3,008,214
`B. H. FOSTER ETAL
`Nov. 14, 1961
`FLEXIBLE INFLATABLE FABRIC AND METHOD OF MAKING THE SAME
`Filed Jan. 22, 1957
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`2 Sheets-Sheet 1
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`It? Inf-ll,
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`' INVENTORS
`BOUT/V514 A’. F0672???
`A/A J'J/? HA 00A 0
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`BY Wm ATTORNEY
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`INTEX EXHIBIT 2013, Pg. 1
`Bestway v. Intex; PGR2017-00003
`
`

`

`3,008,214
`B. H. FOSTER ETAL
`Nov. 14, 1961
`FLEXIBLE INFLATABLE FABRIC AND METHOD OF MAKING THE SAME
`Filed Jan. 22, 1957
`
`2 Sheets-Sheet 2
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`Z £Z—?_ 5
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`40
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`INVENTORS
`BOUTWELL 1'74 FOSTER
`IVA 58/5 HADOAD
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`ATTORNEY
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`INTEX EXHIBIT 2013, Pg. 2
`Bestway v. Intex; PGR2017-00003
`
`

`

`United States Patent ()?ice
`
`3,008,214
`Patented Nov. 14, 1961
`
`1
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`3,008,214
`FLEXIBLE INFLATABLE FABRIC AND
`METHOD OF MAKING THE SAME
`Boutwell H. Foster, Maplewood, and Nassib' Haddad,
`Iselin, N.J., assignors to United States Rubber Com
`pany, New York, N.Y., a corporation of New Jersey
`Filed Jan. 22, 1957, Ser. No. 635,199
`3 Claims. (Cl. 28-80)
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`tages referred to above and provides an in?atable fabric
`having improved properties and characteristics as will be
`evident from the detailed description that appears further
`along herein.
`The primary object of this invention is to provide an
`improved fabric for use in making an in?atable article
`which is adapted to be readily ?exed, by bending or twist
`ing, in a plurality of directions whether in in?ated or
`collapsed condition.
`Another object of the invention is to provide a light
`weight, compact, strong, durable and air-impervious
`fabric for in?atable articles.
`The invention has for a further object the provision of
`a fabric of the character indicated which is reasonable in
`manufacturing cost and which is capable of performing its
`intended functions in ‘an entirely satisfactory manner.
`A preferred and recommended fabric according to this
`invention comprises a pair of woven fabric plies which
`are positioned one against the other and which are di
`rectly connected by weaving along intersecting ?rst and
`second pluralities of spaced parallel rows or lines. Such
`rows or lines are formed by yarns which are common to
`both plies. Portions of pairs of intersecting and succes
`sive parallel lines de?ne in?atable pockets in the fabric.
`Such pockets may be square, oblong or any other paral
`lelogram con?guration. The plies are disconnected along
`a part of each line which constitutes a side of each of the
`pockets to allow free passage of air between any pocket
`and immediately adjacent pockets.
`Each ply is provided with a substantially coextensive,
`?exible and air-impervious coating to retain air admitted
`into the pockets. The ?nished fabric when in?ated is
`adapted to be readily ?exed along any of the referred-to
`rows or lines. ‘
`The plies may be disconnected along the end parts or
`an intermediate part of each line which constitutes a side
`of each pocket, as desired. This allows passage of air
`between the pockets and still permits ready ?exing of the
`fabric when in?ated.
`The enumerated objects and other objects, together
`with the advantages of this invention, will be readily un
`derstood by persons versed in the art from the following
`detailed description and the accompanying drawings
`which respectively describe and illustrate several fabrics
`constructed in accordance with the invention.
