US008562773B2
`
`(12) United States Patent
`Lin et al.
`
`(10) Patent N0.:
`(45) Date of Patent:
`
`US 8,562,773 B2
`Oct. 22, 2013
`
`(54) METHOD OF PRODUCING AN INTERNAL
`TENSIONING STRUCTURE USEABLE WITH
`INFLATABLE DEVICES
`
`(71) Applicant: InteX Recreation Corp., Long Beach,
`CA (US)
`
`(72) Inventors: Hua Hsiang Lin, Fujian (CN); Yaw
`Yuan Hsu, Fujian (CN)
`
`(73) Assignee: InteX Recreation Corporation, Long
`Beach, CA (US)
`
`( * ) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`
`(21) Appl.No.: 13/668,799
`
`(22) Filed:
`
`Nov. 5, 2012
`
`(65)
`
`Prior Publication Data
`US 2013/0228268 A1
`Sep. 5, 2013
`
`Related US. Application Data
`(63) Continuation
`of
`application
`PCT/US2012/042079, ?led on Jun. 12, 2012.
`
`No.
`
`(30)
`
`Foreign Application Priority Data
`
`Mar. 2, 2012 (CN) ........................ .. 2012 1 0053146
`
`Mar. 2, 2012 (CN) . . . . .
`. . . . . .. 2012 1 0053183
`Mar. 2, 2012 (CN) .................... .. 2012 2 0075738 U
`Mar. 2, 2012 (CN) .................... .. 2012 2 0075742 U
`
`(51) Int. Cl.
`B29C 70/52
`(52) US. Cl.
`USPC .............................. .. 156/166; 156/179; 5/711
`
`(2006.01)
`
`(58) Field of Classi?cation Search
`USPC ............ .. 156/166, 272.2, 158, 163, 178, 179,
`156/308.2, 434, 439, 440; 5/681, 727, 728,
`5/729, 158, 711, 710, 712; 139/410
`See application ?le for complete search history.
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`4/1906 Whall
`818,321 A
`7/1956 Barker
`2,753,573 A
`3,008,213 A 11/1961 Foster et a1.
`428/108
`3,573,151 A *
`3/1971 Dawbarn ..... ..
`4,295,918 A * 10/1981 Benson etal. .............. .. 156/434
`5,249,323 A 10/1993 Kikuchiet a1.
`5,985,071 A * 11/1999 Wynne etal. ............... .. 156/181
`6,543,962 B2* 4/2003 Wells .......................... .. 404/118
`7,254,853 B1
`8/2007 Kim
`7,591,036 B2
`9/2009 Lin et a1.
`
`* cited by examiner
`
`Primary Examiner * KatarZyna WyroZebski Lee
`Assistant Examiner * Vishal l Patel
`(74) Attorney, Agent, or Firm * Faegre Baker Daniels LLP
`
`ABSTRACT
`(57)
`An internal tensioning structure for use in an in?atable prod
`uct ful?lls the basic function of maintaining tWo adjacent
`in?atable surfaces in a desired geometric arrangement When
`the in?atable 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 in?atable product.
`
`5 Claims, 28 Drawing Sheets
`
`INTEX EXHIBIT 2023, Pg. 1
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`U.S. Patent
`
`0a. 22, 2013
`Oct. 22, 2013
`
`Sheet 1 0f 28
`Sheet 1 of 28
`
`US 8,562,773 B2
`US 8,562,773 B2
`
`FIG. 1
`
`INTEX EXHIBIT 2023, Pg 2
`
`Bestway v. Intex; PGR2017-00003
`
`INTEX EXHIBIT 2023, Pg. 2
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`
`0a. 22, 2013
`
`Sheet 2 0f 28
`
`US 8,562,773 B2
`
`FIG. 2
`
`INTEX EXHIBIT 2023, Pg. 3
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`
`0a. 22, 2013
`
`Sheet 3 0f 28
`
`US 8,562,773 B2
`
`FIG. 3
`
`INTEX EXHIBIT 2023, Pg. 4
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`
`0a. 22, 2013
`
`Sheet 4 0f 28
`
`US 8,562,773 B2
`
`FIG. 4
`
`INTEX EXHIBIT 2023, Pg. 5
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`
`0a. 22, 2013
`
`Sheet 5 0f 28
`
`US 8,562,773 B2
`
`FIG. 5
`
`INTEX EXHIBIT 2023, Pg. 6
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`
`Oct. 22, 2013
`
`Sheet 6 0f 28
`
`US 8,562,773 B2
`
`INTEX EXHIBIT 2023, Pg. 7
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`Oct. 22 2013
`
`Sheet 7 of 28
`
`FIG.7
`
`Bestway v. Intex; 0000000000 03
`
`,
`
`.
