Sewn fusion seal process for producing air-holding vehicle restraint systems

• US 6,630,220 B1
• Filed: 05/17/2000
• Issued: 10/07/2003
• Est. Priority Date: 01/28/2000
• Status: Expired due to Fees

• Current Assignee: Bradford Coatings, Llc
• Original Assignee: Bradford Industries, Inc.
• Inventors: Veiga, Manuel J.
• Primary Examiner(s): Juska, Cheryl A.
• Assistant Examiner(s): SINGH-PANDEY, ARTI R
• Application Number:
  US09/572,176
• Time in Patent Office: 1,238 Days
• Field of Search: 428/12, 428/577, 428/33, 428/34.1, 428/34.3, 428/34.5, 428/34.6, 428/34.7, 428/35.2, 428/35.7, 428/35.9, 428/36.1, 428/59, 428/61, 428/66.4, 428/66.6, 428/66.7, 428/68, 428/69, 428/102, 428/121, 428/130, 428/131, 442/64, 442/65, 442/66, 442/164, 442/168, 280/728.1, 280/743
• US Class Current: 428/102
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B60R 2021/23514 coated fabric
• CPC Class Codes: B60R 2021/23576 Sewing
• CPC Class Codes: B60R 2021/2358 Bonding
• CPC Class Codes: B60R 21/235 characterised by their material
• CPC Class Codes: Y10T 428/12229 Intermediate article [e.g., blank, etc.]
• CPC Class Codes: Y10T 428/13 Hollow or container type article [e.g., tube, vase, etc.]
• CPC Class Codes: Y10T 428/1307 Bag or tubular film [e.g., pouch, flexible food casing, envelope, etc.]
• CPC Class Codes: Y10T 428/1314 Contains fabric, fiber particle, or filament made of glass, ceramic, or sintered, fused, fired, or calcined metal oxide, or metal carbide or other inorganic compound [e.g., fiber glass, mineral fiber, sand, etc.]
• CPC Class Codes: Y10T 428/1317 Multilayer [continuous layer]
• CPC Class Codes: Y10T 428/1321 Polymer or resin containing [i.e., natural or synthetic]
• CPC Class Codes: Y10T 428/1334 Nonself-supporting tubular film or bag [e.g., pouch, envelope, packet, etc.]
• CPC Class Codes: Y10T 428/1352 Polymer or resin containing [i.e., natural or synthetic]
• CPC Class Codes: Y10T 428/1359 Three or more layers [continuous layer]
• 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 428/193 Double faced corrugated sheets or webs connected
• CPC Class Codes: Y10T 428/197 with noncoplanar reinforcement
• CPC Class Codes: Y10T 428/215 Seal, gasket, or packing
• CPC Class Codes: Y10T 428/218 Aperture containing
• CPC Class Codes: Y10T 428/219 Edge structure
• CPC Class Codes: Y10T 428/23 : Sheet including cover or casing
• CPC Class Codes: Y10T 428/231 : Filled with gas other than air; or under vacuum
• CPC Class Codes: Y10T 428/24033 : including stitching and discrete fastener[s], coating or bond
• CPC Class Codes: Y10T 428/2419 : Fold at edge
• CPC Class Codes: Y10T 428/24264 : Particular fold structure [e.g., beveled, etc.]
• CPC Class Codes: Y10T 428/24273 : including aperture
• CPC Class Codes: Y10T 442/2041 : Two or more non-extruded coatings or impregnations
• CPC Class Codes: Y10T 442/2049 : Each major face of the fabric has at least one coating or impregnation
• CPC Class Codes: Y10T 442/2057 : At least two coatings or impregnations of different chemical composition
• CPC Class Codes: Y10T 442/2861 : Coated or impregnated synthetic organic fiber fabric
• CPC Class Codes: Y10T 442/2893 : Coated or impregnated polyamide fiber fabric

