Method for Manufacturing a Volume Element Inflatable With a Gas, In Particular a Water Sports Equipment

Abstract

The invention relates to a method for manufacturing volume element (10) which is inflatable with a gas, the method comprising the steps of: providing at least one first tube element (12) which comprises at least one first tube (1, 4) which is inflatable with the gas and is formed by at least two layers which are arranged one above the other, are formed from a per se limp material, and are connected with each other along at least one first seam (16d, 36); and providing at least one second tube element (14, 15) which comprises at least one second tube (5, 8) which is inflatable with the gas and is formed by at least two layers which are arranged one above the other, are formed from a per se limp material, and are connected with each other along at least one second seam (18d, 38), wherein the tube elements (12, 14) are provided in such a way that the seams (16d, 18d, 36, 38) are arranged on mutually facing sides of the tube elements (12, 14) and have, at least in respective length portions (40), curvatures that are different from each other.

Claims

1. A method for manufacturing a volume element which is inflatable with a gas, the method comprising the steps of: providing at least one first tube element which comprises at least one first tube which is inflatable with the gas and is formed by at least two layers which are arranged one above the other, are formed from a per se limp material, and are connected with each other along at least one first seam; and providing at least one second tube element which comprises at least one second tube which is inflatable with the gas and is formed by at least two layers which are arranged one above the other, are formed from a per se limp material, and are connected with each other along at least one second seam, wherein the tube elements are provided in such a way that the seams are arranged on mutually facing sides of the tube elements and have, at least in respective length portions, curvatures that are different from each other.

2. A method according to claim 1, wherein the tube elements are provided in such a way that the seams are spaced from each other over their respective complete extension.

3. A method according to claim 1, wherein the tube elements are provided as separately formed tube parts.

4. A method according to claim 1, wherein the tubes comprise respective free ends, wherein the tube elements are provided in such a way that the free ends are spaced from each other, and wherein the ends are moved towards each other, in particular in such a way that the ends touch.

5. A method according to claim 4, wherein the ends are moved towards each other by folding a sub-area of the respective tube element about a folding axis, the sub-area comprising the respective ends.

6. A method according to claim 4, wherein the tubes are fluidically and/or mechanically connected with each other via the ends.

7. A method according to claim 4, wherein the tubes are connected with each other via the ends by means of at least one adhesive joint.

8. A method according to claim 1, wherein the layers are formed from fibers, and wherein the tube elements are provided in such a way that the fibers enclose with the longitudinal extension direction of the volume element an angle ranging from 25 degrees to 65 degrees, in particular from 35 degrees to 55 degrees.

9. A method according to claim 1, wherein the respective layers are connected with each other along the respective seam by gluing and/or welding and/or sewing.

10. A method according to claim 1, wherein the volume element is manufactured as a water sports equipment, in particular as a surf board, a paddle board, a standup paddle board or an air mattress, or is used for a water sports equipment, in particular as a surf board, a paddle board, a standup paddle board or an air mattress.

Description

[0042] The drawing shows in:

[0043] FIG. 1 a schematic plan view of a volume element configured as a water sports equipment in its inflated state;

[0044] FIG. 2 a schematic plan view of tube elements of the volume element, wherein FIG. 2 serves for illustrating a first embodiment of a method for manufacturing the volume element;

[0045] FIG. 3 a schematic plan view of the tube elements, wherein FIG. 3 serves for illustrating a second embodiment for manufacturing the volume element;

[0046] FIG. 4 a schematic plan view of the tube elements, wherein FIG. 4 serves for illustrating a third embodiment of the method for manufacturing the volume element;

[0047] FIG. 5 a schematic plan view of the tube elements, wherein FIG. 5 serves for the illustrating a fourth embodiment of the method for manufacturing the volume element;

[0048] FIG. 6 a schematic plan view of the tube elements, wherein FIG. 6 serves for illustrating a fifth embodiment of the method for manufacturing the volume element;

[0049] FIG. 7 a schematic plan view of the tube elements, wherein FIG. 7 serves for illustrating a sixth embodiment of the method for manufacturing the volume element;

[0050] FIG. 8 a schematic plan view of the tube elements, wherein FIG. 8 serves for illustrating a seventh embodiment of the method for manufacturing the volume element; and

[0051] FIG. 9 a schematic plan view of the tube elements, wherein FIG. 9 serves for illustrating an eighth embodiment of the method for manufacturing the volume element.

[0052] In the figures identical or functionally identical elements are equipped with the same reference signs.