`
`INTEX EXHIBIT 2023, Pg. 8
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`
`0a. 22, 2013
`
`Sheet 8 0f 28
`
`US 8,562,773 B2
`
`FIG. 8
`
`FIG. 9
`
`INTEX EXHIBIT 2023, Pg. 9
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`
`0a. 22, 2013
`
`Sheet 9 0f 28
`
`US 8,562,773 B2
`
`H
`
`FIG. 10
`
`INTEX EXHIBIT 2023, Pg. 10
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`Oct. 22, 2013
`
`Sheet 10 of 28
`
`US 8,562,773 B2
`
`
`
`INTEX EXHIBIT 2023, Pg. 11
`
`Bestway v. Intex; PGR2017-00003
`
`INTEX EXHIBIT 2023, Pg. 11
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`
`0a. 22, 2013
`
`Sheet 11 0f 28
`
`US 8,562,773 B2
`
`103 <
`
`32
`
`FIG. 14
`
`FIG. 15
`
`INTEX EXHIBIT 2023, Pg. 12
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`
`0a. 22, 2013
`
`Sheet 12 0f 28
`
`US 8,562,773 B2
`
`FIG. 16
`
`INTEX EXHIBIT 2023, Pg. 13
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`
`0a. 22, 2013
`
`Sheet 13 0f 28
`
`US 8,562,773 B2
`
`FIG. 18
`
`FIG. 19
`
`INTEX EXHIBIT 2023, Pg. 14
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`
`0a. 22, 2013
`
`Sheet 14 0f 28
`
`US 8,562,773 B2
`
`FIG. 20
`
`INTEX EXHIBIT 2023, Pg. 15
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`U.S. Patent
`
`0a. 22, 2013
`Oct. 22, 2013
`
`Sheet 15 0f 28
`Sheet 15 of 28
`
`US 8,562,773 B2
`US 8,562,773 B2
`
`203,303
`
`FIG.21
`5 .QI
`
`303
`
`
`303203
`
`203,303203
`
`
`
`INTEX EXHIBIT 2023, Pg. 16
`
`Bestway v. Intex; PGR2017-00003
`
`INTEX EXHIBIT 2023, Pg. 16
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`
`0a. 22, 2013
`
`Sheet 16 0f 28
`
`US 8,562,773 B2
`
`FIG. 22
`
`INTEX EXHIBIT 2023, Pg. 17
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`U.S. Patent
`
`0a. 22, 2013
`Oct. 22, 2013
`
`Sheet 17 0f 28
`Sheet 17 of 28
`
`US 8,562,773 B2
`US 8,562,773 B2
`
`.....!!l!|
`
`203,303
`
`FIG.23
`
`INTEX EXHIBIT 2023, Pg. 18
`
`Bestway v. Intex; PGR2017-00003
`
`INTEX EXHIBIT 2023, Pg. 18
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`U.S. Patent
`
`0a. 22, 2013
`Oct. 22, 2013
`
`Sheet 18 0f 28
`Sheet 18 of 28
`
`US 8,562,773 B2
`US 8,562,773 B2
`
`INTEX EXHIBIT 2023, Pg. 19
`
`Bestway v. Intex; PGR2017-00003
`
`INTEX EXHIBIT 2023, Pg. 19
`Bestway v. Intex; PGR2017-00003
`
`

`

`US. Patent
`U.S. Patent
`
`0a. 22, 2013
`Oct. 22, 2013
`
`Sheet 19 of 28
`Sheet 19 0f 28
`
`US 8,562,773 B2
`US 8,562,773 B2
`
`INTEX EXHIBIT 2023,
`
`. 20
`
`Bestway v. Intex; PGR2017-
`
`03
`
`INTEX EXHIBIT 2023, Pg. 20
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`Oct. 22, 2013
`
`Sheet 20 of 28
`
`US 8,562,773 B2
`
