Structurally efficient inflatable protective device

• US 5,482,317 A
• Filed: 06/28/1993
• Issued: 01/09/1996
• Est. Priority Date: 06/28/1993
• Status: Expired due to Term

• Current Assignee: Sandia Corporation (Martin Marietta Corporation)
• Original Assignee: Sandia Corporation (Martin Marietta Corporation)
• Inventors: Whinery, Larry D., Gwinn, Kenneth W., Nelsen, James M., McBride, Donald D., Luna, Daniel A., Holder, Joseph P., Bliton, Richard J.
• Primary Examiner(s): Focarino, Margaret A.
• Assistant Examiner(s): English, Peter C.
• Application Number:
  US08/082,471
• Time in Patent Office: 925 Days
• Field of Search: 280/743 R, 280/743 A, 280/728 R, 280/739, 280/741, 280/743.1, 280/743.2, 280/728.1, 383/3, 428/35.5, 428/36.1, 428/224, 428/225
• US Class Current: 280/743.1
• CPC Class Codes: B60R 2021/23382 Internal tether means
• CPC Class Codes: B60R 2021/23576 Sewing
• CPC Class Codes: B60R 2021/2358 Bonding
• CPC Class Codes: B60R 21/231 characterised by their shape, construction or spatial configuration
• CPC Class Codes: B60R 21/233 comprising a plurality of individual compartments; comprising two or more bag-like members, one within the other B60R21/232 takes precedence
• CPC Class Codes: B60R 21/2338 Tethers
• CPC Class Codes: B60R 21/235 characterised by their material
• CPC Class Codes: Y10T 428/1362 Textile, fabric, cloth, or pile containing [e.g., web, net, woven, knitted, mesh, nonwoven, matted, etc.]

Abstract

An apparatus and method for making a low cost, self-venting, inflatable protective cushion of simple and structurally efficient design with a shape and construction that optimizes the cushion'"'"'s ability to withstand inflation pressures and impact when deployed which includes a sheet defined by at least one fold line and a plurality of flap portions, each flap portion having a base edge corresponding to a fold line and at least two side edges each extending outwardly from a base edge and ultimately converging to meet each other, the flap portions being folded at the fold line(s) and being joined at corresponding side edges to define an inflatable chamber. The inflatable protective cushion and method for making same may further include a lightweight, low permeability, fabric that optimizes the cushion'"'"'s ability to withstand inflation pressures and impact when deployed and minimizes the packed volume of the cushion when stored.

Claims

1. An inflatable protective cushion comprising a sheet of material defined by four or fewer fold lines and a plurality of flap portions, each flap portion having a base edge corresponding to a fold line and at least two side edges each extending outwardly from the base edge and ultimately converging to meet each other, the flap portions being folded at the fold lines with each of the flap portions substantially converged to form an apex above the sheet and being joined at corresponding side edges to define an inflatable chamber.

2. A cushion as recited in claim 1, wherein said sheet is a single piece of material.

3. A cushion as recited in claim 1, wherein said sheet is made of a material having a grab tensile strength of less than 255 lbs. tongue tear strength of less than 8.0 lbs., a Mullen burst strength of less than 325 psi, and an air permeability of less than 1.10 cfm/sq. ft. at a pressure drop of 0.5 in. of water across the material.

4. A cushion as recited in claim 3, wherein said sheet is substantially in the shape of a square, said sheet having a central portion substantially in the shape of a square, and said flap portions are substantially triangular.

5. A cushion as recited in claim 1, wherein said material has a weight of less than 4.0 oz./sq.yd.

6. A cushion as recited in claim 5, wherein the material has a weight between 1.9-3.2 oz./sq.yd.

7. A cushion as recited in claim 6, wherein said sheet is a cloth woven with 30-200 denier yarn.

8. A cushion as recited in claim 7, wherein said sheet has a grab tensile strength of less than 255 lbs., tongue tear strength of less than 8.0 lbs., a Mullen burst strength of less than 325 psi, and an air permeability of less than 1.10 cfm/sq. ft. at a pressure drop of 0.5 in. of water across the material.

