Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
  • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
  • B29C63/0017—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor characterised by the choice of the material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
  • B29C63/48—Preparation of the surfaces
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
  • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
  • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
  • B29C65/5057—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like positioned between the surfaces to be joined
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/01—General aspects dealing with the joint area or with the area to be joined
  • B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
  • B29C66/028—Non-mechanical surface pre-treatments, i.e. by flame treatment, electric discharge treatment, plasma treatment, wave energy or particle radiation
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/01—General aspects dealing with the joint area or with the area to be joined
  • B29C66/05—Particular design of joint configurations
  • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
  • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
  • B29C66/112—Single lapped joints
  • B29C66/1122—Single lap to lap joints, i.e. overlap joints
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
  • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
  • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
  • B29C66/532—Joining single elements to the wall of tubular articles, hollow articles or bars
  • B29C66/5326—Joining single elements to the wall of tubular articles, hollow articles or bars said single elements being substantially flat
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
  • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
  • B29C66/727—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being porous, e.g. foam
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
  • B29D22/00—Producing hollow articles
  • B29D22/02—Inflatable articles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
  • B29C63/48—Preparation of the surfaces
  • B29C2063/483—Preparation of the surfaces by applying a liquid
  • B29C2063/485—Preparation of the surfaces by applying a liquid the liquid being an adhesive
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C2793/00—Shaping techniques involving a cutting or machining operation
  • B29C2793/009—Shaping techniques involving a cutting or machining operation after shaping
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
  • B29C63/02—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
  • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
  • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2022/00—Hollow articles
  • B29L2022/02—Inflatable articles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
  • B63B—SHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPING 
  • B63B32/00—Water sports boards; Accessories therefor
  • B63B32/50—Boards characterised by their constructional features
  • B63B32/51—Inflatable boards, e.g. drop-stitch inflatable boards
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
  • B63B—SHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPING 
  • B63B34/00—Vessels specially adapted for water sports or leisure; Body-supporting devices specially adapted for water sports or leisure
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
  • B63B—SHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPING 
  • B63B7/00—Collapsible, foldable, inflatable or like vessels
  • B63B7/06—Collapsible, foldable, inflatable or like vessels having parts of non-rigid material
  • B63B7/08—Inflatable

Definitions

• the field of this invention relates to a method of manufacture of an inflatable product with an attachable foam finish and an inflatable product with an attachable foam finish manufactured using said method.
• Water-based inflatable platforms have become popular as solutions for many water-based applications. For example, such inflatable platforms enable easy boat or yacht maintenance. Other example applications include leisure activities, such as sunbathing, or diving inflatable platforms. They also provide a readily extendable deck space or additional work space for boats or yachts. Also water-based applications include docking stations for watersports’ equipment, jet-skis, Seabobs, surf boards, stand-up paddle boards (SUP’s), etc. Also, a number of water-based sports equipment, such as surfboards and SUPs would benefit from an ability to apply different surface types to the boards.
• FIG. 1 shows three illustrations 110, 120, 130, of a bubbling effect 115, 125, 135 of a teak-surface where PE foam has been attached to a water-based inflatable platform.
• the PE foam sticks very well to itself and also to solid boats, such as fibre glass.
• the bond does not last. This has been a known problem for a number of years amongst water-based platform manufacturers in attempting to bond such different surfaces together.
• the inventors of the present invention have recognised and appreciated a need for an improved method of manufacture with an attachable foam finish, for example of a foam surface on to, say, a Polyvinyl chloride (PVCTM), HypalonTM or NeopreneTM material for connecting to an inflatable water-based platform, such as a pool surround, Jet-ski docking station, Seabob docking station, or land-based platform such as a gym mat, or water-based sports item, such as a stand-up paddle board (SUP) or a number of other applications, as identified later.
• PVCTM Polyvinyl chloride
• HypalonTM or NeopreneTM material for connecting to an inflatable water-based platform, such as a pool surround, Jet-ski docking station, Seabob docking station, or land-based platform such as a gym mat
• water-based sports item such as a stand-up paddle board (SUP) or a number of other applications, as identified later.
• SUP stand-up paddle board
• the invention seeks to mitigate, alleviate or eliminate one or more of the above mentioned disadvantages, either singly or in any combination.
• aspects of the invention provide for a method of manufacture of an inflatable product with an attachable foam finish, and an inflatable product with an attachable foam finish that is manufactured according to said method.
