System and method for attaching components within an inflatable object

Abstract

A method and system for permanently attaching a component to the interior surface of an inflatable object where the component is provided with a coating of a heat activatable material that is heat sealed to a surface of a film that forms the inflatable object. The heat activatable material can be a heat activated adhesive to adhere the component to a plastic interior surface of the inflatable object or can be polyethylene material that is adhered to a polyethylene interior surface of the inflatable object. A combination of heat and pressure is used to affix the contacting surfaces together in a strong, welded bond. The component can be a sound module, light module or decorative component that is sealed within the interior of the finally constructed inflatable object.

1 . A method of affixing a component to a film for use in producing an inflatable object having an enclosed interior, said method comprising the steps of: 
 providing a component having a surface having at least a portion thereof coated with a heat activatable material to be affixed into the interior of the inflatable object,    providing a film having one surface thereof comprised of a plastic material that is adapted to be processed to form an inflatable object,    placing the component upon the one surface of the film with the surface having at least a portion thereof coated with the heat activatable material contacting the one surface of the film, and    heat and pressure sealing the heat activatable material coated surface of the component to the one surface of the film.    
   
   
       2 . The method of affixing a component as defined in  claim 1  wherein the step of providing a film comprises providing a film having one surface comprised of polyethylene.  
   
   
       3 . The method of affixing a component as defined in  claim 1  wherein the step of providing a component comprises providing a component having a heat activatable surface of a heat activatable adhesive.  
   
   
       4 . The method of affixing a component as defined in  claim 2  wherein the step of providing a component comprises providing a component having a heat activatable surface of polyethylene.  
   
   
       5 . The method of affixing a component as defined in  claim 1  wherein the step of heat and pressure sealing the heat activatable material surface of the component to the plastic surface of the film comprises providing a heater that is movable between a position displaced away from the surfaces to a position in close proximity to the surfaces to cause heat emitted from the heater to reach the surfaces.  
   
   
       6 . The method of affixing a component as defined in  claim 5  wherein the step of providing a heater comprises providing a heater having a hot head coated with a non stick surface.  
   
   
       7 . The method of affixing a component as defined in  claim 5  wherein the step of heat and pressure sealing the heat activatable material coated surface of the component to the polyethylene surface of the nylon film comprises positioning a protective material intermediate the heater and the polyethylene surfaces.  
   
   
       8 . The method of affixing a component as defined in  claim 1  wherein the step of providing a component comprises providing a sound module.  
   
   
       9 . The method of affixing a component as defined in  claim 1  wherein the step of providing a film comprises providing a nylon film having an exterior metalized skin.  
   
   
       10 . The method of firmly affixing a component as defined in  claim 1  wherein the step of placing the component onto the film comprises providing a robotic arm and manipulating the robotic arm to pick up the component from a remote location and move the component to a predetermined position upon the one surface of the film.  
   
   
       11 . A method of manufacturing an inflatable object having a component affixed to the interior thereof, the method comprising the steps of: 
 providing a component having a surface having at least a portion thereof coated with a heat activatable material to be affixed into the interior of an inflatable object,    providing a first film comprised having one surface thereof comprised of a plastic material that is adapted to be processed to form an inflatable object,    heat and pressure sealing the heat activatable material coated surface of the 20 component to the plastic surface of the first film,    providing a second film having one surface thereof comprised of a plastic material, and    peripherally heat sealing the first film to the second film to form a sealed envelope there between with the component located within that sealed envelope.    
   
   
       12 . The method of manufacturing an inflatable object as defined in  claim 11  wherein the steps of providing a first and second film comprise providing nylon films having interior polyethylene surfaces.  
   
   
       13 . A method of manufacturing an inflatable object as defined in  claim 11  further including the step of continuously moving the film and intermittently stopping the film to carry out the step of heat and pressure sealing the heat activatable coated surface of the component to the plastic surface of the first film.  
   
   
       14 . A method of manufacturing an inflatable object as defined in  claim 11  wherein the step of providing a component comprises providing a sound module.  
   
   
       15 . A method of manufacturing an inflatable object as defined in  claim 14  wherein the sound module is comprised of a foam material having the heat activatable material coating.  
   
   
       16 . A system for affixing a component within an inflatable object, said system comprising: 
 a system for moving a film having a plastic surface;    means to stop the movement of the film at predetermined intervals,    a placement mechanism adapted to position a component having a heat activatable material coating onto the film at a selected location upon the film with the heat activatable material coated surface of the component facing the plastic surface of the film,    a heater adapted to be normally located displaced from the film, the heater adapted to be moved to a location in close proximity to the film so as to heat the film to affix the component to the film.    
   
   
       17 . The system as defined in  claim 16  wherein the heater is moved by a piston from a lower position to be raised to an upper position beneath the film in close proximity thereto.  
   
   
       18 . The system as defined in  claim 16  wherein a protective material is located intermediate the heater and the film during the heating process.  
   
   
       19 . The system of  claim 18  wherein the protective material is polytetrafluroethylene.  
   
   
       20 .  0 The system of  claim 16  wherein the placement mechanism is a robotic arm.  
   
   
       21 . An inflatable object comprised of a film having a plastic interior surface adapted to contain an inflating gas and a component having a surface coated with a heat activatable material heat sealed to the plastic interior surface of the inflatable object.  
   
   
       22 . The inflatable object as defined in  claim 21  wherein the plastic interior surface of the inflatable object is polyethylene.  
   
   
       23 . The inflatable object as defined in  claim 22  wherein the heat activatable material coating on the component is polyethylene.  
   
   
       24 . The inflatable object as defined in  claim 21  wherein the heat activatable material coating on the component is a heat activatable adhesive.  
   
   
       25 . The inflatable object as defined in  claim 21  wherein the component is a device capable of producing a sound or light.