[0053] FIG. 1 in a schematic plan view shows a volume element designated as a whole as 10, wherein in FIG. 10 an inflated state of the volume element 10 is illustrated. The volume element 10 is configured therein as water sports equipment, wherein the volume element 10 can be configured as surfboard, paddle board, or standup paddle board. Further, it is conceivable that the volume element 10 is used for such water sports equipment representing a volume device. Therein the volume element 10 for instance is a core, which at least partly, in particular predominantly, is enveloped by an envelope.

[0054] The volume element 10 comprises a multitude of tubes 1, 2, 3, 4, 5, 6, 7, and 8, which are inflatable with a gas, in particular with air. This means that for inflating the volume element 10 the named gas is passed, in particular blown, into the tubes 1, 2, 3, 4, 5, 6, 7, and 8. By inflating the tubes 1, 2, 3, 4, 5, 6, 7, and 8 the volume element 10 is transferred from its uninflated state or non-inflated state into its inflated state.

[0055] The tubes 1, 2, 3, and 4 are components of a first tube element 12, wherein the tubes 5, 6, 7, 8 are components of a second tube element 14 of the volume element 10. This means that the first tube element 12 of the volume element 10 comprises the tubes 1, 2, 3, and 4, wherein the tube element 14 of the volume element 10 comprises the tubes 5, 6, 7, and 8. As part of the method for manufacturing the volume element 10 for instance in a first step of the method the first tube element 12 is provided, which comprises the tubes 1, 2, 3, and 4, which are inflatable with the gas. Therein the tube 1 is for instance a so-called first tube of the volume element 10 or the tube element 12. In a second step of the method for instance the second tube element 14 is provided, which comprises the tubes 5, 6, 7, and 8, which are inflatable with the gas. Therein the tube 5 is for instance a second tube of the tube element 14.

[0056] If the tube elements 12 and 14 are provided for instance as separate or separately configured tube parts, the tube element 14 for instance comprises at least one first layer and at least one second layer that is configured separately from the first layer, wherein the respective layer is formed from a per se limp material, i.e. a material that is limp as to its shape. Whilst the material is preferably limp, however, it is airtight and inelastic, i.e. non-elastic. Thus the material upon inflation does not or only slightly expand. Further upon provision of the tube elements 12 and 14 as separate tube parts the tube element 14 for instance comprises a third layer that is configured to be separate from the first layer and separate from the second layer as well as a fourth layer that is configured to be separate from the first, second, and third layer. Also the third and fourth layer are each formed from a per se limp material, wherein the previous and the following explanations given with regard to the first layer can also be applied to the other layers and vice versa. The respective layer or the respective material for instance comprises fibers or is at least formed from fibers, wherein the respective layer or the respective material can be configured as a fabric.

[0057] For manufacturing the tube element 12 the first layer is arranged on the second layer and for manufacturing the tubes 1, 2, 3, and 4 connected along respective seams 16a-d with the second layer. The respective seam 16a-d is an at least substantially line-shaped connection spot or an at least substantially line-shaped connection area, at which or in which the first layer is connected with the second layer, whereby the tubes 1, 2, 3, and 4 are formed. Therein from FIG. 1 it can be seen that the respective seam 16a-d at least in a respective length portion has a curved course and thus a curvature.

[0058] For manufacturing the tube element 14 for instance the third layer is arranged on the fourth layer and along respective seams 18a-d connected with the fourth layer. Therein the following and previous explanations given with regard to the respective seam 16a-d can be applied to the respective seam 18a-d and vice versa. The respective layers are glued to each other for instance along the respective seam 16a-d or 18a-d and/or welded together and/or sewed together and/or connected in a different way with each other.

[0059] The tube elements 12 and 14 are for instance at least mechanically connected with each other so that the tube elements 12 and 14 are fixed to each other. For instance the first tube element 12 is manufactured by connecting the first layer with the second layer whilst forming the tubes 1, 2, 3, and 4. Further, for instance initially the second tube element 14 is manufactured by connecting the third layer with the fourth layer and whilst forming the tubes 5, 6, 7, and 8. The tube elements 12 and 14, which comprise the respective tubes 1, 2, 3, and 4 or 5, 6, 7, and 8, thus are initially separate components, which for instance are connected at least mechanically with each other. For this purpose for instance the first tube 1 is at least mechanically connected with the second tube 5. For this purpose for instance at least respective, initially spaced apart sub-areas of the tube elements 12 and 14 are moved towards each other and then, in particular mechanically, connected with each other.