• FIG. 1 illustrates various views of a water-based inflatable platform exhibiting a known bubbling effect due to the glue-bonding of the PE foam and PVC platform.
• FIG. 2 illustrates an example flowchart of a method of manufacture of a platform according to example embodiments of the present invention.
• FIG. 3 illustrates various views of a first-phase of a method of manufacture of a foam surface to a water-based inflatable platform according to example embodiments of the present invention.
• FIG. 4 illustrates various views of the second phase of the method of manufacture of a foam surface to a water-based inflatable platform, according to example embodiments of the present invention.
• FIG. 5 illustrates various views of a third phase of the method of manufacture of a foam surface to a water-based inflatable platform, according to example embodiments of the present invention.
• FIG. 6 illustrates various views of a fourth phase of the method of manufacture of a foam surface to a water-based inflatable platform, and a high pressure system according to some example embodiments of the present invention.
• the field of this invention relates to a method of manufacturing an inflatable product with an attachable foam finish, by connecting foam on to a flexible, gluable and/or weldable material, such as Polyvinyl chloride (PVCTM), HypalonTM or NeopreneTM, to create an attachable foam finished surface for connecting to the inflatable or inflated or partially inflated or deflated product.
• a flexible, gluable and/or weldable material such as Polyvinyl chloride (PVCTM), HypalonTM or NeopreneTM
• PVCTM Polyvinyl chloride
• HypalonTM HypalonTM
• NeopreneTM Neoprene
• the field of this invention also relates to a method of manufacturing an inflatable product with an attachable foam finish, by modifying a molecular structure of the foam and sticking the treated form directly on to a product, such as a platform surface, for example using a high pressure roller system.
• the term‘flexible, glueable and/or weldable material’ will be used to indicate any of PVCTM, HypalonTM or NeopreneTM (or indeed any other fabric that may be used in a manufacture of inflatable products, such as Polyurethane) that is sufficiently flexible for the application that it is being used for and that is suitable for gluing and/or welding together, unless a specific example is identified.
• the inflatable products may include various finish options to the surface design, for example a) PE teak effect foam finish in various colours, b) EVA or EVA/PE blend teak effect foam finish in various colours, c) PE foam for another design and colour finish d) EVA or EVA/PE blend other design & colour finish.
• the term ‘foam’ is intended to cover any type of foam material or foam finish that is capable of being glued to a flexible, glueable and/or weldable material, unless a specific example is identified.
• Concepts described herein relate to manufacturing and applying a finish, such as a non-skid finish to an inflatable product, which may be inflated, partially inflated or deflated.
• Applications include an attachable foam finish for an inflatable water-based platform, such as one or more of: an inflatable water-based platform, such as a Jet-ski docking station, Seabob docking station, an inflatable swimming pool surround, an inflatable ‘air deck’ platform, custom made docks, docking stations for other waterbom craft, such as sea planes, tenders, etc. inflatable beach clubs, inflatable boat bottoms, waterbom craft, inflatable water-based seats or land-based platform such as gym mats or mattresses, inflatable land-based seats, or water-based sports item, such as a stand-up paddle board (SUP), surf boards.
• an inflatable water-based platform such as a Jet-ski docking station, Seabob docking station, an inflatable swimming pool surround, an inflatable ‘air deck’ platform, custom made docks, docking stations for other waterbom craft, such as sea planes, tenders, etc. inflatable beach clubs, inflatable boat bottoms, waterbom craft, inflatable water-based seats or land-based platform such as gym mats or mattresses, inflatable land-based seats,
• a flame treatment may be employed in the early stages of manufacture, for example using a gas bottle with a high intensity flame, to treat the back of the PE foam prior to gluing.
• One problem that results from using flame treated is that when the flame treated foam is to be glued to a flexible, glueable and/or weldable material inflatable product surface, the surface that is to be glued or welded tends to be partially inflated so that the foam takes the right shape at full inflation. In essence, this means that the glue bonding is difficult, simply because if you are pushing down through the soft foam surface to a soft surface underneath it is difficult to obtain a good bond. This is especially the case over larger areas, such as found with inflatable product surfaces.