`In the drawings:
`FIG. 1 is ‘a top plan view of an in?atable article having
`a fabric of this invention incorporated therein, the article
`being shown in unin?a-ted condition;
`FIG. 2 corresponds to and illustrates the article of
`FIG. 1 in in?ated condition;
`FIG. 3 is a top plan view of a portion of the fabric
`of the article shown in FIG. 1 prior to its being coated
`with a ?exible, air-impervious material;
`FIG. 4 is an enlarged view taken along line 4-4 of
`FIG. 3;
`'
`FIG. 5 corresponds to FIG. 4 and illustrates the fabric
`with the coatings applied thereto;
`FIGS. 6 and 7 correspond to FIGS. 4 and 5, respec
`tively, and illustrate a modi?cation of this invention; and
`FIG. 8 is similar to FIG. 3 and illustrates another
`modi?cation of this invention.
`Referring now to the drawings wherein like reference
`numerals denote corresponding parts throughout the sev
`eral views, we have illustrated in FIGS. 3 and 4 an un
`coated fabric 10 which is woven by an ordinary loom, as
`distinguished from a plush loom or other special loom.
`Fabric 10 consists of a pair of fabric plies 11 and v12 which
`
`This invention relates generally to the art of fabrics
`and, in one of its more speci?c aspects, to a double face
`or two-ply fabric for use in making ?exible in?atable arti
`cles, and to the method of making the same.
`The fabric of this invention has wide application. It
`is particularly useful in manufacturing in?atable articles
`requiring a relatively high degree of ?exibility in more
`than one direction, whether in de?ated or in?ated condi
`tion. Such articles include items of clothing, life jackets,
`insulating coverings and liners, tops for convertible auto
`mobiles, moisture-proof pads for baby cribs, and the like.
`It has generally been the practice in the past to make
`many in?atable articles from coated plush loom fabrics
`and from coated plies of ordinary fabrics. Articles here
`tofore made from these fabrics are objectionable for sev
`eral reasons. In the ?rst place, the articles frequently do
`not possess the desired degree of ?exibility when in?ated.
`Also due to manufacturing complexities, procedural dif
`?culties and the considerable amount of hand work in
`volved, the cost of producing the articles has been neces
`sarily high.
`A plush loom weaves two fabrics simultaneously and
`maintains them a predetermined distance apart at the
`point of weaving. When a plush loom is used, a number
`of warp yarns from one of the fabrics are transferred to
`the second fabric at regular intervals and are interwoven
`with the ?lling yarns of the second fabric for a speci?ed
`distance. These warp yarns are then transferred back to
`the ?rst fabric. This procedure is repeated so that the
`?nal product has regular rows of uniformly spaced free
`?oating warp yarns which are perpendicular to the face
`fabrics when extended to their full length.
`Plush loom fabrics of the type described above have
`been used in the manufacture of in?atable objects. For
`example, in making an air mattress that will measure two
`inches in thickness when in?ated, a plush loom fabric
`with two inch ?oating warp or spacer yarns is employed.
`The fabric is coated with rubber or other ?exible and
`air-impervious material and cut to the desired size. The
`edges are then sealed with the coating material or a seal
`ing strip, and a valve is inserted in a selected location.
`Upon admitting air into the article through the valve, the
`fabric expands until the spacer yarns are extended to their
`full length. The principal disadvantages of in?atable arti
`cles made from plush loom fabrics are (a) high cost, for
`the reason that plush looms are more complex and ex
`pensive than ordinary looms; !and (b) in?exibility of the
`articles due to their being rigid when fully in?ated.
`In the manufacture of in?atable articles from ordinary
`coated fabrics, a large amount of hand work must be per
`formed to space 'and/ or hold the fabrics in position, there
`by resulting in high labor costs. Moreover, it is usually
`di?icult to make relatively thin multi-seotion in?atable
`articles with ordinary fabrics and employing conventional
`techniques. Additionally, the articles are more rigid in
`a direction parallel to the lines of contact between the
`two faces than perpendicular to such lines. Here we
`have reference to conventional in?atable fabrics.
