Welding process and product for inflatable product

• US 10,076,874 B2
• Filed: 01/26/2017
• Issued: 09/18/2018
• Est. Priority Date: 11/25/2013
• Status: Active Grant

• Current Assignee: Intex Marketing Ltd. (Intex Corporation)
• Original Assignee: Intex Marketing Ltd. (Intex Corporation)
• Inventors: Lin, Hua Hsiang, Hsu, Yaw Yuan
• Primary Examiner(s): Goff, II, John L
• Application Number:
  US15/416,601
• Publication Number:
  US 20170136726A1
• Time in Patent Office: 600 Days
• Field of Search: 156264, 156265, 156289, 1563084
• CPC Class Codes: A47C 27/081 of pneumatic type
• CPC Class Codes: A47C 27/087 with means for connecting opposite sides, e.g. internal ties or strips
• CPC Class Codes: B29C 65/04 Dielectric heating, e.g. high-frequency welding , i.e. radio frequency welding of plastic materials having dielectric properties, e.g. PVC
• CPC Class Codes: B29C 65/242 the heat transfer being achieved by contact, i.e. a heated tool being brought into contact with the welding tool and afterwards withdrawn from it
• CPC Class Codes: B29C 66/004 Preventing sticking together, e.g. of some areas of the parts to be joined
• CPC Class Codes: B29C 66/0044 using a separating sheet, e.g. fixed on the joining tool
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/438 Joining sheets for making hollow-walled, channelled structures or multi-tubular articles
• CPC Class Codes: B29C 66/4722 Fixing strips to surfaces other than edge faces fixing strips to edge faces B29C63/0026
• CPC Class Codes: B29C 66/474 said single elements being substantially non-flat
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/723 being multi-layered B29C66/7292, B29C66/72941 take precedence
• CPC Class Codes: B29C 66/7315 Mechanical properties
• CPC Class Codes: B29C 66/73921 characterised by the materials of both parts being thermoplastics
• CPC Class Codes: B29C 66/81427 comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
• CPC Class Codes: B29C 66/8322 Joining or pressing tools reciprocating along one axis
• CPC Class Codes: B29C 66/8432 Machines for making separate joints at the same time mounted in parallel or in series
• CPC Class Codes: B29K 2027/06 PVC, i.e. polyvinylchloride
• CPC Class Codes: B29K 2105/256 Sheets, plates, blanks or films
• CPC Class Codes: B29L 2022/02 Inflatable articles balls B29L2031/54 ; inner tyres B29L2023/245
• CPC Class Codes: B29L 2031/751 : Mattresses, cushions upholstery B29L2031/58
• CPC Class Codes: B32B 2327/06 : PVC, i.e. polyvinylchloride
• CPC Class Codes: B32B 27/06 : as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 27/304 : comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 29/002 : as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/06; next to a bituminous or tarry layer B32B11/06; next to a water-setting substance layer B32B13/08; next to a metal layer B32B15/12; next to a glass layer B32B17/065; next to a layer formed of natural mineral fibres or particles B32B19/046; next to a wood layer B32B21/06; next to a cellulosic plastic layer B32B23/06; next to a natural or synthetic rubber layer B32B25/06; next to a synthetic resin layer B32B27/10
• CPC Class Codes: B32B 3/085 : spaced apart pieces on the surface of a layer
• CPC Class Codes: B32B 3/266 : characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 37/06 : characterised by the heating method
• CPC Class Codes: B32B 37/26 : with at least one layer which influences the bonding during the lamination process, e.g. release layers or pressure equalising layers
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/24 : one layer being a fibrous or filamentary layer
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B32B 7/14 : applied in spaced arrangements, e.g. in stripes
• CPC Class Codes: Y10T 428/1352 : Polymer or resin containing [i.e., natural or synthetic]

Abstract

A welding process of an inflatable product is provided that includes using isolating members between first and second portions of weldable tensioning members to resist the first and second portions of the weldable tensioning structures being welded together during welding of the first portions to a first sheet of weldable material and welding of the second portions to a second sheet of weldable material.