• the inventors of the present invention identified that using this flame treated foam approach, following just the high intensity flame treatment to the back of the PE foam, bubbles would start to appear under the teak foam where the bond was not acceptable to the inflatable product. It is envisaged that a similar result would occur using EVA foam. For example, it was determined that the inflatable product would heat in the sun, the air pockets in the non-glued parts would expand and push the foam upwards and become unsightly to the top of the inflatable product.
• a yet further problem was identified in that the treatment, either flame or Corona, did not last. Notably, the inventors of the present invention identified this lack of longevity as being a consequence of the Corona or flame treatment changing the molecular structure of the surface of the foam. The inventors identified that the 100% molecular change lasts only for approx. 20 mins tested within a laboratory for Corona treatment only. In some instances, it was noted that there was still some molecular change (for example around 70%) after 20mins, which still allows (some, but slightly less than ideal) bonding to the foam.
• the inventors of the present invention have described a method of manufacture of a foam surface to a water-based inflatable product that includes the application of a layer of glue on to the back of the foam as soon as possible after foam treatment, which in some examples is either corona or flame treatment, preferably within 20 minutes of the foam treatment, in order to seal in the molecular structure change.
• foam treatment which in some examples is either corona or flame treatment, preferably within 20 minutes of the foam treatment, in order to seal in the molecular structure change.
• the gluing process requires two or three layers of glue, initially one layer of glue on the foam and one layer of glue on the flexible, glueable and/or weldable material surface.
• the manufacture should allow this first layer applied to both surface to dry to touch. Thereafter, in some examples, a second layer of glue is then applied to both surfaces and whilst they are still tacky, they are brought together to form a strong bond.
• first molecule sealing glue layer is applied to the foam, thereby sealing the molecules in on the foam, and allowed to dry to touch.
• a first layer of glue may also be applied to the flexible, glueable and/or weldable material.
• a second layer of glue is then applied to both surfaces and allowed to dry completely, a third layer of glue may then be applied to both surfaces and whilst they are still tacky, they are bought together to form a strong bond.
• a flexible, glueable and/or weldable material sheet may be placed on the back of the PE foam, whilst the foam is face down on a hard surface to achieve a really good bond.
• NeopreneTM sticks to HypalonTM, and therefore in some examples, NeopreneTM is used to stick NeopreneTM-backed foam to HypalonTM products.
• the advantage of this method is that the worker can see and feel if the glue is still‘open’ and assess that the two material surfaces are bonding together successfully.
• the hard surface of the table also allows the worker to push down with a hard implement and manipulate/work out any air bubbles.
• gluing the entire foam surface with the flexible, glueable and/or weldable material on the back, to the inflatable product may be both expensive in terms of glue, but also labour intensive. Therefore, in some examples, only parts of the flexible, glueable and/or weldable material backed foam are glued to the surface of the inflatable product.
• the parts that are glued may encompass one or more the following: around the full edge of the foam, on the joins (typically the foam may be joined every lm (approx.), under, say, the VelcroTM strips where accessories may be applied as it is important that the foam does not lift when pulling off the accessories.
• the inventors proposed to introduce air release gaps along the edges, for example about a 1.5 - 3cm long non glued part. In some examples, these may appear approx every 1 meter, or so, in each glued section on both sides to allow heated expanded air to escape.
• NeopreneTM sticks to HypalonTM, and therefore, in some examples, NeopreneTM strips, such as 6cm wide strips that are configured for the length of the foam are used to join foam to stick to HypalonTM platforms.
• foam surfaces may be joined with PVC strips to stick to PVC platforms (or indeed any of the aforementioned products).
• the weight of the flexible, glueable and/or weldable material glued to the back of the foam also acts as a weight to pull the foam down and not lift as much (say, in the heat of the sun), or allow the foam to expand and stretch in to bubbles.
• the concepts described herein may be used in land-based platforms, such as with air tracks for gym equipment, etc.
• land-based platforms as compared to water-based platforms, ballasts are not required.
• the manufacturing concepts described herein may be achieved using a vacuum process to apply pressure between the respective layers when glued, for example to minimise the risk of air gaps.
• the vacuum process may be used to glue the PVC (or other flexible, glueable and/or weldable material) backed foam and gluing the foam to the entire surface of the product, or the surface of the product just round the edges and at the joins of the foam, as the vacuum could apply the pressure needed, in order to reduce or eliminate any air pockets in between each section.