`This invention eliminates the objections and disadvan
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`INTEX EXHIBIT 2013, Pg. 3
`Bestway v. Intex; PGR2017-00003
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`3,008,214
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`TABLE 2
`All cotton fabric having oblong pockets approximately
`.725" by .625"
`(1) Width, inches ___________ __ 37.625.
`(2) Weight, oz./sq. yd _______ __ 9.22.
`(3) Ends/inch ______________ _. 93.84 of 30/2 cotton.
`(4) Picks/inch ______________ _. ‘89.6 of 30/2 cotton.
`(5) Patterns/inch warp ______ __ 1.38.
`(6) Patterns/inch ?ll ________ __ 1.60.
`(7) Warp strength, lbs _______ __ 128.
`(8) Filling strength, lbs ______ __ 132.
`(9) Percent Warp crimp ______ _. 11.9.
`(10) Percent ?lling crimp _____ __ 6.25.
`(11) Thickness, inches, at .1 p.s.i-, .0440.
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`10
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`15
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`3
`are made of suitable relatively non-shrinkable yarns, such
`as cotton, nylon and the like. Ply 11 includes warp
`yarns 13 and ?ller yarns 14. Ply 12 includes correspond
`ing warp yarns 15 and ?ller yarns 16. The plies are
`simultaneously woven and connected in the warp direc
`tion along a ?rst plurality of spaced parallel lines or
`rows 17, and in the ?lling direction along a second plu
`rality of spaced parallel lines or rows 18 which intersect
`line 17 as shown in FIG. 3. Each line 17 and 18 may
`consist of one or more Warp or ?ller yarns which are
`common to both‘ plies. The fabric construction shown in
`FIG. 4_utilizes three common warp yarns in each line
`or row 17.
`.
`Pairs of intersecting and successive lines 17 and 18
`de?ne pockets or cells 21 which are formed by and be
`tween the fabric plies. The pattern of lines 17 and 18
`shown in FIG. 3 results in squarepockets of equal size.
`It is to be, borne in mind that the\p'ocket7de?ning lines
`may be arranged in other patterns so as to de?ne pockets
`having a con?guration other than square. The pockets
`may, for example, be oblong or diamond shaped and
`may be of a plurality of sizes in a particular fabric. It is
`suilicient for the purposes of this invention to utilize
`pockets de?ned by corresponding lines arranged in the
`form of a parallelogram.
`I The plies are disconnected in the regions of intersections
`of lines 17 and 18 as indicated at 22 in FIG. 3, thereby
`establishing direct communication between any selected
`pocket and the pockets immediately adjacent thereto.
`This allows free passage of air from any pocket to adja
`cent pockets in the ?nished article.
`Each ply 11 and 12 is provided with an outer coating
`23 (FIG. 5) of rubber or other suitable ?exible, air
`impervious material. The fabric of FIGS. 3 and 4 with
`coatings 23 applied thereto is designated by numeral 24
`in FIG. 5.
`Reference is next had to FIGS. 1 and 2 which illustrate
`an in?atable article in the nature of a simple pad 25 which
`is' made from a piece of fabric 24. The pad is shown in
`unin?ated condition in FIG. 1 and in in?ated condition
`in FIG. 2. The pad includes sealing strips 26 which are
`made of an appropriate material, such as rubberized fab
`ric, and which are applied to and seal the edges of coated
`fabric 24 to prevent escape of air from its interior. A
`45
`?exible in?ating tube 27 is secured to the fabric with
`the aid of a sealing ring 28 and communicates directly
`with one of the pockets.
`'
`It will be apparent that the pad may be readily in?ated
`by admitting air under pressure thereinto by way of tube
`27. The air admitted into the pocket communicating di
`rectly with the tube ?ows into the other‘ pockets by way
`of the passages 22 in ‘regions where the plies are discon
`nected along lines 17 and 18. These regions do not ma
`terially aifect the ?exibility of the article, whether unin
`?ated or in?ated, along lines 17 and 18 as will be appre
`ciated from a consideration of the drawings.