[0060] Alternatively or additionally it is conceivable that the tubes 1, 2, 3, 4, 5, 6, 7, and 8 via their respective, initially free ends are connected with each other at least mechanically. Alternatively or additionally it is conceivable that the tubes 1 and 5 via their respective, initially free ends are connected with each other at least mechanically and/or that the tubes 1 and 5 via respective sub-areas extending from the respective free end of the tubes 1 and 5 are connected with each other at least mechanically. In particular it can be envisaged that the respective tubes 1, 2, 3, 4, 5, 6, 7, and 8, in particular via their respective initially free ends, are connected fluidically with each other so that for instance the afore-mentioned gas can flow between the tubes 1, 2, 3, 4, 5, 6, 7, and 8 (1-8).

[0061] FIG. 1 shows the volume element 10 in its inflated state, in which the volume element 10 on its top side 20, which can be discerned in FIG. 1, and on its bottom side, which faces away from the top side 20 and cannot be discerned in FIG. 1, at least substantially is configured even or flat. Further, the volume element 10 in its inflated state has no folds or only a very small number of minor folds. This is realizable by a special method for manufacturing the volume element 10, wherein this method or several embodiments of the method is or are explained in the following.

[0062] As an alternative to the provision of tube elements 12 and 14 as separate tube parts it is possible to provide the tube elements 12 and 14 as interconnected tube elements or as coherent integral unit. Therein the first layer is configured as a single piece with the third layer so that the first layer and the third layer for instance form a fifth layer. Further, the second layer is configured as a single piece with the fourth layer so that the second and the fourth layer form a single-piece sixth layer that is configured to be separate from the fifth layer. For manufacturing the tube elements 12 and 14 for instance the fifth layer is arranged on the sixth layer and along the seams 16a-d and 18a-d is connected with the sixth layer, whereby the tubes 1-8 are manufactured.

[0063] FIG. 1 shows the volume element 10 for instance in an idealized or simplified representation, in which the tubes 1 and 5, in particular the tube elements 12 and 14, relative to an imaginary central axis 22 are configured to be symmetrical, in particular mirror-symmetrical relative to each other. The central axis 22 thus is a symmetry axis, which lies in a symmetry plane extending perpendicularly to the image plane of FIG. 1. Further, the volume element 10 has a longitudinal extension direction shown in FIG. 1 by a double arrow 24 since the volume element 10 has a length extending along the longitudinal extension direction, the length being larger than a width extending along a second direction extending perpendicularly to the longitudinal extension direction. This second direction is illustrated in FIG. 1 by a double arrow 26.

[0064] Based on FIG. 2 in the following a first embodiment of the method for manufacturing the volume element 10 is illustrated. From FIG. 2 it can be seen that the tube elements 12 and 14 are provided in such a way that the respective tubes 1, 2, 3, and 4 (1-4) each comprise a first free end 28 and the tubes 5, 6, 7, and 8 (5-8) each comprise a second free end 30, wherein the free ends 28 and 30 initially are spaced apart from each other. In the first embodiment between the free ends 28 and 30 of the tubes 1 and 5 a first distance d1, between the free ends 28 and 30 of the tubes 2 and 6 a second distance d2, between the free ends 28 and 30 of the tubes 3 and 7 a third distance d3, and between the free ends 28 and 30 of the tubes 4 and 8 a fourth distance d4 is provided. Therein the distance d1 is smaller than the distance d2, which is smaller than the distance d3, which in turn is smaller than the distance d4. In other words, it applies: d1<d2<d3<d4.

[0065] Further in the first embodiment the tube elements 12 and 14 are provided in such a way that the tubes 1 to 4 each have a third free end 32 and the tubes 5-8 each have a fourth free end 34, wherein the free ends 32 and 34 initially are spaced apart from each other. Thus between the free ends 32 and 34 of the tubes 1 and 5 a distance D1, between the free ends 32 and 34 of the tubes 2 and 6 a distance D2, between the free ends 32 and 34 of the tubes 3 and 7 a distance D3, and between the free ends 32 and 34 of the tubes 4 to 8 a fourth distance D4 exists. It applies: D1<D2<D3<D4. This means that the respective distance between the respective free ends 28 and 30 or 32 and 34 in the longitudinal extension direction of the volume element 10 increases towards the outside. The tube elements 12 and 14 thus are provided in such a way that at least respective sub-areas of the tube elements 12 and 14 comprising the respective ends 28 and 30 or 32 and 34 are initially spaced apart from each other.