• a high-pressure roller system may be equally employed to apply the PVC(or other flexible, glueable and/or weldable material) backed foam pad to the surface of the platform or product across the entire surface or around the edges and joins, in order to minimise and push out the air left underneath.
• a method of manufacture of an inflatable product may include modifying a molecular structure of at least one foam surface; and gluing a flexible, glueable and/or weldable material directly onto the modified at least one foam surface and concurrently gluing the modified at least one foam surface to the inflatable product using, say, a high pressure roller system or a vacuum pressure approach to achieve a good bond on the entire surface (or part, e.g. around the edges and/or joins) of the inflatable product and foam.
• the concurrent gluing of the modified at least one foam surface to the inflatable product may be most suitable for small items, or for items that are not in the sun, as foam with no PVC, etc., on the back of the surface, may well expand and bubble in the heat of the sun in all of the non-glued section.
• this ‘tacky period’ (sometimes referred to as ‘open time’) is also dependent on the glue type, and in some examples with some glues the ‘tacky period’ may be longer or shorter than 30mins. In some examples, it is envisaged that the‘open time’ for some glues may be extended by heating with a hot air gun.
• foams such as Ethylene- Vinyl Acetate (EVA) and Polyethylene closed cell foam, also called PE foam, and a PE/EVA foam mix.
• EVA Ethylene- Vinyl Acetate
• PE foam Polyethylene closed cell foam
• PE/EVA foam mix PE/EVA foam mix
• other foams with a non-teak effect may be employed. All foam types do not bond well to PVC or HypalonTM or NeopreneTM.
• HypalonTM is a chlorosulfonated polyethylene (CSPE) synthetic rubber (CSM), noted for its resistance to chemicals, temperature extremes, and ultraviolet light.
• CSPE chlorosulfonated polyethylene
• Polyvinyl Chloride is a common thermoplastic used in construction, available in two forms: rigid and flexible, and generally known for its hardness.
• NeopreneTM rubber is a highly resistant synthetic material and is used for a variety of outdoor and marine applications. Also known as polychloroprene and invented by DuPont in 1931, it is produced by the polymerization of chloroprene. NeopreneTM rubber resists degradation more than natural or synthetic rubber.
• Such a foam-flexible, glueable and/or weldable material bonded arrangement is also used on PVC stand up paddle boards, for example. It is a small pad that can be replaced.
• a typical thickness of the foam is of the order of a 6mm layer, e.g. a 3mm layer of brown foam & a 3mm layer of black foam sandwiched together, for example with the lines cut out to create a suitable visual effect.
• a PVC SUP may employ a foam layer of about 3mm thick.
• a pad to be applied to the SUP or surf board is first treated with burning or corona treatment, following which the molecular change is sealed using glue.
• the SUP board or surfboard may be partially inflated when a pad is glued to the board.
• the pad may be first positioned when the SUP or surf board is inflated, then the board may be deflated thereby allowing the pad to be then pushed down to, say, a hard surface of a table to achieve a good bond. Thereafter, the board may be inflated immediately in order to set glue in right place.
• the SUPs may be inflated to, say, l378mb/ 20psi, thereby providing a very rigid and hard surface in order to put the foam on and push down upon, i.e. apply at full inflation.
• the foam pad being applied to the SUP board or surf board may be automated, for example using a high pressure roller system.
• an example flowchart 200 illustrates a method of manufacture of an inflatable product according to example embodiments of the present invention.
• examples of the invention apply burning or corona treatment first to the foam underside surfaces at 202, which are later joined, cut and shaped. This burning or corona treatment to modifies the molecular structure and helps to create a bond to the flexible, glueable and/or weldable material.
• the inventors determined that a layer of glue is applied to the back of the burnt or corona treated foam surface (which in some examples may be in a form of a foam sheet) at 204, in order to seal in the molecular structure change imparted due to the burning or corona treatment.
• the layer of glue may be applied to the burnt or corona treated foam surface at 204 within a relatively short period of time, say within 20 minutes (although this time limit could vary dependent upon the application and materials being used.
• the technician may glue all of the foam surface or a partial amount thereof, say, apply glue at every lm.
• a first layer of glue may also be applied to the flexible, glueable and/or weldable material (such as PVC) at this stage e.g., at the same time as glue is applied to the burnt or corona treated foam. Additionally, the glue is allowed to dry to the touch.