`FIG.27
`
`INTEX EXHIBIT 2023, Pg. 21
`
`Bestway v. Intex; PGR2017-00003
`
`INTEX EXHIBIT 2023, Pg. 21
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`Oct. 22, 2013
`
`Sheet 21 of 28
`
`US 8,562,773 B2
`
`FIG.28
`
`INTEX EXHIBIT 2023, Pg. 22
`
`Bestway v. Intex; PGR2017-00003
`
`INTEX EXHIBIT 2023, Pg. 22
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`Oct. 22, 2013
`
`Sheet 22 of 28
`
`US 8,562,773 B2
`
`INTEX EXHIBIT 2023, Pg. 23
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`Oct. 22, 2013
`
`Sheet 23 of 28
`
`US 8,562,773 B2
`
`FIG. 31
`
`INTEX EXHIBIT 2023, Pg. 24
`
`Bestway v Intex, PGR2017 00003
`
`INTEX EXHIBIT 2023, Pg. 24
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`Oct. 22, 2013
`
`Sheet 24 of 28
`
`US 8,562,773 B2
`
`INTEX EXHIBIT 2023, Pg. 25
`
`Bestway v. Intex; PGR2017-00003
`
`INTEX EXHIBIT 2023, Pg. 25
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`Oct. 22, 2013
`
`Sheet 25 of 28
`
`US 8,562,773 B2
`
`INTEX EXHIBIT 2023, Pg. 26
`
`Bestway v. Intex; PGR2017-00003
`
`INTEX EXHIBIT 2023, Pg. 26
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`Oct. 22, 2013
`
`Sheet 26 of 28
`
`US 8,562,773 B2
`
`INTEX EXHIBIT 2023, Pg. 27
`
`Bestway v. Intex; PGR2017-00003
`
`INTEX EXHIBIT 2023, Pg. 27
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`Oct. 22, 2013
`
`Sheet 27 of 28
`
`US 8,562,773 B2
`
`FIG. 35
`
`INTEX EXHIBIT 2023, Pg. 28
`
`Bestway v. Intex; PGR2017-00003
`
`INTEX EXHIBIT 2023, Pg. 28
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`Oct. 22, 2013
`
`Sheet 28 of 28
`
`US 8,562,773 B2
`
`INTEX EXHIBIT 2023, Pg. 29
`
`Bestway v. Intex; PGR2017-00003
`
`INTEX EXHIBIT 2023, Pg. 29
`Bestway v. Intex; PGR2017-00003
`
`

`

`US 8,562,773 B2
`
`1
`METHOD OF PRODUCING AN INTERNAL
`TENSIONING STRUCTURE USEABLE WITH
`INFLATABLE DEVICES
`
`RELATED APPLICATIONS
`
`This application is a continuation of PCT Application
`Serial No. PCT/US2012/042079, filed Jun. 12, 2012, which
`claims priority to Chinese Patent Application Serial No.
`201210053143.X, filed Mar. 2, 2012, Chinese Patent Appli-
`cation Serial No. 201210053146.3, filed Mar. 2, 2012, Chi-
`nese Patent Application Serial No. 201220075738.0, filed
`Mar. 2, 2012, and Chinese Patent Application Serial No.
`201220075742.7, filed Mar. 2, 2012 and the disclosures of
`which are expressly incorporated by reference herein.
`
`BACKGROUND
`
`1. Technical Field
`
`The present disclosure relates to an inflatable product
`structure, and in particular to an inflatable product structure
`which is light in weight and low in cost.
