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US 2014/0273697 A1Published application
Energy absorbing fabric and method of manufacturing same
AssigneeYKK Corporation of America
InventorTIMOTHY M. RUSSELL
Life of this patent
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Abstract
Energy absorbing fabrics that are generally flat and that have a controllable and significant elongation distance. The fabrics are comprised of elongation yarns, such as partially oriented yarns (POY), and binder yarns, where the elongation yarns and the binder yarns have various weave-in percentages depending on the desired amount of elongation. In certain embodiments, because they are generally flat, the energy absorbing fabrics are suitable for use in retractors. Also provided are processes of manufacturing generally flat, energy absorbing fabrics.
Claims18
A fabric comprising:
- (i) a first layer comprising a first set of elongation yarns extending in a substantially warp direction, wherein the elongation yarns of the first set of elongation yarns are interwoven with one another;
- (ii) a second layer comprising a second set of elongation yarns extending in a substantially warp direction, wherein the elongation yarns of the second set of elongation yarns are interwoven with one another;
- (iii) a plurality of binder yarns that are interwoven between the first layer and the second layer to bind the first set of elongation yarns with the second set of elongation yarns;
- and
- (iv) a plurality of lateral yarns, wherein some of the plurality of lateral yarns extend in a substantially weft direction across the fabric between the first set of elongation yarns and others of the plurality of lateral yarns extend in a substantially weft direction across the fabric between the second set of elongation yarns;
- wherein at least one of the plurality of binder yarns interweaves pairs of lateral yarns in the first layer with pairs of lateral yarns in the second layer,
- wherein the at least one of the plurality of binder yarns exits the first layer and reenters the first layer along a plurality of first sections such that each of the first sections includes one of the pairs of lateral yarns,
- wherein the at least one of the plurality of binder yarns exits the second layer and reenters the second layer along a plurality of second sections such that each of the second sections includes another of the pairs of lateral yarns, and
- wherein the elongation yarns have a shrinkage characteristic that is greater than a shrinkage characteristic of the binder yarns and wherein the binder yarns have a tensile strength that is greater than a tensile strength of the elongation yarns.
6 more elements
A fabric comprising:
- a first layer comprising a first set of elongation yarns extending in a substantially warp direction, wherein the elongation yarns of the first set of elongation yarns are interwoven with one another;
- (ii) a second layer comprising a second set of elongation yarns extending in a substantially warp direction, wherein the elongation yarns of the second set of elongation yarns are interwoven with one another;
- (iii) a plurality of binder yarns, at least one of which is interwoven between the first layer and the second layer at various points along a length of the fabric to secure the first layer with the second layer;
- and
- (iv) a plurality of lateral yarns that extend in a substantially weft direction across the fabric in between each of the first and second layers;
- wherein at least one of the plurality of binder yarns interweaves groups of lateral yarns in the first layer with groups of lateral yarns in the second layer,
- wherein the at least one of the plurality of binder yarns exits the first layer and reenters the first layer along a plurality of first bands such that each of the first bands includes one of the groups of lateral yarns,
- wherein the at least one of the plurality of binder yarns exits the second layer and reenters the second layer along a plurality of second bands such that each of the second bands includes another of the groups of lateral yarns,
- wherein the elongation yarns have a shrinkage characteristic that is greater than a shrinkage characteristic of the binder yarns and wherein the binder yarns have a tensile strength that is greater than a tensile strength of the elongation yarns, and
- wherein the binder yarns are longer than the elongation yarns.
7 more elements
A method of weaving a fabric comprising:
- interweaving a first set of elongation yarns with one another in a substantially warp direction to form a first layer of the fabric;
- (ii) interweaving a second set of elongation yarns with one another in a substantially warp direction to form a second layer of the fabric;
- (iii) interweaving a plurality of lateral yarns in a substantially weft direction across the fabric such that some of the plurality of lateral yarns interweave between the first set of elongation yarns and others of the plurality of lateral yarns interweave between the second set of elongation yarns;
- and
- (iv) interweaving at least one binder yarn between the first layer and the second layer along a length of the fabric to secure the first layer with the second layer such that the at least one binder yarn exits the first layer and reenters the first layer along a plurality of first sections, where each of the first sections includes a group of lateral yarns and such that the at least one binder yarn exits the second layer and reenters the second layer along a plurality of second sections, where each of the second sections includes another group of lateral yarns.
2 more elements
Dependencies are inferred from the claim text.