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:
an upper plastic sheet;
a lower plastic sheet disposed opposite the upper plastic sheet, the upper and lower plastic sheets configured to become spaced apart to define a gap when the inflatable product is inflated;
a plurality of tensioning structures sized to span the gap between the upper plastic sheet and the lower plastic sheet when the inflatable product is inflated, the tensioning structures each comprising:
a plurality of strands defining a first side, a second side, and plurality of holes extending through the plurality of strands from the first side to the second side;
a first upper strip having the plurality of strands affixed thereto and being affixed to the upper plastic sheet, the first upper strip having an upper surface and a lower surface, the plurality of strands being positioned between the upper surface of the first upper strip and the upper plastic sheet, the plurality of strands being spaced apart from the lower surface of the first upper strip;
a lower strip having the plurality of strands affixed thereto and being affixed to the lower plastic sheet, the lower strip having an upper surface and a lower surface, the plurality of strands being positioned between the lower surface of the lower strip and the lower plastic sheet, the plurality of strands being spaced apart from the upper surface of the lower strip; and
a second upper strip having the plurality of strands affixed thereto and being affixed to the upper plastic sheet, the second upper strip having an upper surface and a lower surface, the lower surface of the second upper strip being positioned between the plurality of strands and the upper plastic sheet,
the upper strips each have a first longitudinal edge and a second longitudinal edge spaced apart from the first longitudinal edge, the plurality of strands extend beyond the first longitudinal edges of the upper strips and the plurality of strands terminate at first terminal ends at or around the second longitudinal edges of the upper strips,
the first upper strip includes portions that are spaced apart from portions of the second upper strip by the first terminal ends of the plurality of strands and
the first upper strip includes portions that are in direct contact with portions of the second upper strip.
2. The inflatable product of claim 1 , wherein
adjacent tensioning structures of the plurality of tensioning structures are spaced apart by a first distance, and
adjacent strands of one of the adjacent tensioning structures are spaced apart by a second distance that is significantly smaller than the first distance.
3. The inflatable product of claim 2 , wherein the upper and lower strips have a length and a width that is substantially less than the length and the first distance is greater than the width of the upper and lower strips.
4. The inflatable product of claim 2 , wherein the gap has a width and the first distance is greater than the width of the gap.
5. The inflatable product of claim 2 , wherein each strand includes a first leg extending between the upper and lower plastic sheets and a second leg extending parallel to the upper plastic sheet.
6. The inflatable product of claim 5 , wherein the upper and lower strips have a length and a width that is substantially less than the length and the first leg of the strands has a length greater than the width of the upper and lower strips.
7. The inflatable product of claim 6 , wherein the second leg of the strands has a length that is substantially equal to the width of the upper and lower strips.
8. The inflatable product of claim 2 , wherein the upper plastic sheet includes first portions positioned away from the plurality of tensioning structures that define a first ply count and second portions positioned adjacent the plurality of tensioning structures that cooperate with the tensioning structures to define a second ply count, the first ply count is less than the second ply count.
9. The inflatable product of claim 8 , wherein the first ply count is at least two less than the second ply count.
10. The inflatable product of claim 1 , the plurality of tensioning structures further comprising a second lower strip having the plurality of strands affixed thereto and being affixed to the lower plastic sheet, the second lower strip having an upper surface and a lower surface, the upper surface of the second lower strip being positioned between the plurality of strands and the lower plastic sheet.
11. The inflatable product of claim 1 , wherein the lower strip and second upper strip are coplanar.
12. The inflatable product of claim 1 , wherein the upper plastic sheet comprises an upper sheet of an inflatable mattress, and the lower plastic sheet comprises a lower sheet of the inflatable mattress.
13. The inflatable product of claim 12 , wherein the upper sheet includes a sleeping surface and the lower sheet includes a ground-contacting surface.
14. The inflatable product of claim 1 , wherein said plurality of strands are woven together with an additional plurality of strands to form a fabric.
15. The inflatable product of claim 1 , wherein each of the plurality of strands are spaced apart from one another.
16. The inflatable product of claim 1 , wherein the entire axial extent of each of the plurality of strands is spaced apart from the entire axial extent of each neighboring strand, such that the plurality of strands are evenly spaced apart.
17. The inflatable product of claim 1 , wherein the plurality of strands are parallel to one another.
18. The inflatable product of claim 1 , the plurality of strands comprise tensile strands, each of the a plurality of discrete tensioning structures further comprising at least one reinforcement strand coupled to the tensile strands.
19. The inflatable product of claim 18 , wherein the reinforcement strands are substantially perpendicular to the tensile strands.
20. The inflatable product of claim 19 , wherein the reinforcement strands abut and are fixedly connected to at least one of the first upper strip, the second upper strip, and the lower strip.