Abstract

A method is disclosed for producing an air-holding vehicle restraint system, wherein a textile fabric is coated on at least one side with a thermoplastic polymeric material and folded along its lengthwise direction to form a closed bottom end and two open upper ends, with the coated side of the fabric facing inwardly. The method also comprises folding a portion of each of the upper open ends of the textile fabric so that they turn outwardly to form a coated platform, and laying a sealing tape upon the coated platform. The sealing tape is then secured to the coated platform and sealed to the coated platform. The method further comprises cutting the coated textile fabric along predetermined side edges to form an air-holding vehicle restraint system of desired shape, and sealing the cut side edges of the coated textile fabric. In an alternative embodiment; an intermediate electroconductive layer is positioned between the coated platform and the sealing tape to provide electroconductive assistance for heat sealing by microwaves in a microwave oven. An air-holding vehicle restraint system is also disclosed which is produced by the method of the invention.

Claims

1. An air-holding vehicle restraint system, which comprises:

a) a textile fabric having a thermoplastic polymeric coating on at least one side thereof, said coated fabric being folded along its lengthwise direction to form a closed bottom end and two open upper ends, with the coated side of the fabric facing inwardly, each of said upper open ends of said textile fabric being turned outwardly to form a coated platform;

b) a sealing tape positioned upon said coated platform and in contact therewith;

c) means to secure said sealing tape to said coated platform, said sealing tape being sealed to said coated platform and said coated textile fabric being cut along predetermined side edges; and

d) means to seal said cut side edges of said coated textile fabric to form an airholding vehicle restraint system of desired shape.

2. The air holding vehicle restraint system according to claim 1 wherein said means to secure said sealing tape to said coated platform comprises sewn stitches and heat sealing.

3. The air holding vehicle restraint system of claim 2 wherein said side edges of said textile fabric are sealed by sewing and heat sealing.

4. The air holding vehicle restraint system of claim 3 wherein said upper open ends of said taped, sealed platform are folded upwardly and secured together to form a tubeshaped structure at the upper end of said air-holding vehicle restraint system.

5. The air holding vehicle restraint system of claim 4 wherein said upper open ends of said taped, sealed platform are secured by sewn stitches.

6. The air holding vehicle restraint system of claim 5 wherein said textile fabric is comprised of synthetic fibers.

7. The air holding vehicle restraint system of claim 5 wherein said textile fabric is a knitted, woven, or non-woven fabric.

8. The air holding vehicle restraint system of claim 6 wherein said synthetic fibers are selected from the group consisting of polyamides and polyesters.

9. The air holding vehicle restraint system of claim 6 wherein said textile fabric is woven nylon.

10. The air holding vehicle restraint system of claim 9 wherein said coating of thermoplastic polymeric material on said at least one side of said textile fabric comprises a first adhesive coating layer selected from the group consisting of aromatic and aliphatic polyester or polyether polyurethanes and a second elastomeric coating layer which comprises an elastomeric polyether or polyester polyurethane.

11. The air holding vehicle restraint system of claim 10 wherein said sealing tape comprises a textile fabric coated on at least one side with a polymeric material.

12. The air holding vehicle restraint system of claim 11 wherein said textile fabric of said sealing tape is comprised of synthetic fibers and is knitted, woven or non-woven.

13. The air holding vehicle restraint system of claim 12 wherein said polymeric material coating on said sealing tape is polyurethane.

14. The air holding vehicle restraint system of claim 12 wherein said textile fabric of said sealing tape is woven nylon.

15. The air holding vehicle restraint system of claim 13 wherein said synthetic fibers of said sealing tape are selected from the group consisting of polyamides and polyesters.

16. The air holding restraint system of claim 14 wherein said sealing tape is laid upon said coated platform with its thermoplastic polyurethane coating in face-to-face contacting relationship with said polyurethane coated platform.

17. The air holding vehicle restraint system of claim 16 wherein said adhesive coating layer, on said at least one side of said textile fabric has a coating weight of from about 0.3 ounces/sq. yd. to about 1.5 ounces/sq. yd. and said second coating layer has a solids content of from about 30% to about 100% by weight.

18. The air holding vehicle restraint system of claim 17 wherein said second coating layer, on said at least one side of said textile fabric has a coating weight of from about 1 ounce/sq.yd. to about 8 ounces/sq.yd.