Claims

1. A method for producing an inflatable product including the steps of

providing a first sheet made of weldable plastic,

providing a second sheet made of weldable plastic, the first and second sheets cooperating to define an inflatable chamber,

providing a side panel;

providing a plurality of tensioning structures, each tensioning structure including a weldable plastic, the plurality of tensioning structures including a first portion and a second portion,

providing an isolating member material on a roll, the isolating member material being configured to isolate the first portions of the tensioning structures from the second portions of the tensioning structures, and

unwrapping a plurality of isolating members from the roll,

positioning at least one of the plurality of isolating members between the first and second portions of each of the plurality of tensioning structures,

welding the first portion of the plurality of tensioning structures to the first sheet while at least one of the plurality of isolating members is positioned between respective first and second portions of each of the plurality of tensioning structures, such that the isolating member prevents any welding of the first portion to the second portion during said step of welding the first portion,

welding the second portion of the plurality of tensioning structures to the second sheet while at least one of the plurality of isolating members is positioned between respective first and second portions of each of the plurality of tensioning structures, such that the isolating member prevents any welding of the first portion to the second portion during said step of welding the second portion; and

sealing the first and second sheets together by welding the side panel to the first and second sheets to define the inflatable chamber, the plurality of isolating members being positioned between the first sheet and the second sheet and within a periphery of the side panel during the sealing step, such that the plurality of isolating members remain positioned in the inflatable chamber together with the plurality of tensioning structures after the sealing step.

2. The method of claim 1, wherein the isolating member material is non-metallic.

3. The method of claim 1, wherein the isolating member material is a film.

4. The method of claim 1, further comprising the step of cutting a plurality of strips of the isolating member material from the roll to create the plurality of isolating members.

5. The method of claim 4, wherein the step of cutting each strip occurs before positioning of a respective isolating member is complete.

6. The method of claim 4, wherein the step of cutting each strip occurs after positioning of a respective isolating member is complete.

7. The method of claim 1, wherein the first and second portions of the plurality of tensioning structures are each weld strips.

8. The method of claim 1, wherein the isolating member material is formed of insulating paper, release paper, non-woven fabric, laminated fabric, oxford fabric, or plastic.

9. The method of claim 1, wherein the welding steps are performed simultaneously by simultaneously welding the first and second portions of the plurality of tensioning structures to the first and second sheets respectively.

10. The method of claim 1, further comprising folding each of the plurality of tensioning structures before the welding steps, wherein the tensioning structures remain folded during the welding steps.

11. The method of claim 10, wherein the folding step includes positioning the first portions of the tensioning structures adjacent the second portions of the tensioning structures with the plurality of isolating members respectively disposed therebetween.

12. The method of claim 1, further comprising the step of clamping the first portions and second portions of the plurality of tensioning structures together during the welding steps.

13. The method of claim 12, further comprising the step of unclamping the first and second portions of the plurality of tensioning structures and separating the first and second portions of the plurality of tensioning structures after the welding steps.

14. The method of claim 12, wherein the step of clamping comprises clamping the first and second sheets, the first and second portions of the plurality of tensioning structures, and the plurality of isolating members by upper and lower bars during the welding steps.

15. The method of claim 1, wherein the first and second portions of the plurality of tensioning structures are each pairs of weld strips.

16. The method of claim 1, wherein the first and second portions of the plurality of tensioning structures are each single weld strips.

17. The method of claim 1, wherein each of the plurality of tensioning structures includes a plurality of strands.

18. The method of claim 17, wherein a plastic adhesive sheet is provided on the plurality of strands.

19. The method of claim 1, wherein each of the plurality of tensioning structures includes an alignment strand.

20. The method of claim 1, wherein the first and second portions of each tensioning structure are separated by a thickness less than a thickness of the tensioning structure during the welding steps.

21. The method of claim 1, wherein the plurality of isolating members comprise non-metallic isolating members.

22. The method of claim 21, wherein the non-metallic isolating members are each formed from a flexible film.

23. The method of claim 9, wherein the plurality of isolating members are respectively positioned between the first and second portions during the step of simultaneously welding.

