Inflatable fabrics having woven attachment points between fabric panels

• US 6,595,244 B1
• Filed: 09/25/2000
• Issued: 07/22/2003
• Est. Priority Date: 09/24/1999
• Status: Expired due to Term

• Current Assignee: Milliken & Company
• Original Assignee: Milliken & Company
• Inventors: Sollars, John A. Jr.
• Primary Examiner(s): Calvert, John J.
• Assistant Examiner(s): Muromoto, Jr., Robert H.
• Application Number:
  US09/668,857
• Time in Patent Office: 1,030 Days
• Field of Search: 139/389, 280/728.1, 428/36.1
• US Class Current: 139/389
• CPC Class Codes: B60R 2021/23542 Weaving
• CPC Class Codes: B60R 21/235 characterised by their material
• CPC Class Codes: D03D 1/02 Inflatable articles
• CPC Class Codes: D03D 11/02 Fabrics formed with pockets, tubes, loops, folds, tucks or flaps fabrics consisting of a single tube D03D3/02
• CPC Class Codes: Y10T 428/1362 Textile, fabric, cloth, or pile containing [e.g., web, net, woven, knitted, mesh, nonwoven, matted, etc.]
• CPC Class Codes: Y10T 428/24025 Superposed movable attached layers or components
• CPC Class Codes: Y10T 428/24562 Interlaminar spaces
• CPC Class Codes: Y10T 442/3179 Woven fabric is characterized by a particular or differential weave other than fabric in which the strand denier or warp/weft pick count is specified

Abstract

All-woven inflatable fabrics having at least one area of two layers and at least one attachment point or “seam” where a single layer of fabric is formed. Such single fabric layers may be constructed through the utilization of basket weave patterns. The single fabric layers provide a relatively a effective manner of reducing air permeability within the entire fabric article by decreasing the possibility of yarn shifting upon inflation of the inflatable fabric. Alternatively, the presence of at least a second single fabric layer area adjacent to the first and separated by and narrow double fabric layer area can further reduce the possibility of yarn shifting in the first single fabric layer area. Such a fabric may be utilized in numerous and various applications wherein fabric inflation is desired or necessary. In particular, the inventive fabric may be incorporated within an airbag cushion.

Claims

1. An inflatable fabric comprising at least two layers of fabric in certain discrete areas of the fabric and at least one narrow single fabric layer at a discrete area within said fabric, wherein said at least one narrow single fabric layer is formed solely from a basket weave pattern of an even number of yarns, at most 12 yarns in width, and wherein said at least one narrow single fabric layer has at least one curved portion.

2. The fabric of claim 1 wherein said at least two layers of fabric within said inflatable fabric are formed solely from one type of weave pattern, wherein said weave pattern is not a basket weave pattern.

3. The fabric of claim 2 wherein the weave pattern of said at least two layers of fabric within said inflatable fabric is a plain weave pattern.

49. The fabric of claim 1 wherein at least two discrete narrow areas of single fabric layers are present within said inflatable fabric, wherein said at least two single fabric layers are separated by an area of two layers of fabric, and wherein the lengths of each single layer is from 4 to 8 yarns in length.

50. The fabric of claim 49 wherein said at least two single fabric layer areas are seams through the inflatable fabric which run parallel to each other.

51. The fabric of claim 49 wherein said at least two single fabric layer areas are constructed solely from basket weave patterns containing at least two yarns per basket pattern and at most four yarns per basket pattern.

52. The fabric of claim 50 wherein said separator two layers of fabric between said two single layers of fabric comprises an even number of weft yarns.

53. The fabric of claim 52 wherein said separator two layers of fabric comprises at most 12 weft yarns and at least 2 weft yarns.

54. The fabric of claim 53 wherein said at least two single fabric layers are constructed solely from two-by-two basket weave patterns and said separator double fabric layer comprises four weft yarns.

4. An inflatable fabric comprising at least two layers of fabric in certain discrete areas of the fabric and at least one narrow single fabric layer at a discrete area within said fabric, wherein said at least one narrow single fabric layer is formed solely from a basked weave pattern of an even number of yarns, at most 12 yarns in width, wherein at least two discrete narrow areas of single fabric layers are present within said inflatable fabric, wherein said at least two single fabric layers are separated by an area of two layers of fabric, and wherein the lengths of each single layer is from 4 to 8 yarns in length.