`' The following tables set forth data in respect to typical
`uncoated and coated fabrics embodying the form of con
`struction shown in FIGS. ‘3 and 4:
`'
`TABLE 1
`All cotton fabric having approximately 1.125" square
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`TABLE 3
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`All nylon fabric having approximately 1.0 " square
`pockets
`(1) Width, inches __________ _. 12.19.
`(2) Weight, oz./sq. yd _____ __ 2.83.
`(3) Ends/pocket __________ .._ 108 of 100 denier nylon.
`( 4) Picks/pocket __________ .. 106 of 100 denier nylon.
`(5) Thickness, inches, at .1 p.s.i. .0072.
`TABLE 4
`All nylon fabric having approximately 2" square pockets
`(1) Width, inches; _______ _. 11.875.
`(2) Weight, oz./sq. yd _____ _. 2.91.
`(3) Ends/pocket _________ -e 212 of 100 denier nylon.
`(4) Picks/pocket _________ __ 210 of 100 denier nylon.
`(5) Thickness, in., at 0.1 p.s.i- .0072.
`TABLE 5
`All nylon fabric having approximately square pockets
`Before being coated:
`(1) Width, inches ____ __ 44.5.
`(2) Weight, oz./sq. y'd. _. 2.88.
`(3) Ends/pocket _____ .._ 160 of 100 denier nylon.
`(4) Picks/pocket _____ _- 160 of 100 denier nylon.
`(5) Thickness, inches, at
`.
`0.1 p.s.i________- .0130.
`( 6) Dimensions of pock
`ets, inches _____ __ 1.50 square.
`After being ‘coated on both sides:
`('1) Width, inches____a ___________ __ 41.75.
`(2) Weight, oz./sq. yd. __________ __ l7.2.
`(3) Thickness, inches, at 0.1 p.s.i. ..___ .021.
`(4) Dimensions of pocket, inches_____ 1.40): 1.34.
`FIG. 6 illustrates an uncoated fabric 30 comprising a
`pair of ordinary fabric plies 31 and 32 which are joined
`together along lines or rows corresponding to lines 17
`and 18 of FIG. 3 by mechanical stitches 33. As shown,
`each line of juncture between the plies consists of three
`rows of stitches. It will be appreciated that a lesser or
`a greater number of rows of stitches may be used, de
`pending on the materials employed and the requisite
`strength of the ?nished product. The fabric of FIG. 6
`de?nes intercommunicating pockets 34 corresponding to
`pockets 21 of FIGS. 4 and 5.
`Each ply 31 and 32 is provided with a coating of a
`?exible air-impervious material 35 (FIG. 7) which may
`be the same as the material of coatings 23 of FIG. 5.
`The thus coated fabric is identi?ed by numeral 36 in
`FIG. 7.
`FIG. 8 illustrates an uncoated woven fabric 37 that is
`very similar to fabric 10 of FIG. 3. Fabric 37 con
`sists of a pair of woven fabric plies that are connected
`by weaving along intersecting ?rst and second pluralities
`of spaced parallel lines 38 and 39, which correspond to
`lines 17 and 18 of FIG. 3. Fabric 37 differs over fabric
`10 only in that its plies are disconnected along inter
`mediate portions of the lines which de?ne individual
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`pockets
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`‘
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`(1) Width, inches____>___'_..’__‘__'. 19.44.
`(2) Weight, oz./s'q. yd ________ _. 11.6.
`(3) Erids/inch;__‘_____'___'_____ 82.0 of 20/2 cotton.
`(4) Picks/inch ______________ __ 72.5 of 20/2 cotton.
`(5) Patterns/inch warp _______ _. L88.
`(6) Patterns/inch ?1l___..‘ _____ __ .88.
`(7) Warp strength,'1bs____‘_____- 168.
`(8) Filling strength, lbs _______ -."163.
`(9) Percent warp crimp _____ __‘_. 14.0.
`(10) Percent ?lling crimp ______ __ 6.25.
