significant loads and maintain pressure within a specified range.

Implementation Method 1

The air inlet is configured receive air from an inflator to raise the air pressure inside the first and second inflatable regions, to transform the laminated sheet from the planar shape to the three-dimensional chair shape

Methodology Applied

Scientific EffectPressure increase: Pressure Increase

Implementation Method 2

a seam-crossing passage positioned across the folding seam that enables fluidic communication between the first inflatable region and the second inflatable region

Methodology Applied

Scientific EffectFluid flow:

Data Source

PatentUS12180621B2Woven inflatable devices and method of making the same

Publication Date: 2024.12.31 BELL THOMAS G

AI summary

Woven inflatable devices and methods for making woven inflatable devices are provided. The woven inflatable devices include a laminated sheet with inflatable regions that when inflated cause the laminated sheet to transform from a planar shape to a three-dimensional shape such as a chair, container, or kiteboard harness.