[0066] This provision of the tube elements 12 and 14 for instance in the provision of the tube elements 12 and 14 as integral unit is realized in such a way that between the tube elements 12 and 14 material is detached or cut out, in particular at least substantially in the shape of a triangle or wedge. In other words the described provision of the tube elements 12 and 14 is realized for instance by corresponding processing, in particular trimming, of the tube elements 12 and 14, in particular the respective layers.

[0067] From FIG. 2 it can further be seen that the respective layers are also connected with each other along respective seams 36 and 38, wherein the first tube 1 is formed at least partly by the seam 36, in particular by the seams 36 and 16a, and the tube 5 at least partly by the seam 38, in particular by the seams 38 and 18a. In the first embodiment the seam 36 is a first seam, wherein the seam 38 is a second seam.

[0068] The seams 36 and 38 in FIG. 1 cannot be discerned or not as precisely one seam N since the seams 36 and 38 in the finished manufactured and inflated state of the volume element 10 coincide and therein lie in particular on the central axis 22. In a state illustrated in FIG. 2, in which the volume element 10 is not yet completely manufactured and not inflated, i. e. uninflated, the seams 36 and 38 do not fully coincide or do not fully lie on the central axis 22. In other words: As part of the method the tube elements 12 and 14as can be seen from FIG. 2are provided in such a way that the free ends 28 and 30 or the ends 32 and 34 are arranged spaced apart from each other and the seams 36 and 38 are arranged on sides of the tube elements 12 and 14 which face each other. The seams 36 and 38 thus are adjacent seams, in particular immediately adjacent or directly adjacent seams, since between the seams 36 and 38 no further seams of the volume element 10 are arranged. Therein the seams 36 and 38 at least in respective length portions 40, which in the present case are directly adjacent and directly opposite each other, have curvatures that are different from each other. From FIG. 2 it can be seen that the seams 36 and 38 in the respective length portion 40 have the same shape or the same course, however, the curvatures of the seams 36 and 38 in the respective length portion 40 differ from each other with regard to their sign, since the seam 36 relative to the image plane of FIG. 2 curves towards the left away from the central axis 22 and the seam 38 curves towards the right away from the central axis 22. This state, which is illustrated in FIG. 2, the volume element 10 has adopted for instance if the volume element 10 lies on a tabletop or on an at least substantially horizontal plane and is uninflated.

[0069] The sub-areas, which are initially free and spaced apart from each other, in the present case the ends 28 and 30 or 32 and 34 are then moved towards each other, whereby for instance the volume element 10 adopts a connected state or reaches a connected state, in which the tube elements 12 and 14, in particular via their free ends 28 and 30 or 32 and 34 and/or via sub-areas extending in the longitudinal extension direction from the free ends 28 and 30 or 32 and 34, are at least mechanically connected with each other. By this connecting of the tube elements 12 and 14 the afore-mentioned connected state, in which the sub-areas, in particular ends 28 and 30 or 32 and 34 are moved towards each other, is fixed. In the fixed connected state the initially non-inflated volume element 10 for instance has a shape, which is similar to a shape of a kayak or canoe or which is reminiscent of the shape of a kayak or canoe. This is for instance the case since the volume element 10 in its non-inflated state on the top side 20 and/or on the bottom side has a curvature similar to the curvature of a kayak or a canoe at its tip. If then, however, the volume element 10 is inflated so that the afore-mentioned curvature of the volume element 10 is at least diminished or removed. This means that by the inflating of the volume element 10 or the tubes 1-8 the shape that is reminiscent of a kayak or canoe reverts so that the volume element 10 in its inflatable state on the top side 20 and on the bottom side is at least substantially even or flat. Further, the seams 36 and 38 come to lie on the central axis 22 or coincide.

[0070] In the first embodiment the tube elements 12 and 14 are provided in such a way that for instance the seams 36 and 38 in their length portions 40 do not touch and in the length portions 40 are spaced apart from each other, wherein the seams 36 and 38 touch in respective second length portions 42 extending in the longitudinal extension direction of the volume element 10 from the respective length portions 40.

[0071] If the volume element 10 is used for instance as core of a volume device andas suggested aboveat least partly, in particular at least largely, is enveloped and thus sheathed by an envelope, which is also referred to as sheath, therein for instance a so-called rocker of the volume element 10 or the volume device on the whole is created. The envelope forms for instance an outer skin of the volume device. The term rocker refers to a curvature, bend, or upward bending, which comprises the volume element 10 or the volume devicein particular after the manufacture of the rockerat least in the inflated state.