24. The method of claim 1, wherein the first and second portions of the plurality of tensioning structures are spaced apart by the plurality of isolating members.

25. A method for producing an inflatable product including the steps of

providing a first sheet made of weldable plastic,

providing a second sheet made of weldable plastic, the first and second sheets cooperating to define an inflatable chamber,

providing a side panel,

providing a plurality of tensioning structures, each tensioning structure including a weldable plastic, the plurality of tensioning structures including a first portion and a second portion,

providing an isolating member material on a roll, the isolating member material comprising a film configured to isolate the first portions of the tensioning structures from the second portions of the tensioning structures, and

unwrapping a plurality of isolating members from the roll,

positioning at least one of the plurality of isolating members between the first and second portions of each of the plurality of tensioning structures,

welding the first portion of the plurality of tensioning structures to the first sheet while at least one of the plurality of isolating members is positioned between respective first and second portions of each of the plurality of tensioning structures, such that the isolating member prevents any welding of the first portion to the second portion during said step of welding the first portion,

welding the second portion of the plurality of tensioning structures to the second sheet while at least one of the plurality of isolating members is positioned between respective first and second portions of each of the plurality of tensioning structures, such that the isolating member prevents any welding of the first portion to the second portion during said step of welding the second portion;

and

sealing the first and second sheets together by welding the side panel to the first and second sheets to define the inflatable chamber while the plurality of isolating members are positioned in the inflatable chamber.

26. The method of claim 25, wherein the isolating member material is non-metallic.

27. The method of claim 25, further comprising the step of cutting a plurality of strips of the isolating member material from the roll to create the plurality of isolating members.

28. The method of claim 27, wherein the step of cutting each strip occurs before positioning of a respective isolating member is complete.

29. The method of claim 27, wherein the step of cutting each strip occurs after positioning of a respective isolating member is complete.

30. The method of claim 25, wherein the first and second portions of the plurality of tensioning structures are each weld strips.

31. The method of claim 25, wherein the isolating member material is formed of insulating paper, release paper, non-woven fabric, laminated fabric, oxford fabric, or plastic.

32. The method of claim 25, wherein the welding steps are performed simultaneously by simultaneously welding the first and second portions of the plurality of tensioning structures to the first and second sheets respectively.

33. The method of claim 32, wherein the plurality of isolating members are respectively positioned between the first and second portions during the step of simultaneously welding.

34. The method of claim 25, further comprising folding each of the plurality of tensioning structures before the welding steps, wherein the tensioning structures remain folded during the welding steps.

35. The method of claim 34, wherein the folding step includes positioning the first portions of the tensioning structures adjacent the second portions of the tensioning structures with the plurality of isolating members respectively disposed therebetween.

36. The method of claim 25, further comprising the step of clamping the first portions and second portions of the plurality of tensioning structures together during the welding steps.

37. The method of claim 36, further comprising the step of unclamping the first and second portions of the plurality of tensioning structures and separating the first and second portions of the plurality of tensioning structures after the welding steps.

38. The method of claim 36, wherein the step of clamping comprises clamping the first and second sheets, the first and second portions of the plurality of tensioning structures, and the plurality of isolating members by upper and lower bars during the welding steps.

39. The method of claim 25, wherein the first and second portions of the plurality of tensioning structures are each pairs of weld strips.

40. The method of claim 25, wherein the first and second portions of the plurality of tensioning structures are each single weld strips.

41. The method of claim 25, wherein each of the plurality of tensioning structures includes a plurality of strands.

42. The method of claim 41, wherein a plastic adhesive sheet is provided on the plurality of strands.

43. The method of claim 25, wherein each of the plurality of tensioning structures includes an alignment strand.

44. The method of claim 25, wherein the first and second portions of each tensioning structure are separated by a thickness less than a thickness of the tensioning structure during the welding steps.

45. The method of claim 25, wherein the plurality of isolating members comprise non-metallic isolating members.

46. The method of claim 45, wherein the non-metallic isolating members are each formed from a flexible film.

47. The method of claim 25, wherein the first and second portions of the plurality of tensioning structures are spaced apart by the plurality of isolating members.