• the burnt or corona treated foam surfaces require a reasonably quick application of, say, glue, to seal in the molecular change to the foam. Ideally, the burnt or corona treated foam surfaces will not be subjected to any, or significant, amounts of touching that may impact the sealing of the molecular change.
• a second (and optionally a third) application of glue may be applied to both a back of the flexible, glueable and/or weldable material sheet (e.g. a PVC or Hypalon or neopreneTM sheet) and to the burnt or corona treated foam and attached together with a small test overhang of the PVC, HypalonTM or NeopreneTM.
• the second layer of glue is applied to both surfaces such that they are bought together when tacky. If a third layer of glue is employed, then the second layer is allowed to dry to the touch before the 3 rd layer is applied and both surfaces are bought together when tacky.
• a heat gun may be used to affect the drying times of the glue, in order to make it tacky again. It is also envisaged that in some examples the hot air gun may applied to the glue on the foam. In some examples, it is envisaged that the manufacturing process may be wholly automated for a quick and efficient bond.
• the overhang may be trimmed and the PVC, HypalonTM or NeopreneTM- backed foam surfaces (for example in the form of sheets) brought together (e.g. on a firm table).
• the glue must be dried before the test can begin. Therefore, in some examples, a minimum of a day’s delay may be used depending upon glue used.
• the inventors of the present invention identified that it takes approx. 3 days for full drying time using a typical glue, but the test of the bond can be done after 1 day.
• the overhang is pulled away from the foam sheet to the full surround. It is particularly important along the sides of the foam that will be joined. If the bond is not good, say due to insufficient burning or corona treatment to the edges, then the foam can be trimmed and the test performed again before final joining. This is a good test to see if the corona or burning treatment has been successful.
• foam surfaces e.g. foam sheets
• cutting and/or shaping of the foam surfaces may be performed, e.g. addressing middle parts of the respective sheets that may have become mis-aligned during the burning or Corona treatment.
• the foam surfaces e.g. foam sheets
• these foam surfaces may be cut and/or shaped any time after 202.
• the inventors have also identified that the Corona treatment doesn’t tend to change the shape of the foam, unlike burning, therefore in some examples it is envisaged that the foam may be cut and shaped before corona treatment.
• the inflatable product may be partially inflated (or in some examples fully inflated).
• the inflatable platform would need to be fully (or nearly fully) inflated for the foam to be measured and cut to a correct shape.
• partial inflation is performed at a PVC HypalonTM or NeopreneTM-backed foam application stage 216, when glue is applied around some or all of the edges. Thereafter, when the product is fully inflated it pulls the foam pad tight in appearance, and results with no wrinkles in the appearance of the foam.
• a manufacturer may apply a trade-off between a need to glue the entire sheet of PVC HypalonTM or NeopreneTM-backed foam to the platform surface and the extent of partial inflation.
• the inventors have identified that the amount of glue and the level of partial inflation may be dependent upon the size of the inflatable product and the scale of the foam coverage, in order to ensure that the PVC backed foam is stretched tight when inflated but avoids resulting in a banana-shape of the inflatable product.
• This trade-off between gluing, partial (or full) inflation and avoiding a potential banana-shape problem may happen when partially (or fully) gluing of the foam pad just round the edges of the foam and along each join too.
• each individual platform is measured and the foam surface (e.g. foam sheets), cut and shaped to fit the specific platform measurements.
• D-Ring covers may be glued to an underside of the foam surface (e.g. foam sheet) and allowed to dry, and the VelcroTM stitched to the top and the edge of the foam stitched.
• a different order to some steps of the manufacturing process may be applied, e.g., the edge of the foam could be stitched first and then the D-Ring covers glued on.
• a different order may include gluing sheets together then cut and shape.
• all the sheets (e.g. lm x 2m) of foam with material on the back are joined together with the flexible, glueable and/or weldable material (e.g. PVC, Hypalon or Neoprene) for example in 6cm wide joining strips of material, which run the length of the foam surfaces or sheets being joined.
• the joining strip material should match the material to the back of the sheet of the foam, e.g., PVC to PVC, although as HypalonTM sticks to NeopreneTM, those sheets backed in HypalonTM or NeopreneTM can be joined with either of these materials.
• the foam could be joined with these joining strips after the burning and corona treatment, without necessarily applying the PVC, HypalonTM or NeopreneTM to the back of the foam first.