19. The air holding vehicle restraint system according to claim 18 wherein said textile fabric is coated on a second side with a polymeric material.

20. The air holding vehicle restraint system according to claim 19 wherein said coating of polymeric material on said second side of said textile material comprises a coating layer of polysiloxane.

21. The air holding vehicle restraint system of claim 1 wherein said coating of thermoplastic polymeric material on said at least one side of said textile fabric comprises a first adhesive coating layer selected from the group consisting of aromatic or aliphatic polyester or polyether polyurethanes and a second elastomeric coating layer consisting of an elastomeric polyether or polyester polyurethane.

22. The air holding restraint system of claim 21 wherein said adhesive coating layer has a coating weight of from 0.3 ounces/sq. yd. to about 1.5 ounces/sq.yd. and said second coating layer has a solids content of from about 30% to about 100% by weight.

23. The air holding restraint system of claim 22 wherein said second coating layer has a coating weight of from about 1 ounce/sq. yd. to about 8 ounces/sq. yd.

24. The air holding restraint system of claim 22 wherein said intermediate unsupported electroconductive strip is a polyurethane film.

25. The air holding restraint system of claim 23 wherein said unsupported electroconductive strip is sewn between said coated platform and said coated sealing tape.

26. The air holding restraint system of claim 25 wherein said unsupported electroconductive strip is a film strip having electroconductive material therein.

27. The air holding restraint system of claim 24 wherein said heat sealing is effected by radio frequency sealing, hot air sealing or ultrasonic sealing.

28. The air holding restraint system of claim 27 wherein said heat sealing is effected by radio frequency sealing at a frequency of from about 10 to about 80 megahertz.

29. The air holding restraint system of claim 1 wherein an additional intermediate layer is positioned between said coated platform and said coated sealing tape, said intermediate layer comprising an electroconductive strip.

30. The air holding restraint system of claim 29 wherein said intermediate electroconductive strip comprises an unsupported film strip.

31. The air holding restraint system of claim 30 wherein said electroconductive material is selected from the group consisting of powdered metal, carbon black, stainless steel and aluminum and is in the form of particles interspersed therethrough.

32. An air-holding vehicle restraint system, which comprises:

a) a textile fabric having a thermoplastic polymeric coating, said coated fabric being folded along its lengthwise direction to form a closed bottom end and two open upper ends, with the coated side of the fabric facing inwardly, each of said upper open ends of said textile fabric being turned outwardly to form a coated platform;

b) a sealing tape positioned upon said coated platform and in contact therewith;

c) sewn stitches to secure said sealing tape to said coated platform, said sealing tape being heat sealed to said coated platform, and said coated textile fabric being cut along predetermined side edges; and

d) heat formed seals to seal said cut side edges of said coated textile fabric to form an air-holding vehicle restraint system of desired shape.

33. The air-holding vehicle restraint system of claim 32 wherein said heat formed seals on said side edges are formed by radio frequency heat sealing.

34. The air-holding vehicle restraint system of claim 33 (wherein said heat formed seals on said side edges are formed by radio frequency sealing at a frequency of from about 10 to about 80 megahertz.

35. An air-holding vehicle restraint system, which comprises:

a) a textile fabric having a thermoplastic polymeric coating, said coated fabric being folded along its lengthwise direction to form a closed bottom end and two open upper ends, with the coated side of the fabric facing inwardly, each of said upper open ends of said textile fabric being turned outwardly to form a coated platform;

b) a sealing tape positioned upon said coated platform and in contact therewith;

c) an intermediate electroconductive strip positioned between said coated platform and said sealing tape, said intermediate strip having electroconductive material therein;

d) sewn stitches to secure said sealing tape and said intermediate conductive strip to said coated platform, said sealing tape being heat sealed to said coated platform, and said coated textile fabric being cut along predetermined side edges; and

e) heat formed seals to seal said cut side edges of said coated textile fabric to form an air-holding vehicle restraint system of desired shape.

36. The air holding vehicle restraint system of claim 35 wherein said electroconductive material is selected from the group consisting of powdered metal, carbon black, stainless steel and aluminum, and is in the form of particles interspersed therethrough.