`2. Description of the Related Art
`Inflatable products, are light in weight, easy to house, and
`easy to carry. Such products technologies have been used for
`outdoor items and toys, as well as various household goods
`including inflatable beds, inflatable sofas and the like.
`Many inflatable products utilize internal structures in order
`to form the product into its intended, predetermined shape
`upon inflation. For example, one type of inflatable bed,
`referred to as a wave-shaped, straight-strip or I-shaped inflat-
`able bed, may include a tension-band type internal structure
`arranged along wave-shaped, straight-line or I-shaped path-
`ways within the internal cavity. Another type of inflatable
`bed, referred to as a column-type inflatable bed, has tension
`bands arranged into honeycomb-shaped or cylindrical struc-
`tures within the inflatable cavity.
`These internal tension-band structures disposed in the cav-
`ity of the inflatable bed give shape to the bed as internal
`pressure increases, thereby preventing the inflatable bed from
`expanding evenly on all sides in the manner of a balloon.
`More particularly, in order to maintain an inflatable bed as a
`rectangular shape, the tension bands join the upper and lower
`surfaces ofthe inflatable bed to one another. To allow passage
`ofpressurized air to both sides ofthese joining structures, the
`tension bands may be formed as belts stretching between the
`upper and lower surfaces, or as vertical expanses of material
`with air columns formed therein. The number and spacing of
`the tension bands is proportional to the sharpness of the
`rectangularity of the inflated product. That is to say, a greater
`number and/or linear extent of tension bands within the pres-
`surized cavity results in a more “flat” bed surface.
`In conventional inflatable products such as the inflatable
`beds described above, the tension bands are made of PVC
`sheets with a suflicient thickness to ensure spreading of force
`and concomitant reductions in stress in the product material.
`For example, the tension bands of known inflatable beds or
`sofas may have a thickness of about 0.36 mm. For some
`known water carrier devices, such as inflatable swimming
`pools, the internal tension bands may have a thickness of
`about 0.38 mm, while “sandwich” type inflatable swimming
`pools may have a thickness of 0.7-0.8 mm.
`Thus, conventional inflatable structures utilizing belt- or
`sheet-like PVC tension bands meet the force requirements of
`the product by varying the thickness of the tension bands.
`However, where continuous plastic strips or belts are utilized,
`such tension bands contribute to increased weight of the
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`2
`
`inflatable product. Similarly, an increase in thickness and/or
`spatial density of solid-strip tension bands also increases the
`compressed/folded volume of the deflated inflatable struc-
`ture.
`
`SUMMARY
`
`The present disclosure provides an internal tensiomng
`structure for use in an inflatable product, and a method for
`producing the same. The tensioning structure 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 tensiomng structure and the inflatable prod-
`uct.
`
`Various configurations of the tensioning structure are con-
`templated within the scope of the present disclosure. In one
`embodiment, a pair of parallel plastic strips has a plurality of
`strands extending therebetween to connect the plastic strips to
`one another, with the strands substantially parallel to one
`another and substantially perpendicular to the plastic strips.
`In another embodiment, a similar arrangement oftwo parallel
`plastic strips are connected by a plurality of strands with each
`adjacent pair of such strands converging to a point at one of
`the plastic strips in a “V” configuration. Either embodiment
`may be incorporated into a tensioning structure with one of a
`number of geometric arrangements within the inflatable cav-
`ity, such as linear, cylindrical, wave-shaped, etc.
`According to one embodiment thereof, the present disclo-
`sure provides an inflatable product comprising: a first sheet
`and a second sheet disposed opposite the first sheet, the first
`and second sheets spaced apart to define a gap when the
`inflatable product is inflated. The inflatable product further
`includes a tensioning structure having a gap portion spanning
`the gap between the first sheet and the second sheet to main-
`tain a spatial relationship between the first and second sheets
`when the inflatable product is inflated. The gap portion has an
`extent measured along the surface of at least one of the first
`sheet and the second sheet. The gap portion occupies a vol-
`ume and has an operable area occupied by gap portion of the
`tensioning structure defined as the total area of the gap
`between the first sheet and the second sheet, as measured
`along the extent ofthe gap portion ofthe tensiomng structure.
