Internal Tensioning Structure Useable with Inflatable Devices
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.
1 . An inflatable product comprising:
a first sheet;
a second sheet disposed opposite the first sheet, the first and second sheets spaced apart to define a gap;
a tensioning structure spanning the gap between the first sheet and the second sheet, the tensioning structure comprising:
a plurality of strands uniformly spaced apart and arranged substantially parallel to one another; and
a plurality of weld strips including a first weld strip and a second weld strip spaced apart from one another and substantially perpendicular to the plurality of strands, each of the plurality of weld strips affixed to each of the plurality of strands, and each of the plurality of weld strips affixed to at least one of the first sheet and the second sheet, each of the first and second weld strips having a length, a width, and a thickness, the length of each of the first and second weld strips being greater than the width of each of the first and second weld strips, the first weld strip being spaced apart from the second weld strip by a distance greater than the width of the first weld strip.
2 . The inflatable product of claim 1 , wherein the plurality of weld strips comprise upper and lower weld strips disposed on opposing sides of the plurality of strands, the strands affixed to and captured between the upper and lower weld strips.
3 . The inflatable product of claim 1 , wherein the tensioning structure further comprises a weld sheet defining a width corresponding to an overall width of the plurality of strands, the plurality of strands affixed to the weld sheet, and at least one of the plurality of weld strips affixed to a first side of the weld sheet.
4 . The inflatable product of claim 3 , wherein another of the plurality of weld strips is affixed to a second side of the weld sheet opposite the first side.
5 . The inflatable product of claim 3 , wherein the weld sheet comprises a continuous piece of material extending across the plurality of strands.
6 . The inflatable product of claim 1 , wherein the tensioning structure further comprises at least one reinforcement strand disposed substantially perpendicular to the plurality of strands, the at least one reinforcement strand fixed to at least one of the plurality of weld strips.
7 . The inflatable product of claim 1 , wherein the plurality of strands comprise a plurality of twisted filaments.
8 . An inflatable product comprising:
a first sheet;
a second sheet disposed opposite the first sheet, the first and second sheets spaced apart to define a gap;
a tensioning structure spanning the gap between the first sheet and the second sheet, the tensioning structure comprising:
an upper weld strip having a length, a width, and a thickness, the width being less than the length;
a lower weld strip arranged substantially parallel to the upper weld strip and spaced apart from the upper weld strip and having a length, a width, and a thickness, the width of the lower weld strip being less than the length of the lower weld strip; and
a plurality of end-to-end V-shaped strands arranged between the upper and lower weld strips, each of the V-shaped strands having upper and lower ends fixed to the upper and lower weld strips, respectively, with the upper ends extending in the direction of the width of the upper weld strip and the lower ends extending in the direction of the width of the lower weld strip.
9 . The inflatable product of claim 8 , wherein the tensioning structure further comprises a second pair of weld strips arranged to capture the upper and lower ends of the V-shaped strands between the upper and lower weld strips and the second pair of weld strips, respectively.
10 . The inflatable product of claim 8 , wherein the tensioning structure further comprises at least one reinforcement strand disposed along a longitudinal extend of at least one of the upper and lower weld strips.
11 . The inflatable product of claim 10 , wherein the at least one reinforcement strand comprises a plurality of twisted filaments.
12 . The inflatable product of claim 8 , wherein the plurality of V-shaped strands comprise a plurality of twisted filaments.
13 . (canceled)
14 . The inflatable product of claim 8 , wherein the plurality of end-to-end V-shaped strands are formed from a single, continuous strand.
15 . An inflatable product comprising:
a first sheet;
a second sheet disposed opposite the first sheet, the first and second sheets spaced apart to define a gap, the first sheet and the second sheet cooperating to at least partially bound an inflatable chamber;
a plurality of discrete tensioning structures positioned in the inflatable chamber and welded to respective inner surfaces of the first and second sheets such that the plurality of discrete tensioning structure span the gap, each of the plurality of discrete tensioning structures comprising:
an upper weld strip affixed to one of the first sheet and the second sheet;
a lower weld strip affixed to the other of the first sheet and the second sheet; and
a plurality of strands connecting the upper and lower weld strips to one another.
16 . The inflatable product of claim 15 , wherein the plurality of tensioning structures further comprise at least one reinforcing strand, the reinforcing strand disposed along a longitudinal extent of at least one of the upper and lower weld strips.