5. The fabric of claim 4 wherein said at least two single fabric layer areas are seams through the inflatable fabric which run parallel to each other.

6. The fabric of claim 4 wherein said at least two single fabric layer areas are constructed solely from basket weave patterns containing at least two yarns per basket pattern and at most four yarns per basket pattern.

7. The fabric of claim 5 wherein said separator two layers of fabric between said two single layers of fabric comprises an even number of weft yarns.

8. The fabric of claim 7 wherein said separator two layers of fabric comprises at most 12 weft yarns and at least 2 weft yarns.

9. The fabric of claim 8 wherein said at least two single fabric layers are constructed solely from two-by-two basket weave patterns and said separator two layers of fabric comprises four weft yarns.

35. The fabric of claim 4, wherein said fabric is formed on at least one of a jacquard and dobby loom.

10. An inflatable fabric comprising at least two layers of fabric in certain discrete areas of the fabric and at least one single fabric layer at a discrete area within said fabric, wherein the weave diagram for such a fabric does not exhibit more than three consecutive unfilled blocks in any row or column, and wherein said at least one single fabric layer has at least one curved portion.

11. An inflatable fabric comprising at least two layers of fabric in certain discrete areas of the fabric and at least one single fabric layer at a discrete area within said fabric, wherein only two separate weave densities are present within the entire fabric structure, wherein the junction of said two layers and said single fabric layer has floats of three picks or less, and wherein said at least one single fabric layer has at least one curved portion.

12. An inflatable fabric comprising at least two layers of fabric in certain discrete areas of the fabric and at least one narrow single fabric layer at at least two discrete areas within said fabric, wherein said at least one narrow single fabric layer is formed solely from a basket weave pattern of an even number of yarns, at most 12 yarns in width, wherein at least two discrete narrow areas of single fabric layers are present within said inflatable fabric, wherein said at least two areas of single fabric layers are separated by an area of the at least two layers of fabric, and wherein the width of each single layer is from 4 to 8 yarns in length.

13. The fabric of claim 12 wherein said at least two single fabric layer areas are seams through the inflatable fabric which run parallel to each other.

14. The fabric of claim 12 wherein said at least two single fabric layer areas are constructed solely from basket weave patterns containing at least two yarns per basket pattern and at most four yarns per basket pattern.

15. The fabric of claim 12 wherein said separator area of two layers of fabric between said two single layers of fabric comprises an even number of weft yarns.

16. The fabric of claim 15 wherein said separator area of two layers of fabric comprises at most 12 weft yarns and at least 2 weft yarns.

17. The fabric of claim 16 wherein said at least two single fabric layers are constructed solely from two-by-two basket weave patterns and said separator area of two layers of fabric comprises four weft yarns.

18. The fabric as recited in claim 12, wherein said fabric has three different types of patterns, the first pattern is a repeated plain weave pattern throughout at least two layers of fabric which must always initiate at a location in the warp direction of 4X+1, with X representing the number of pick arrangement a weave diagram, and at a location in the fill direction of 4X+1, thus, the pick arrangement including the specific two layer plain-weave-signifying-block begins at the block four spaces below it in both directions, the second pattern is an “

up-down”

basket weave pattern wherein an empty block must exist and always initiate the basket-weave pattern at a location in the warp direction of 4X+1, with X representing the number of repeating pick arrangements within the diagram, and at a location in the fill direction of 4X+1, when a single layer fabric is desired, thus, the pattern including the pertinent signifying “

up-down”

block includes an empty block within the basket-weave pick arrangement in both the warp and fill directions four spaces below it, and the third pattern is basically a “

down-up”

basket weave pattern to a single fabric layer and must always initiate at a location in the warp direction of 4X+1 and fill of 4X+3, or warp of 4X+3 and fill of 4X+1, when a seam is desired, such a specific arrangement of differing “

up-down”

basket weave and “

down-up”

basket weave pattern is necessary to effectuate the continuous and repeated weave construction wherein no more than three floats or empty blocks are present simultaneously within the target fabric structure.