`The gap portion of the tensioning structure defines an oper-
`able area-to-volume ratio of at least 10 square millimeters per
`cubic millimeter.
`
`According to another embodiment thereof, the present dis-
`closure provides an inflatable product comprising: a first
`sheet and a second sheet disposed opposite the first sheet. The
`first and second sheets are spaced apart to define a gap when
`the inflatable product is inflated. The inflatable product fur-
`ther includes a tensioning structure having a gap portion
`spanning the gap between the first sheet and the second sheet
`to maintain a spatial relationship between the first and second
`sheets when the inflatable product is inflated. The gap portion
`has an extent measured along the surface of at least one ofthe
`first sheet and the second sheet. The gap portion has an oper-
`able area occupied by gap portion of the tensioning structure
`defined as the total area of the gap between the first sheet and
`the second sheet, as measured along the extent of the gap
`portion of the tensiomng structure. The gap portion of the
`tensioning structure has a total weight such that the tension-
`
`INTEX EXHIBIT 2023, Pg. 30
`
`Bestway v. Intex; PGR2017-00003
`
`INTEX EXHIBIT 2023, Pg. 30
`Bestway v. Intex; PGR2017-00003
`
`

`

`US 8,562,773 B2
`
`3
`ing structure defines an operable area-to-weight ratio of at
`least 6,000 square centimeters per kilogram.
`According to another embodiment thereof, the present dis-
`closure provides an inflatable product comprising: a first
`sheet and a second sheet disposed opposite the first sheet. The
`first and second sheets are spaced apart to define a gap when
`the inflatable product is inflated; The inflatable product fur-
`ther comprises a tensioning structure having a gap portion
`spanning the gap between the first sheet and the second sheet
`to maintain a spatial relationship between the first and second
`sheets when the inflatable product is inflated. The gap portion
`of the tensioning structure has an average thickness of less
`than 0.125 millimeters.
`
`According to yet another embodiment thereof, the present
`disclosure provides 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 spaced
`apart from one another and substantially perpendicular to the
`plurality of strands, each ofthe plurality ofweld strips aflixed
`to each of the plurality of strands, and each of the plurality of
`weld strips aflixed to at least one of the first sheet and the
`second sheet.
`
`According to still another embodiment thereof, the present
`disclosure provides 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 in parallel;
`and a first weld sheet having the plurality of strands aflixed to
`an upper surface of the first weld sheet.
`According to still another embodiment thereof, the present
`disclosure provides 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; a lower weld strip arranged substantially parallel
`to the upper weld strip and spaced apart from the upper weld
`strip span the gap between the first sheet and the second sheet;
`and a plurality of end-to-end V- shaped strands arranged
`between weld strips, each of the V-shaped strands having
`upper and lower ends fixed to the upper and lower weld strips,
`respectively.
`According to still another embodiment thereof, the present
`disclosure provides 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 respective inner surfaces of the first and second
`sheets such that the plurality of tensioning structure span the
`gap, each ofthe plurality oftensioning structures comprising:
`an upper weld strip aflixed to one of the first sheet and the
`second sheet; a lower weld strip aflixed to the other ofthe first
`sheet and the second sheet; and a plurality of strands connect-
`ing the upper and lower weld strips to one another.
`According to still another embodiment thereof, the present
`invention provides 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
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`4
`welded to inner surfaces of the first and second sheets such
`
`that the plurality oftensioning structures span the gap, each of
`the plurality of tensioning structures comprising: a weld
`sheet; a plurality of strands, and the plurality of strands sub-
`stantially evenly spaced and arranged substantially parallel to
`one another, the plurality of strands aflixed to the weld sheet;
`and a weld strip aflixed to each end ofthe weld sheet such that
`a longitudinal extent of the weld strip is substantially perpen-
`dicular to the plurality of strands, respective ends of the
`plurality of strands are aflixed to the weld strip, and each of
`the weld strips are welded to one of the first sheet and the
`second sheet.
