Three-dimensional reinforced membrane
A three-dimensional reinforced membrane is designed to be inflated and used in various structural applications. A dropstitch or double wall fabric may be reinforced with one or more coatings, such as urethane-based coatings, and may also be laminated in accordance with various disclosed embodiments.
1. An inflatable device, comprising:
a three-dimensional reinforced membrane, including:
a dropstitch fabric having a first side and a second side;
a first tie coat comprising a solvent-based reactive adhesive applied to at least one of the first and second sides of the dropstitch fabric;
a second tie coat comprising a solvent-based reactive adhesive applied to the first tie coat; and
a laminated substrate applied to the second tie coat, the laminated substrate comprising a nylon fabric with a coated layer of thermoplastic polyurethane (TPU), wherein the inflatable device is inflatable to a pressure of up to about 45 pounds per square inch (psi).
2. The inflatable device of claim 1 , wherein the three-dimensional membrane is characterized by a screw puncture resistance in the range of 140 to 230 pounds.
3. The inflatable device of claim 1 , wherein the three-dimensional membrane is characterized by a tensile strength in the range of 300 to 500 pounds per inch in the warp direction and/or a tensile strength in the range of 200 to 600 pounds per inch in the fill direction.
4. The inflatable device of claim 1 , wherein the second tie coat is formulated to provide heat stability, UV resistance, antimicrobial resistance, weatherability, and/or chemical resistance to the three-dimensional membrane.
5. The inflatable device of claim 1 , wherein the dropstitch fabric comprises at least one of nylon, polyester, and fiberglass.
6. The inflatable device of claim 5 , wherein the dropstitch fabric comprises nylon 66 fabric.
7. The inflatable device of claim 1 , wherein the solvent-based reactive adhesive of the first tie coat comprises a urethane-based material.
8. The inflatable device of claim 1 , wherein the laminated substrate comprises:
a first extruded film;
a second extruded film; and
a fabric layer between the first extruded film and the second extruded film.
9. The inflatable device of claim 1 , wherein the laminated substrate comprises:
an extruded film; and
a fabric layer in adjacent relation with the extruded film.
10. The inflatable device of claim 1 , wherein the solvent-based reactive adhesive of the second tie coat comprises a urethane-based material.
11. An inflatable device, comprising:
a three-dimensional membrane, including:
a dropstitch fabric having a first side and a second side;
a first tie coat comprising a solvent-based reactive adhesive applied to the first side of the dropstitch fabric;
a second tie coat comprising a solvent-based reactive adhesive applied to the first tie coat, the first tie coat being positioned between the first side of the dropstitch fabric and the second tie coat;
a first extruded film adhered to the second tie coat;
a first laminated substrate adhered to the first extruded film, the first laminated substrate comprising a second outer extruded film and a first fabric layer in adjacent relation with the second outer extruded film, an outer surface of the second outer extruded film forming a first outer surface of the three-dimensional membrane;
a third tie coat comprising a solvent-based reactive adhesive applied to the second side of the dropstitch fabric;
a fourth tie coat comprising a solvent-based reactive adhesive applied to the third tie coat, the third tie coat being positioned between the second side of the dropstitch fabric and the fourth tie coat;
a third extruded film adhered to the fourth tie coat; and
a second laminated substrate adhered to the third extruded film, the second laminated substrate comprising a fourth outer extruded film and a second fabric layer in adjacent relation with the fourth outer extruded film, an outer surface of the fourth outer extruded film forming a second outer surface of the three-dimensional membrane, wherein the inflatable device is inflatable to a pressure of up to about 45 pounds per square inch (psi).
12. The inflatable device of claim 11 , wherein the dropstitch fabric comprises at least one of nylon, polyester, and fiberglass.
13. The inflatable device of claim 12 , wherein the dropstitch fabric comprises nylon 66 fabric.
14. The inflatable device of claim 11 , wherein the three-dimensional membrane is characterized by a screw puncture resistance in the range of 140 to 230 pounds.
15. The inflatable device of claim 11 , wherein the three-dimensional membrane is characterized by a tensile strength in the range of 300 to 500 pounds per inch in the warp direction and/or a tensile strength in the range of 200 to 600 pounds per inch in the fill direction.
16. The inflatable device of claim 11 , wherein the second tie coat is formulated to provide heat stability, UV resistance, antimicrobial resistance, weatherability, and/or chemical resistance to the three-dimensional membrane.
17. The inflatable device of claim 11 , wherein the solvent-based reactive adhesive of one or more of the tie coats comprises a urethane-based material.