`(11) Thickness, inches,“at .‘1 p.s.i-- .0617.
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`INTEX EXHIBIT 2013, Pg. 4
`Bestway v. Intex; PGR2017-00003
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`

`

`5
`pockets, as indicated at 40. This allows ready passage
`of air from any selected pocket to immediately adjacent
`pockets, as in the case of the earlier described forms of
`the invention. It will be apparent that articles embody
`ing the fabric of FIG. 8 are readily ?exible along lines
`38 and 39 when in collapsed or in?ated condition.
`From the foregoing it is believed that the objects and
`advantages of the herein described in?atable fabric and
`of the method of making the same, will be apparent to
`those skilled in the art, without further description. It
`is to be understood, however, that the invention may be
`embodied otherwise than as here shown and described
`and that various changes may be made without depart—
`ing from the spirit, or sacri?cing any of the advantages
`of the invention.
`We claim:
`1. In a fabric for use in making in?atable articles, a
`pair of ?exible plies positioned one against the other
`and directly connected along a ?rst plurality of spaced
`parallel lines and a second plurality of spaced parallel
`lines which intersect the ?rst purality of lines, portions
`of pairs of intersecting and successive parallel lines de
`?ning in?atable pockets of generally parallelogram con
`?guration, the plies being disconnected at the corners of
`each of said pockets to allow passage of air between
`any pocket and immediately adjacent pockets, the fabric
`when imperviously coated and in?ated being adapted to
`be readily ?exed along any of said lines.
`2. In a fabric for use in making in?atable articles, a
`pair of woven fabric plies positioned one against the
`other and directly connected by weaving along a ?rst
`plurality of spaced parallel lines and a second plurality
`of spaced parallel lines which intersect the ?rst plurality
`of lines, said lines being formed by yarns which are com
`mon to both plies, portions of pairs intersecting and
`successive parallel lines de?ning in?atable pockets of
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`8,008,214
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`generally parallelogram con?guration, the plies being dis
`connected at the corners of each of said pockets to allow
`passage of air between any pocket and immediately ad
`jacent pockets, each ply being provided with a substan
`tially coextensive, ?exible, air-impervious coating, the
`fabric when in?ated being adapted to be readily ?exed
`along any of said lines.
`‘
`3. ‘In a fabric for use in making in?atable articles, a
`pair of woven fabric plies positioned one against the
`other and directly connected by stitching along a ?rst
`plurality of spaced parallel lines and a second plurality
`of spaced parallel lines which intersect the ?rst plurality
`of lines, portions of pairs of intersecting and successive
`parallel lines de?ning in?atable pockets of generally par
`allelogram con?guration, the plies being disconnected at
`the corners of each of said pockets to allow passage of
`air between any pocket and immediately adjacent pockets,
`each ply being provided with a substantially coextensive;
`?exible, air-impervious coating, the fabric when in?ated
`being adapted to be readily ?exed along any of said lines.
`References Cited in the ?le of this patent
`UNITED STATES PATENTS
`Hardenbrook _________ __ Feb. 22, 1887
`Robeson .____; ________ __ June 18, 1918
`Dwight ______________ .. Aug. 22, 1922
`Wallwork ___________ __ May 24, 1949
`Goldberg ____________ .._ Feb. 21, 1950
`Morner ______________ __ Nov. 20, 1951
`Mauney et a1. _________ _._. May 1, 1956
`McCord et al. _________ __ Aug. 7, 1956
`Maris et al. ___________ __ Aug. 7, 1956
`Runton _____________ __ Oct.30, 1956
`FOREIGN PATENTS
`Great Britain _________ __ Mar. 14, 1933
`
`558,265
`1,269,746
`1,426,720
`2,471,380
`2,498,077
`2,575,764
`2,743,510
`2,757,434
`2,757,437
`2,768,420
`
`389,848
`
`INTEX EXHIBIT 2013, Pg. 5
`Bestway v. Intex; PGR2017-00003
`
`