• the remaining part of the uncovered foam could then have PVC, HypalonTM or NeopreneTM subsequently applied, or just not bother to apply PVC, HypalonTM or NeopreneTM to the remaining part if it was for a small (e.g.‘pad’) surface area, or when used with a high pressure application system, etc.
• the D-rings are glued to the underside of the D-Ring covers.
• the D-Rings may be glued at any stage to the underside.
• the bonded structure is then glued to the partially inflated platform at 216 with, in some examples, glue applied round the full edge with air vents, fully under the D- ring part (which is very important as a strong bond is essential), under the joins of the foam, under VelcroTM etc.
• air escape gaps may be provided at approx. 2cm, on either edge of each section along the edge, when gluing the entire sheet of foam to the surface of the partially inflated platform, in order to allow air to escape.
• the product, or platform in this particular example may be fully inflated or deflated in other examples when the final gluing is performed.
• the final gluing may be performed around the edges of the product, or platform in this particular example, and not under each join or the Velcro strips etc.
• the final bonded structure may be glued on in many different ways, either in part or as a whole.
• a high pressure system may be employed after the step of applying burning or corona treatment to the foam in order to modify the molecular structure and help to create a bond to the flexible, glueable and/or weldable material.
• a layer of glue is applied to the back of the burnt or corona treated foam surface (which in some examples may be in a form of a foam sheet) at 204, in order to seal in the molecular structure change imparted due to the burning or corona treatment.
• a first layer of glue would need to be applied to the top platform surface, followed by 2 nd or 3 rd layers on both the foam and platform surfaces and bought together when tacky to achieve a good bond.
• the ‘open time’ of the glue is an important factor in the manufacturing process and a quick (or automated) approach to applying the glue to both surfaces is an important consideration.
• a high pressure system may be applied (e.g. in an automated process).
• the high pressure system at 207 may apply the burnt or corona treated foam, with the molecular change sealed by the glue, direct to the product, e.g. a platform that is either deflated, partially inflated or inflated at 216.
• the high pressure system may be a roller-based system where a roller is configured to apply pressure to the product and the burnt or corona treated foam when the glue retains sufficient stickiness.
• the high pressure system may be a vacuum-based system where a vacuum is created in a sealed enclosure to apply pressure to the product and the burnt or corona treated foam when the glue retains sufficient stickiness. In these examples, no intermediate bonded structure is employed.
• examples may employ one or more of the intervening steps relating to constructing the product or the foam in a suitable shape or form, e.g. trim and join one or more sheets at 208, or cut or shape foam 209, or use partially inflated, deflated or inflated product at 210 or apply other items to the product, such as D-rings, stitch Velcro or stitching, at 211, say.
• a first pictorial view 310 illustrates a PE foam sheet.
• the PE foam sheet is of a sixe of l02cm wide by 203cm long.
• smaller or larger sheets may be used, for example with l.5m wide and shorter length of l .5m, or for use in manufacturing custom- made docking stations or very long inflatable platforms sheets of l02cm wide by up to lOm long may be employed.
• a second view 320 illustrates the foam with a slightly shiny surface to the back.
• a third view 330 illustrates the foam after high intensity flame treatment.
• a fourth view 340 illustrates a comparison of the foam together, before and after the high intensity foam treatment.
• the burning phase may also be applied to EVA foam or a PE/EVA foam mix.
• FIG. 4 various views of a second phase of the method of manufacture of a foam surface to a water-based inflatable platform are illustrated according to example embodiments of the present invention.
• This second phase follows the first phase of burning or corona treatment, and includes applying the glue and flexible, glueable and/or weldable material sheet.
• a first pictorial view 410 illustrates a foam sheet with a black PVC version of the flexible, glueable and/ or weldable material located on the back.
• a black PVC version of the flexible, glueable and/or weldable material may be used as the lines on the teak effect foam are black and the PVC material colour is chosen to match.
• the foam is joined in the lines and a matching colour of PVC to the lines means that the joins can be hidden from view.
• the lines on the foam may be provided and available in different colours, and in such situations a different colour PVC to match the lines may be chosen.
• a second view 420 illustrates the extra PVC overhang of the PVC sheet to pull on to test bond of the glue either partially or all the way round. In a partial glue process, for example on three sides, it is possible to line up the first edge with no overhang and the overhang is purely so there is enough PVC to cover the sheet and not have to be precise in the gluing process.