`
`According to still another embodiment thereof, the present
`invention provides a method for producing a tensioning struc-
`ture of an inflatable product, the method comprising: arrang-
`ing at least one of a welder and an adhesive device down-
`stream ofa strand guide; supplying a plurality of strands to the
`welder or the adhesive device via the strand guide, such that
`the supplied strands are substantially uniformly spaced apart
`and arranged substantially parallel to one another; position-
`ing weld strips on a first die ofthe welder or gluing device, the
`weld strips having a longitudinal extent corresponding to an
`overall width of the plurality of strands; advancing a second
`die of the welder or gluing device into an operable position in
`which the first and second dies are disposed at opposing sides
`of the weld strips, activating the welder or gluing device to
`fixedly connect the weld strips to the plurality of strands, such
`that the weld strips are aflixed to the plurality of strands in a
`spaced apart and substantially parallel arrangement, and such
`that the weld strips are substantially perpendicular to the
`plurality of strands.
`According to still another embodiment thereof, the present
`invention provides a method for producing a tensioning struc-
`ture of an inflatable product comprises: arranging a hot roller
`downstream ofa strand guide; supplying a plurality of strands
`to the hot roller via the strand guide, such that the supplied
`strands are substantially uniformly spaced apart and arranged
`substantially parallel to one another; arranging a conveying
`roller downstream of the strand guide, the conveying roller
`operable to deliver at least one weld sheet to the hot roller, the
`at least one weld sheet having a width corresponding to an
`overall width of the plurality of strands; and passing the
`plurality of strands and the at least one weld sheet through the
`hot roller, such that the plurality of strands become aflixed to
`the at least one weld sheet.
`
`According to still another embodiment thereof, the present
`invention provides a method for producing a tensioning struc-
`ture, the method comprising: arranging a first pair of weld
`strips parallel to one another on a joining device; wrapping at
`least one continuous strand around a plurality of members
`arranged along a pair of rows adjacent the first pair of weld
`strips, respectively, each ofthe pair ofrows ofmembers offset
`with respect to the other of the pair of rows of members, the
`step of wrapping comprising alternating between the pair of
`rows, such that the at least one continuous strand forms a
`plurality of end-to-end V-shaped strands; and using the join-
`ing device to join the first pair ofweld strips to the plurality of
`strands at respective V-shaped comers formed by the at least
`one continuous strand, such that the tensioning structure has
`a tensile strength along a direction perpendicular to a longi-
`tudinal extent of the first pair of weld strips.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`The above mentioned and other features and advantages of
`this disclosure, and the manner of attaining them, will
`become more apparent and the invention itself will be better
`
`INTEX EXHIBIT 2023, Pg. 31
`
`Bestway v. Intex; PGR2017-00003
`
`INTEX EXHIBIT 2023, Pg. 31
`Bestway v. Intex; PGR2017-00003
`
`

`

`US 8,562,773 B2
`
`5
`understood by reference to the following description of
`embodiments of the invention taken in conjunction with the
`accompanying drawings, wherein:
`FIG. 1 is an exploded, perspective View of an inflatable
`structure incorporating a tensioning structure made in accor-
`dance with the present disclosure;
`FIG. 2 is an enlarged perspective view of the tensioning
`structure shown in FIG. 1;
`FIG. 3 is an exploded, perspective view of an inflatable bed
`incorporating tensioning structures made in accordance with
`the present disclosure;
`FIG. 4 is an assembled view ofthe inflatable bed ofFIG. 3,
`in which the inflatable bed material is made transparent to
`show the internal arrangement of the tensiomng structures;
`FIG. 5 is an exploded, perspective view of an inflatable bed
`incorporating an alternative geometric arrangement of ten-
`sioning structures made in accordance with the present dis-
`closure;
`FIG. 6 is an assembled view ofthe inflatable bed ofFIG. 5,
`in which the inflatable bed material is made transparent to
`show the internal spatial arrangement ofthe tensioning struc-
`tures;
`FIG. 7 is a perspective view of an apparatus for producing
`bulk material for the tensiomng structures shown in FIGS.