19. The fabric as recited in claim 12, wherein weft yarns are present in each of the fabric layer areas over and under which individual warp yarns have been woven, the at least two layer fabric areas are woven in plain weave patterns, the single fabric layer areas are woven in basket weave patterns, four weft yarns each are configured through each repeating basket weave pattern, however, anywhere from two to twelve weft yarns may be utilized within the single layer fabric areas seams, the intermediate two layer fabric areas comprise each only four weft yarns within plain weave patterns, the number of such intermediate weft yarns between the single layer fabric areas must be in multiples of two to provide the maximum pressure bearing benefits within the two seams with the at least two layer fabric areas.

20. The fabric of claim 12, wherein each of said at least two discrete narrow areas of single fabric form at least one of a seam and seal.

21. The fabric as recited in claim 12, wherein at least one of said at least two discrete narrow areas of single fabric form at least one of a non-linear seam and seal.

22. The fabric as recited in claim 12, wherein said at least two discrete narrow areas of single fabric and said area of at least two layers of fabric form at least one pillowed chamber.

23. The fabric of claim 12, wherein said fabric is formed on at least one of a jacquard and dobby loom.

24. The fabric as recited in claim 12, wherein said fabric is sealed to form a bag.

25. In an inflatable all-woven fabric airbag cushion, the improvement comprising at least two layers of fabric in certain discrete areas of the fabric and at least one single fabric layer at a discrete area within said fabric which forms at least one of a seam and seal which does not exhibit a float of more than three picks, wherein said at least one single fabric layer has at least one curved portion, and wherein a weave diagram having rows and columns of filled and unfilled blocks for the fabric does not exhibit more than three consecutive unfilled blocks in any row or column.

26. In an inflatable all-woven fabric airbag cushion, the improvement comprising at least two layers of fabric in certain discrete areas of the fabric and at least one single fabric layer at a discrete area within said fabric which forms at least one of a seam and seal which does not exhibit a float of more than three picks, wherein said at least one single fabric layer is constructed solely from two-by-two basket weave patterns and, wherein said at least one single fabric layer has at least one curved portion, and said area of at least two layers of fabric comprises four weft yarns.

27. In an inflatable all-woven fabric airbag cushion, the improvement comprising at least two layers of fabric in certain discrete areas of the fabric and at least one single fabric layer at a discrete area within said fabric which forms at least one of a seam and seal which does not exhibit a float of more than three picks, wherein said at least one single fabric layer has at least one curved portion, wherein said fabric has three different types of patterns, the first pattern is a repeated plain weave pattern throughout at least two layers of fabric which must always initiate at a location in the warp direction of 4X+1, with X representing the number of pick arrangement a weave diagram, and at a location in the fill direction of 4X+1 thus, the pick arrangement including the specific two layer plain-weave-signifying-block begins at the block four spaces below it in both directions, the second pattern is an “

up-down”

basket weave pattern wherein an empty block must exist and always initiate the basket-weave pattern at a location in the warp direction of 4X+1, with X representing the number of repeating pick arrangements within the diagram, and at a location in the fill direction of 4X+1, when a single layer fabric is desired thus, the pattern including the pertinent signifying “

up-down”

block includes an empty block within the basket-weave pick arrangement in both the warp and fill directions four spaces below it, and the third pattern is basically a “

down-up”

basket weave pattern to a single fabric layer and must always initiate at a location in the warp direction of 4X+1 and fill of 4X+3, or warp of 4X+3 and fill of 4X+1, when a seam is desired, such a specific arrangement of differing “

up-down”

basket weave and “

down-up”

basket weave pattern is necessary to effectuate the continuous and repeated weave construction wherein no more than three floats or empty blocks are present simultaneously within the target fabric structure.

28. In an inflatable all-woven fabric airbag cushion, the improvement comprising at least two layers of fabric in certain discrete areas of the fabric and at least one single fabric layer at a discrete area within said fabric which forms at least one of a seam and seal which does not exhibit a float of more than three picks, wherein said at least one single fabric layer has at least one curved portion, wherein weft yarns are present in each of the fabric layer areas over and under which individual warp yarns have been woven, the at least two layer fabric areas are woven in plain weave patterns, the single fabric layer areas are woven in basket weave patterns, four weft yarns each are configured through each repeating basket weave pattern, however, anywhere from two to twelve weft yarns may be utilized within the single layer fabric areas or seams, the intermediate two layer fabric areas comprise each only four weft yarns within plain weave patterns, the number of such intermediate weft yarns between the single layer fabric areas must be in multiples of two to provide the maximum pressure bearing benefits within the two seams with the at least two layer fabric areas.