[0072] As part of the manufacture of the volume device the volume element 10 for instance is initially flat, in particular in the inflated state. For instance by means of a mould the rocker is manufactured. For instance the envelope is glued together with the core (volume element 10), wherein the envelope for instance is glued upon the core. It has turned out to be particularly advantageous if the tube elements 12 and 14 and thus the layers are provided in such a way that the fibers of the layers enclose with the longitudinal extension direction of the volume element 10 an angle which lies in the range of 25 inclusively to 65 inclusively, in particular from 35 inclusively to 55 inclusively. In other words the respective limp material is aligned and arranged in such a way that the fibers of the limp material are arranged at an angle of 45+20 relative to the longitudinal extension direction. By such an orientation of the fibers a particularly advantageous torsion stiffness can be realized. Moreover the formation of folds can be prevented particularly well since the material can expand in corresponding directions. Moreover, by this fiber alignment a particularly advantageous shapeability can be realized so that the rocker can be manufactured particularly well.

[0073] In order to realize therein a particularly high stiffness, in particular bending stiffness, of the volume device, it is preferably envisaged that the envelope for instance is formed from a per se limp and preferably airtight and/or inelastic material. The tubes 1-8 therein form for instance respective first chambers, which can be inflated by passing, in particular blowing, the afore-mentioned gas into the first chambers (tubes 1-8). Preferably, the volume element 10 has at least one first connection, via which the gas can be passed or introduced into the tubes 1-8 (first chambers).

[0074] On at least one side facing away from the first chambers the volume element 10 (core) for instance bounds at least one second chamber at least partly, which is partly bounded by the volume element 10 and partly by the envelope. The second chamber thus is arranged between the volume element 10 and the envelope, which is also referred to as sheath. For realizing a particularly high stiffness preferably in the second chamber granular matter is arranged. Further, the second chamber can be evacuated. For this purpose the volume device comprises at least one second connection, via which the second chamber can be evacuated. This means that a gas that is initially contained in the second chamber such as for instance air can be discharged from the second chamber at least partly, in particular at least predominantly, whereby the granular matter arranged in the second chamber is compressed between the volume element 10 and the envelope. This leads to a very high stiffness of the volume device or of a water sports equipment formed by the volume device.

[0075] FIG. 3 shows a second embodiment of the method, in which the tube elements 12 and 14 are provided for instance as integral unit, wherein the respective tubes 1-8 each comprise only exactly one free end 32 or 34. In the first and the second embodiment precisely two tube elements 12 and 14 are provided, wherein the number of tubes 1-8 is larger than the number of tube elements 12 and 14.

[0076] FIG. 4 shows a third embodiment of the method, in which three tube elements 12, 14, and 15 are provided. In the third embodiment the tube element 14 or its tubes 1 and 5 has no free ends, however the tube element 14 has the tubes 6, 7, and 8 with the free ends 30 or 34. In the third embodiment a first one of the directly adjacent seams having the different curvatures is the seam 16a of the tube element 12. The second one of the directly adjacent seams is the seam 38 of the tube element 14, which is arranged between the tube elements 12 and 15. The tubes 1 and 5 of the tube element 14 are formed by the seams 44 and 46 as well as by the seam 38, wherein further the seams 18a and 46 are immediately adjacent seams, which at least in the respective length portions, have different curvatures. In the third embodiment the initially free ends 28 and 30 or 32 and 34 of the tube elements 12, 14, and 15 are moved towards each other.

[0077] FIG. 5 shows a fourth embodiment of the method, wherein the fourth embodiment with regard to the arrangement and in particular alignment of the tube elements 12 and 14 relative to each other differs from the afore-described embodiments. FIG. 6 shows a fifth embodiment of the method, wherein the tube elements 12 and 14 are provided in such a way that the immediately adjacent seams 36 and 38 over their respective entire extension are spaced apart from each other. FIG. 7 shows a sixth embodiment, in which the immediately adjacent seams are the seams 16d and 18d. Therein, however, as described with regard to the first embodimentthe tube elements 12 and 14 are connected with each other via their sides, on which the seams 36 and 38 are arranged. Further, FIG. 8 shows a seventh embodiment of the method, in which the immediately adjacent seams 36 and 38 are provided spaced apart from each other over their complete extension. Finally, FIG. 9 shows an eighth embodiment of the method, in which the immediately adjacent seams are the seams 36 and 18d, whereinas already described with regard to the first and the sixth embodimentthe tube elements 12 and 14 are connected with each other via the seams 36 and 38 or via the sides, on which the seams 36 and 38 are arranged.