Methods for fabricating inflatable devices
AssigneeAir Cruisers Company
InventorsThomas W. Swierkocki, Christian W. Thomson, Stanley J. Pawlowski, Jr, Sean M. Blazick
Life of this patent
Estimating the term…
Abstract
Methods for fabricating inflatable devices made from air- or gas-holding fabrics. Specific embodiments relate to seam tapes, films, structural components or accessories welded to one or more fabric panels. Specifically disclosed is a fabrication system and method that reduces potential damage due to overheating seam areas. This disclosure has been found particularly useful with improved lightweight fabrics that would otherwise be susceptible to damage during welding processes.
Claims11
A method of manufacturing an inflatable device, the method comprising welding a seam tape or seam film to one or more air-holding or gas-holding fabric panels by:
- directing the seam tape or seam film past or through an energy application device prior to contact with the one or more air-holding or gas-holding fabric panels in order to raise a temperature of the seam tape or seam film but not raise the temperature of the one or more air-holding or gas-holding fabric panels, the energy application device configured to provide an application of energy, wherein the application of energy from the energy application device causes at least one surface of the seam tape or seam film to at least partially melt prior to being welded to at least one air-holding or gas-holding fabric panel of the one or more air-holding or gas-holding fabric panels;
- and
- subsequently contacting the seam tape or seam film with the at least one air-holding or gas-holding fabric panel of the one or more air-holding or gas-holding fabric panels while the at least one surface of the seam tape or seam film is at least partially melted.
An energy application system for directing applied energy to a seam tape or seam film to be applied to an air-holding or gas-holding fabric panel in manufacturing an inflatable device, the energy application system defining:
- a first material path for receiving the seam tape or seam film;
- a second material path for receiving the air-holding or gas-holding fabric panel;
- and
- a joining intersection where the first material path and the second material path join, the energy application system further comprising:
- a first pre-heating system along the first material path upstream from the joining intersection and configured to pre-heat the seam tape or seam film before the joining intersection, the first pre-heating system comprising a heated enclosure comprising:
- an inlet for receiving the seam tape or seam film;
- and
- an outlet through which the seam tape or seam film exits,
- wherein the heated enclosure delivers the applied energy to the seam tape or seam film at a temperature higher than a welding temperature, wherein the applied energy raises the temperature of the seam tape or seam film as to at least partially melt a surface of the seam tape or seam film prior to positioning the seam tape or seam film in contact with the air-holding or gas-holding fabric panel but does not raise the temperature of the air-holding or gas-holding fabric panel prior to welding the seam tape or seam film to the air-holding or gas-holding fabric panel and such that the surface of the seam tape or seam film is at least partially melted when the seam tape or seam film is positioned in contact with the air-holding or gas-holding fabric panel;
- and
- a second pre-heating system along the first material path and upstream from the joining intersection, the second pre-heating system configured to pre-heat the seam tape or seam film before the joining intersection, the second pre-heating system comprising a heated roller, a heated wedge, an alternate energy applying device, a primary nozzle, a secondary nozzle, or any combination thereof.
Dependencies are inferred from the claim text.