Method for producing an inflatable product

Patent metadata

Field	Value
Publication number	US-9802359-B2
Application number	US-201414444453-A
Country	US
Kind code	B2
Filing date	Jul 28, 2014
Priority date	Mar 2, 2012
Publication date	Oct 31, 2017
Grant date	Oct 31, 2017

Abstract

An internal tensioning structure for use in an inflatable product fulfills the basic function of maintaining two adjacent inflatable surfaces in a desired geometric arrangement when the inflatable product is pressurized. The tensioning structure is formed by connecting a pair of plastic strips sheets via spaced-apart strands, such as strings or wires. When pulled taut, the strands provide a high tensile strength between the two opposed plastic strips. At the same time, the plastic strips facilitate a strong, long-lasting weld between the tensioning structure and the inflatable product.

First claim

What is claimed is:

1. A method for producing an inflatable product comprising the steps of
providing a first sheet made of weldable plastic,
providing a second sheet made of weldable plastic,
providing a plurality of tensioning structures, each tensioning structure including
at least one tensile sheet having a first side, a second side, and plurality of holes extending through the tensile sheet from the first side to the second side and
a plurality of weld strip materials made of weldable plastic, the plurality of weld strip materials including
a first weld strip material disposed on the first and second sides of the tensile sheet such that the tensile sheet is captured by the first weld strip material, and
a second weld strip material disposed on the first and second sides of the tensile sheet such that the tensile sheet is captured by the second weld strip material, the second weld strip material spaced from the first weld strip material,

a plurality of strands arranged to provide a substantially uniform height among the plurality of tensioning structures throughout the inflatable product;

welding the plurality of tensioning structures to the first sheet by welding the first weld strip material to the first sheet,
welding the plurality of tensioning structures to the second sheet by welding the second weld strip material to the second sheet,
creating an inflatable chamber defined between the first and second sheets by the step of coupling the first sheet to the second sheet, and

providing a valve in communication with the inflatable chamber to facilitate inflation and deflation of the inflatable product.

2. The method of claim 1 , further comprising the step of providing a side wall, wherein the step of coupling the first sheet to the second sheet includes the step of coupling the side wall to the first sheet and coupling the side wall to the second sheet.

3. The method of claim 1 , wherein the at least one tensile sheet is non-woven.

4. The method of claim 2 , wherein the at least one tensile sheet consists of a plurality of fibers.

5. The method of claim 4 , wherein the plurality of fibers cooperate to define the plurality of strands.

6. The method of claim 1 , wherein the plurality of strands includes a first plurality of parallel strands and a second plurality of strands that are perpendicular to the first plurality of parallel strands and the second plurality of strands are positioned on a first side of the first plurality of parallel strands.

7. The method of claim 1 , wherein the plurality of strands includes a first plurality of strands, and the at least one tensile sheet includes a second plurality of strands extending across the first plurality of strands to define the plurality of holes extending from the first side of the tensile sheet to the second side of the tensile sheet.

8. The method of claim 1 , wherein portions of the plurality of holes of the at least one tensile sheet is positioned between the first weld strip material and the first sheet and portions of the plurality of holes of the tensile sheet are positioned between the second weld strip material and the second sheet.

9. The method of claim 1 , wherein the plurality of holes extend from the first weld strip material to the second weld strip material.

10. The method of claim 1 , wherein the first and second weld strip materials include longitudinal edges and a portion of the at least one tensile sheet has portions that extend in a direction perpendicular to the longitudinal edges of the first and second weld strip materials.

11. The method of claim 1 , wherein the at least one tensile sheet includes an outer perimeter having at least four sides, first and second sides of the four sides extend from a terminal end of the first weld strip material to a terminal end of the second weld strip material, and the at least one tensile sheet includes portions that extend from the first side to the second side of the outer perimeter.

12. A method for producing an inflatable mattress comprising the steps of
providing a first sheet made of weldable plastic and having a width and length suitable for a sleeping surface,
providing a second sheet made of weldable plastic and having a width and length suitable for a ground-contacting surface supportive of the first sheet,
providing a plurality of weld strip materials made of weldable plastic,
providing a non-woven sheet material having a first side and a second side,
assembling a plurality of tensioning structures by the steps of
positioning a first of the plurality of weld strip materials on the first and second sides of the non-woven sheet material such that the non-woven sheet material is captured by the first weld strip material, and
positioning a second of the plurality of weld strip materials on the first and second sides of the non-woven sheet material such that the non-woven sheet material is captured by the second weld strip material, the second weld strip material spaced from the first weld strip material,

welding the plurality of tensioning structures to the first sheet by welding at least one of the first and second weld strip materials to the first sheet,
welding the plurality of tensioning structures to the second sheet by welding the other of the first and second weld strip materials to the second sheet,
creating an inflatable chamber defined between the first and second sheets by the step of coupling the first sheet to the second sheet, and
providing a valve in communication with the inflatable chamber to facilitate inflation and deflation of the inflatable mattress.

13. The method of claim 12 , wherein the non-woven sheet material is fabric.

14. The method of claim 12 , wherein the non-woven sheet material includes a plurality of holes extending from the first side to the second side.

15. The method of claim 14 , wherein the non-woven sheet material includes a plurality of strands cooperating to define the plurality of holes.

16. The method of claim 12 , wherein the first and second weld strip materials are substantially parallel to the non-woven sheet material during the steps of positioning the first and second weld strip materials on the first and second sides of the non-woven sheet material.

17. The method of claim 12 , wherein the non-woven sheet material is substantially planar prior to the steps of positioning the first and second weld strip materials on the first and second sides of the non-woven sheet material.

18. The method of claim 12 , wherein the non-woven sheet material includes a plurality of V-shaped portions.

19. The method of claim 18 , wherein the plurality of V-shaped portions includes a first plurality of V-shaped portions and a second plurality of V-shaped portions that are inverted relative to the first plurality of V-shaped portions.

20. The method of claim 18 , wherein the first and second weld strip materials each include a respective pair of longitudinal edges and the V-shaped portions of non-woven sheet material extend between the first and second weld strip materials and traverse the respective pairs of longitudinal edges.

21. A method for producing an inflatable product comprising the steps of
providing a double-layer first sheet made of weldable plastic and having a first layer and a second layer,
providing a second sheet made of weldable plastic,
providing a plurality of weld strips made of weldable plastic,
providing at least one tensile sheet having a first side and a second side,
assembling a plural

Assignees

• Intex Marketing Ltd

Inventors

• Lin Hua Hsiang
• Hsu Yaw Yuan

Classifications

• B29C66/723

  being multi-layered (B29C66/7292, B29C66/72941 take precedence) · CPC title

• A47C27/087 Primary

  with means for connecting opposite sides, e.g. internal ties or strips · CPC title

• B29C66/472

  said single elements being substantially flat · CPC title

• B32B2307/558

  Impact strength, toughness · CPC title

• A47C27/081

  of pneumatic type · CPC title