• a third view 430 illustrates the foam cut along black lines for joining.
• a fourth view 440 illustrates the foam bought together to be joined along the black lines. The foam is cut to shape at this stage, so that the joins are seamless and not visible. For example, in some applications, the foam may have or become mis-shapen through the burning
• FIG. 5 various views of a third phase of the method of manufacture of a PE teak foam surface for a water-based inflatable platform are illustrated according to example embodiments of the present invention.
• a first pictorial view at 510 illustrates foam sheets that are bought together after cutting and shaping along the joins. Here, no gluing is performed, as the foam sheets are just brought together exactly for outside shaping & cutting.
• a second pictorial view at 520 illustrates an inflated or partially inflated platform, which may be used to measure and to fit the foam. The platform can be inflated at any time in the process though.
• a third pictorial view 560 illustrates two sheets of PE teak foam with black PVC sheet back joined together to the underside using a black PVC strip.
• the PVC to PVC bond is very strong.
• the PVC to the back of the foam bonds very well to the black PVC strip.
• two sheets of teak foam, each with a NeopreneTM sheet back could be joined with a black NeopreneTM strip.
• a HypalonTM backed sheet of foam could either be joined with a NeopreneTM Strip of a HypalonTM Strip.
• HypalonTM & NeopreneTM bond to each other but do not bond well to PVC, due to plastisiation migration, the transfer of polymers form from the PVC that, over time, eats away and damages the HypalonTM.
• a fourth view 570 illustrates the shape of the joined foam sheets after gluing and after the joined foam is cut to shape, the D-ring covers are glued on, the VelcroTM is stitched to the foam, and the foam stitched to the edge.
• FIG. 6 a view of a water-based inflatable platform following the method of manufacture as described herein is illustrated, according to example embodiments of the present invention.
• a view 620 illustrates the foam glued 622 to the inflatable platform, around the full edge 624, under the VelcroTM strips, under each join (at approx every lm) and fully under the D-Rings, as illustrated.
• a problem with other known foam pads is that the edge can start to lift. Therefore, examples of the invention propose, in a fourth stage, stitching straight through the foam with PVC on the back, at 630, which helps prevent any fraying and wear of the foam on the ends, for example as a result of repetitive collisions with, say, jet-skis, etc.
• the inflatable products may include various finish options to the surface design, for example a) PE teak effect foam finish in various colours, b) EVA or EVA/PE blend teak effect foam finish in various colours, c) PE foam for another design and colour finish d) EVA or EVA/PE blend other design & colour finish.
• various finish options to the surface design for example a) PE teak effect foam finish in various colours, b) EVA or EVA/PE blend teak effect foam finish in various colours, c) PE foam for another design and colour finish d) EVA or EVA/PE blend other design & colour finish.
• FIG. 6 also illustrates one example of a high pressure system 650 that may be employed according to some examples of the invention.
• the high pressure system 650 includes an inlet 652 coupled to a motor 654 that operates a high pressure system, such as a vacuum system 656.
• the motor may also supply a pressure controller 662 that controls the amount of pressure to be applied, for example through a high-vacuum pressure station 660, when gluing the inflatable product to an attachable foam finish.
• any arrangement of components to achieve the same functionality is effectively ‘associated such that the desired functionality is achieved.
• the order of the operations in FIG. 2 may be changed, for example dependent upon the manufacturing circumstances, the materials being used and product being manufactured.
• any two components herein combined to achieve a particular functionality can be ‘associated with’ each other such that the desired functionality is achieved, irrespective of architectures or intermediary components.
• two components so associated can also be viewed as being‘operably connected’, or‘operably coupled’ to each other to achieve the desired functionality.
• an improved solution is described for method of manufacture of an inflatable product with an attachable foam finish.
• the herein described system provides a secure mechanism for connecting a flexible, glueable and/or weldable material layer to a PE, PE/EVA mix or EVA foam, advantageously to secure them the foam for use in the water or on land or with any of the aforementioned applications.
• the inventors of the present invention have recognised and appreciated a number of problems with existing designs, which have been substantially alleviated with the concepts described herein.

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• Physics & Mathematics (AREA)
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• Laminated Bodies (AREA)
• Lining Or Joining Of Plastics Or The Like (AREA)
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• 2018
  • 2018-11-23 RU RU2020120469A patent/RU2764745C2/ru active
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