29. An inflatable all-woven fabric for use as a pillow chambered inflatable protective cushion in a vehicle passive restraint system such as a side curtain comprising at least two layers of fabric in certain discrete areas of the fabric and at least one narrow single fabric layer at a discrete area within said fabric, wherein said at least one narrow single fabric layer is formed solely from a two-by-two basket weave pattern of an even number of yarns, at most 12 yarns in width, and wherein said at least one narrow single fabric layer has at least one curved portion.

30. The fabric of claim 29 wherein the weave pattern of said at least two layers of fabric within said inflatable fabric is a plain weave pattern.

31. The fabric of claim 29 wherein at least two discrete narrow areas of single fabric layers are present within said inflatable fabric, wherein said at least two single fabric layers are separated by an area of said at least two layers of fabric, and wherein the lengths of each single layer is from 4 to 8 yarns in length.

33. The fabric of claim 29, wherein said at least one narrow single fabric layer is a seam through the inflatable fabric.

34. The fabric as recited in claim 29, wherein said fabric is sealed to form a bag.

58. The fabric of claim 29 wherein at least two discrete narrow areas of single fabric layers are present within said inflatable fabric, wherein said at least two single fabric layers are separated by an area of said at least two layers of fabric, and wherein the lengths of each single layer is from 4 to 8 yarns in length.

32. An inflatable all-woven fabric for use as a pillow chambered inflatable protective cushion in a vehicle passive restraint system such as a side curtain comprising at least two layers of fabric in certain discrete areas of the fabric and at least one narrow single fabric layer at a discrete area within said fabric, wherein said at least one narrow single fabric layer is formed solely from a two-by-two basket weave pattern of an even number of yarns, at most 12 yarns in width, wherein at least two discrete narrow areas of single fabric layers are present within said inflatable fabric, wherein said at least two single fabric layers are separated by an area of said at least two layers of fabric, and wherein the lengths of each single layer is from 4 to 8 yarns in length.

36. In a passive passenger restraint system for a vehicle, the improvement comprising an inflatable protective cushion comprising at least two layers of fabric in certain discrete areas of the fabric and at least one narrow single fabric layer at a discrete area within said fabric, wherein said at least one narrow single fabric layer is formed solely from a basket weave pattern of an even number of yarns, at most 12 yarns in width and forms at least one of a seam and a seal with floats of three picks or less.

37. In an airbag, the improvement comprising an inflatable protective cushion comprising at least two layers of fabric in certain discrete areas of the fabric and at least one narrow single fabric layer at a discrete area within said fabric, wherein said at least one narrow single fabric layer is formed solely from a basket weave pattern of an even number of yarns, at most 12 yarns in width and forms at least one of a seam and a seal with floats of three picks or less.

38. In a side curtain airbag, the improvement comprising an inflatable protective cushion comprising at least two layers of fabric in certain discrete areas of the fabric and at least one narrow single fabric layer at a discrete area within said fabric, wherein said at least one narrow single fabric layer is formed solely from a basket weave pattern of an even number of yarns, at most 12 yarns in width and forms at least one of a seam and a seal with floats of three picks or less.

39. An inflatable fabric adapted for use as an inflatable protective cushion in an occupant restraint system comprising at least two layers of fabric in certain discrete areas of the fabric and at least one narrow single fabric layer at a discrete area within said fabric, wherein said at least one narrow single fabric layer is formed solely from a basket weave pattern of an even number of yarns, at most 12 yarns in width and forms at least one of a non-rectangular seam and seal.

40. The airbag cushion of claim 39, wherein the narrow single fabric layer seam margins are less than or equal to 12 yarns.

41. In an airbag cushion having a multiple layer portion and a single layer portion, the improvement comprising:

a narrow single fabric layer seam margin, followed by a double fabric layer margin, followed by at least one additional narrow single fabric layer seam margin, wherein said single fabric layer has at least one curved portion, and wherein the narrow single fabric layer seam margins are less than or equal to 12 yarns.