`3-6;
`FIG. 8 is an exploded, perspective view showing a first
`embodiment of the bulk material created by the apparatus of
`FIG. 7;
`FIG. 9 is a perspective view showing a first embodiment of
`the bulk material created by the apparatus of FIG. 7;
`FIG. 10 is a perspective view showing a second embodi-
`ment of the bulk material created by the apparatus of FIG. 7;
`FIG. 11 is a perspective view showing a second embodi-
`ment of the bulk material created by the apparatus of FIG. 7;
`FIG. 12 is an exploded, perspective view of a first altema-
`tive tensioning structure made in accordance with the present
`disclosure;
`FIG. 13 is an assembled, perspective view of the first alter-
`native tensioning structure shown in FIG. 12;
`FIG. 14 is an exploded, perspective view of a second alter-
`native tensioning structure made in accordance with the
`present disclosure;
`FIG. 15 is an exploded, perspective view of a third alter-
`native tensioning structure made in accordance with the
`present disclosure;
`FIG. 16 is an assembled, perspective view of the third
`alternative tensioning structure shown in FIG. 15;
`FIG. 17 is an exploded, perspective view of a fourth alter-
`native tensioning structure made in accordance with the
`present disclosure;
`FIG. 18 is an exploded, perspective view of a fifth altema-
`tive tensioning structure made in accordance with the present
`disclosure;
`FIG. 19 is an assembled, perspective view of the fifth
`alternative tensioning structure shown in FIG. 18;
`FIG. 20 is an exploded, perspective view of an inflatable
`bed incorporating alternative tensioning structures made in
`accordance with the present disclosure;
`FIG. 21 is an assembled view ofthe inflatable bed of FIG.
`
`22, in which the inflatable bed material is made transparent to
`show the internal arrangement of the tensiomng structures;
`FIG. 22 is an exploded, perspective view of an inflatable
`bed incorporating an alternative tensioning structures made in
`accordance with the present disclosure, configured in an alter-
`native geometric arrangement;
`
`5
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`6
`FIG. 23 is an assembled view ofthe inflatable bed of FIG.
`
`22, in which the inflatable bed material is made transparent to
`show the internal spatial arrangement of the tensioning struc-
`tures;
`FIG. 24 is a perspective view of an apparatus for producing
`bulk material for the first through fifth alternative tensioning
`structures shown in FIGS. 12-19;
`FIG. 25 is an exploded, perspective view of a sixth alter-
`native tensioning structure made in accordance with the
`present disclosure;
`FIG. 26 is an assembled, perspective view of the sixth
`alternative tensioning structure shown in FIG. 25;
`FIG. 27 is an exploded, perspective view of an inflatable
`bed incorporating the sixth alternative tensioning structure
`shown in FIG. 25;
`FIG. 28 is an assembled view ofthe inflatable bed of FIG.
`
`27, in which the inflatable bed material is made transparent to
`show the internal arrangement of the tensioning structures;
`FIG. 29 is a perspective view of an apparatus for producing
`bulk material for the sixth alternative tensioning structures
`shown in FIGS. 25-28;
`FIG. 30 is an exploded, perspective view of a seventh
`alternative tensioning structure made in accordance with the
`present disclosure;
`FIG. 31 is an assembled, perspective view of the seventh
`alternative tensioning structure shown in FIG. 30;
`FIG. 32 is a perspective view of an apparatus for producing
`bulk material for the seventh alternative tensioning structures
`shown in FIGS. 30 and 31;
`FIG. 33 is a top plan view of portions of tensioning struc-
`tures bunched together during a welding process;
`FIG. 34 is a top plan view of portions of a tensioning
`structure collapsed when the mattress is deflated for storage
`or shipment;
`FIG. 35 is a view similar to FIG. 33 showing portions of
`tensioning structures with strands placed in piles during a
`welding process; and
`FIG. 36 is a view similar to FIG. 33 showing portions of
`tensioning structures shifted relative to each other during a
`welding process.