17 . The inflatable product of claim 15 , wherein the plurality of tensioning structures are welded to the inner surfaces of the first and second sheets along a linear path, and the upper and lower weld strips define a longitudinal extent corresponding to at least one of a width of the inflatable product and a length of the inflatable product.
18 . The inflatable product of claim 15 , wherein the plurality of strands of the plurality of tensioning structures are arranged substantially parallel to one another, with even spacing between neighboring pairs of the plurality of strands.
19 . The inflatable product of claim 15 , wherein the plurality of strands of the plurality of tensioning structures are arranged in a staggered, V-shaped arrangement with even intervals between respective pairs of the plurality of strands.
20 . The inflatable product of claim 15 , wherein at least one weld sheet is arranged between the upper and lower weld strips and along the plurality of strands, the at least one weld sheet affixed to at least a portion of the plurality of strands.
21 . The inflatable product of claim 15 , wherein ends of the upper and lower weld strips are connected to one another such that each of the plurality of tensioning structures forms a columnar body.
22 . An inflatable product comprising:
a first sheet;
a second sheet disposed opposite the first sheet, the first and second sheets spaced apart to define a gap, the first sheet and the second sheet cooperating to at least partially bound an inflatable chamber;
a plurality of tensioning structures welded to inner surfaces of the first and second sheets such that the plurality of tensioning structures span the gap, each of the plurality of tensioning structures comprising:
a weld sheet having a first end and a second end spaced apart from the first end;
a plurality of strands each having respective first and second ends, and the plurality of strands substantially evenly spaced and arranged substantially parallel to one another, the plurality of strands affixed to the weld sheet;
a first weld strip affixed to the first end of the weld sheet such that a longitudinal extent of the first weld strip is substantially perpendicular to the plurality of strands, the first ends of the plurality of strands are affixed to the first weld strip, and the first weld is welded to the first sheet; and
a second weld strip affixed to the second end of the weld sheet such that a longitudinal extent of the second weld strip is substantially perpendicular to the plurality of strands, the second ends of the plurality of strands are affixed to the second weld strip, and the second weld strip is welded to the second sheet.
23 . The inflatable product of claim 22 , wherein the plurality of tensioning structures further comprise at least one reinforcing strand, the reinforcing strand disposed along the longitudinal extent of the weld strip.
24 . The inflatable product of claim 22 , wherein the plurality of tensioning structures are welded to the inner surfaces of the first and second sheets along a linear path.
25 . The inflatable product of claim 22 , wherein ends of the weld strip are connected to one another such that each of the plurality of tensioning structures forms a columnar body.
26 . The inflatable product of claim 1 , wherein first sheet has a length, a width, and a thickness, the width of the first sheet being less than the length of the first sheet, the second sheet has a length, a width, and a thickness, the width of the second sheet being less than the length of the second sheet, the width of the first weld strip is factors less than the width of the first sheet, the width of the second weld strip is factors less than the width of the second sheet.
27 . The inflatable product of claim 8 , the upper ends of the V-shaped strands are captured by the first sheet and the upper weld strip and the lower ends of the V-shaped strands are captured by the second sheet and the lower weld strip.
28 . The inflatable product of claim 15 , wherein the upper weld strips of adjacent discrete tensioning structures are spaced apart from each other, the upper weld strips of adjacent discrete tensioning structures are spaced apart from the lower weld strips of adjacent discrete tensioning structures, and the lower weld strips of adjacent discrete tensioning structures are spaced apart from each other.
29 . The inflatable product of claim 28 , wherein the inflatable product includes a wall at least partially defined by the first sheet, the wall has an interior surface exposed to the inflatable chamber and an exterior surface, the exterior surface of the wall is divided into a first portion and a second portion, the first portion has a first thickness defined between the exterior surface and the interior surface where the first sheet and the upper weld strips of the plurality of tensioning structures are positioned adjacent one another, the second portion has a second thickness defined between the exterior surface and the interior surface where the first sheet is spaced apart from the plurality of tensioning structures, the second thickness is less than the first thickness, and the exterior surface of the second portion is greater than the exterior surface of the first portion.
30 . The inflatable product of claim 22 , wherein the plurality of strands includes a portion extending between the first and second weld strips and the weld sheet extends along the portions of the plurality of strands extending between the first and second weld strips.