42. In an airbag cushion having a multiple layer portion and a single layer portion, the improvement comprising:

a narrow single fabric layer seam margin, followed by a double fabric layer margin, followed by at least one additional narrow single fabric layer seam margin, wherein said single fabric layer has at least one curved portion, and wherein the narrow single fabric layer seam margin consist of a 2×

2 basket weave pattern of from 2-12 yarns wide.

43. In an airbag cushion having a multiple layer portion and a single layer portion, the improvement comprising:

a narrow single fabric layer seam margin, followed by a double fabric layer margin, followed by at least one additional narrow single fabric layer seam margin, wherein said single fabric layer has at least one curved portion, and wherein at least one of said narrow single fabric layer seam margins has substantially no floats of greater than 3 picks.

44. In an airbag cushion formed of a single woven item having multiple layer and single layer portions, the improvement comprising at least one seam comprised of a narrow single fabric layer area between two double layer fabric areas, wherein said at least one narrow single fabric layer has at least one curved portion, and wherein the at least one narrow single fabric layer seam is less than or equal to 12 yarns wide.

45. In an airbag cushion formed of a single woven item having multiple layer and single layer portions, the improvement comprising at least one seam comprised of a narrow single fabric layer area between two double layer fabric areas, wherein said at least one narrow single fabric layer has at least one curved portion, and wherein said at least one narrow single fabric layer seam consists of a 2×

2 basket weave pattern of from 2-12 yarns wide.

46. An inflatable fabric adapted for use as an inflatable protective cushion in an occupant restraint system comprising at least two layers of fabric in certain discrete areas of the fabric and at least one narrow single fabric layer at a discrete area within said fabric, wherein said at least one narrow single fabric layer is formed solely from a basket weave pattern of an even number of yarns, at most 12 yarns in width and forms at least one of a seam and a seal with floats of three picks or less, and wherein said at least one narrow single fabric layer has at least one curved portion.

47. The fabric of claim 46 wherein said at least two layers of fabric within said inflatable fabric are formed solely from one type of weave pattern, wherein said weave pattern is not a basket weave pattern.

48. The fabric of claim 47 wherein the weave pattern of said at least two layers of fabric within said inflatable fabric is a plain weave pattern.

55. The airbag cushion of claim 46, wherein said at least one single fabric layer is constructed solely from two-by-two basket weave patterns and said area of at least two layers of fabric comprises four weft yarns.

56. The airbag cushion as recited in claim 46, wherein said fabric has three different types of patterns, the first pattern is a repeated plain weave pattern throughout at least two layers of fabric which must always initiate at a location in the warp direction of 4X+1, with X representing the number of pick arrangement a weave diagram, and at a location in the fill direction of 4X+1 thus, the pick arrangement including the specific two layer plain-weave-signifying-block begins at the block four spaces below it in both directions, the second pattern is an “

up-down”

basket weave pattern wherein an empty block must exist and always initiate the basket-weave pattern at a location in the warp direction of 4X+1, with X representing the number of repeating pick arrangements within the diagram, and at a location in the fill direction of 4X+1, when a single layer fabric is desired thus, the pattern including the pertinent signifying “

up-down”

block includes an empty block within the basket-weave pick arrangement in both the warp and fill directions four spaces below it, and the third pattern is basically a “

down-up”

basket weave pattern to a single fabric layer and must always initiate at a location in the warp direction of 4X+1 and fill of 4X+3, or warp of 4X+3 and fill of 4X+1, when a seam is desired, such a specific arrangement of differing “

up-down”

basket weave and “

down-up”

basket weave pattern is necessary to effectuate the continuous and repeated weave construction wherein no more than three floats or empty blocks are present simultaneously within the target fabric structure.

57. The airbag cushion as recited in claim 46, wherein weft yarns are present in each of the fabric layer areas over and under which individual warp yarns have been woven, the at least two layer fabric areas are woven in plain weave patterns, the single fabric layer areas are woven in basket weave patterns, four weft yarns each are configured through each repeating basket weave pattern, however, anywhere from two to twelve weft yarns may be utilized within the single layer fabric areas or seams, the intermediate two layer fabric areas comprise each only four weft yarns within plain weave patterns, the number of such intermediate weft yarns being the single layer fabric areas must be in multiples of two to provide the maximum pressure bearing benefits within the two seams with the at least two layer fabric areas.