`Corresponding reference characters indicate correspond-
`ing parts throughout the several views. The exemplifications
`set out herein illustrate exemplary embodiments of the
`present invention, and such exemplifications are not to be
`construed as limiting the scope of the invention in any man-
`ner.
`
`DETAILED DESCRIPTION
`
`The present disclosure provides tensiomng structures
`which give shape to inflatable devices, such as inflatable
`couches, beds or swimming pools. The tensioning structures
`are lightweight and occupy minimal volume when the device
`is deflated and packed away, while also functioning as a
`strong and durable internal support upon inflation and use of
`the inflatable device.
`
`An exemplary tensioning structure in accordance with the
`present disclosure utilizes thin and flexible string- or wire-
`like strands which join two areas of fabric to one another. The
`strands are firmly connected to the adjacent fabric via an
`intermediate material, such as a strip or sheet, and the inter-
`mediate material is in mm firmly connected to the fabric. The
`area of contact between intermediate material and the
`
`attached strands may be manipulated to impart a connection
`strength commensurate with the tensile strength ofthe strand.
`Similarly, the area of contact between the intermediate mate-
`rial and the adjacent fabric may also be manipulated to impart
`
`INTEX EXHIBIT 2023, Pg. 32
`
`Bestway v. Intex; PGR2017-00003
`
`INTEX EXHIBIT 2023, Pg. 32
`Bestway v. Intex; PGR2017-00003
`
`

`

`US 8,562,773 B2
`
`7
`a fabric/tensioning structure connection strength commensu-
`rate with the aggregate tensile strength of all strands in the
`tensioning structure.
`Various tensioning structures and methods of manufactur-
`ing the same are described in detail below. It is contemplated
`that any ofthe present described tensioning structures may be
`used in any inflatable product, either alone, as a group or in
`combination with one another as required or desired for a
`particular design. In addition, it is contemplated that tension-
`ing structures in accordance with the present disclosure can
`be used in other contexts, such as in camping equipment, or in
`any other context where a lightweight, packable structure is
`needed to join two pieces ofmaterial that are urged away from
`one another in use.
`
`1. Weld Strips Joined by Spaced-Apart Strands.
`Turning now to FIGS. 1 and 2, tensioning structure 3 is
`shown joining upper material 1 to lower material 2. In the
`illustrated embodiment, tensioning structure 3 includes upper
`and lower weld strips 31 connected to one another by a
`plurality of substantially parallel strands 32 that define a gap
`portion extending between a gap between upper and lower
`sheets 1, 2. The upper and lower weld strips 31 are in turn
`welded to the upper material 1 and the lower material 2,
`respectively, such that forces urging upper and lower materi-
`als 1, 2 are encountered by tension in strands 32.
`Optionally, reinforcing strands 5 (FIG. 3) may be provided
`along the longitudinal extent of weld strip 31 (i.e., substan-
`tially perpendicular to strands 32). Reinforcing strands 5,
`when provided, may be coupled to tensile strands 32, such as
`by folding strands 32 over reinforcing strands 5, tying strands
`5, 32 to one another, or adhesively securing strands 5, 32 to
`one another. When so coupled, reinforcing strands 5 provide
`additional surface area contact with weld strips 31 and
`thereby improve the resistance of securing strands 5 to pulling
`free from weld strips 31. In addition, the presence ofreinforc-
`ing strands 32 within weld strips 31 improves the tensile
`strength of weld strips 31 along their longitudinal extents.
`The plurality of strands 32 in the tensioning structure 3 as
`shown in FIGS. 1 and 2 are arranged such that the strands 32
`are substantially parallel to one another when strands 32 are
`pulled taut (i.e., when weld strips 31 are drawn away from one
`another). In addition, adj acent pairs of strands 32 may have
`even intervals therebetween, such that a substantially con-
`stant tensile strength of tensioning structure 3 is maintained
`across the longitudinal extent of weld strips 31. In an exem-
`plary embodiment, strands 32 may extend along the entire
`width of weld strips 31, as illustrated in FIGS. 1 and 2, such
`that a large area of contact between strands 32 and weld str