9. A cushion as recited in claim 7, wherein said yarn is nylon.

10. A cushion as recited in claim 9, wherein said woven cloth is calendered.

11. A cushion as recited in claim 9, wherein said sheet is substantially in the shape of a square, said sheet having a central portion substantially in the shape of a square, and said flap portions are substantially triangular.

12. A cushion as recited in claim 7, wherein said woven cloth'"'"'s tensile strength in the lower of the warp and filling directions is no more than 25 percent lower than the tensile strength in the higher of the warp and filling directions.

13. A cushion as recited in claim 12, wherein said woven cloth'"'"'s tensile strength in the lower of the warp and filling directions is no more than 15 percent lower than the tensile strength in the higher of the warp and filling directions.

14. A cushion as recited in claim 5, wherein said sheet is a cloth woven of less than 300 denier yarn.

15. A cushion as recited in claim 1, wherein said sheet is a cloth woven of less than 420 denier yarn.

16. A cushion as recited in claim 1, further comprising:

a seam defined by the area where said side edges are joined; and

means for reinforcing the seam attached to said sheet.

17. A cushion as recited in claim 16, wherein said seam reinforcement means comprises double-sided contact adhesive tape.

18. A cushion as recited in claim 1, further comprising expansion limiting means attached to said sheet.

19. A cushion as recited in claim 18, wherein said expansion limiting means comprises a strap.

20. A cushion as recited in claim 19, wherein said expansion limiting means comprises a plurality of straps with at least one strap running perpendicular to each fold line of said sheet.

21. A cushion as recited in claim 1, further comprising a circumferential collar attached to said sheet near said apex.

22. A cushion as recited in claim 1, wherein said side edges ultimately converge at a means for mounting an inflation device.

23. A cushion as recited in claim 1, wherein said sheet comprises a coating.

24. A sheet for forming an inflatable protective cushion, wherein the sheet is made of a material woven with less than 420 denier yarn having an air permeability of less than 5 cfm/sq. ft. at a pressure drop of 0.5 in. of water across the material and said sheet comprises:

four or fewer fold lines; and

a plurality of flap portions, each flap portion having a base edge corresponding to a fold line and at least two side edges each extending outwardly from the base edge and ultimately converging to meet each other.

25. An inflatable protective device comprising:

a housing;

an inflation device attached to the housing; and

an inflatable protective cushion within the housing comprising a sheet defined by four or fewer fold lines and a plurality of flap portions, each flap portion having a base edge corresponding to a fold line and at least two side edges each extending outwardly from the base edge and ultimately converging to meet each other, the flap portions being folded at the fold lines with each of the flap portions substantially converged to form an apex above the sheet and being joined at corresponding side edges to define an inflatable chamber.

26. An inflatable protective device as defined in claim 25, wherein said sheet is made of a material having a weight less than 4.0 oz/sq. yd.

27. A method for making an inflatable protective cushion comprising the steps of:

constructing a sheet having a polygonal central portion defined by four or fewer fold lines and a plurality of flap portions, each flap portion having a base edge corresponding to a fold line of the central portion and at least two side edges extending outwardly from the base edge and ultimately converging to meet each other;

folding the flap portions at the fold lines with each of the flap portions substantially converged to form an apex above the center of the central portion of the sheet; and

joining adjacent side edges of adjacent flap portions together.

28. A method for making a cushion as recited in claim 27, further comprising the step of attaching a circumferential collar around the side edges of said folded flap portions substantially near the apex of said folded flap portions.

29. A method for making a cushion as recited in claim 28, wherein said sheet is made of a material having a grab tensile strength less than 255 lbs., tongue tear strength of less than 8 lbs., a Mullen burst strength of less than 325 psi, and an air permeability of less than 1.10 cfm/sq. ft. at a pressure drop of 0.5 in. of water across the material.

30. A method for making a cushion as recited in claim 29, further comprising the step of attaching expansion limiting means to said sheet.

31. A method for making a cushion as recited in claim 27 wherein said sheet is made of woven cloth of less than 420 denier yarn.

32. A method for making a cushion as recited in claim 31, wherein said sheet is made of woven cloth of 30-200 denier yarn.