(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2007/0040368 A1
`Manley
`(43) Pub. Date:
`Feb. 22, 2007
`
`US 20070040368Al
`
`(54) ONE-PIECE WOVEN AIRBAG WITH
`TETHERS
`
`Publication Classification
`
`(75)
`
`Inventor: Scott Manley, Gray Court, SC (US)
`
`Correspondence Address,
`DORITY & MANNING, P.A.
`POST OFFICE BOX 1449
`
`(51)
`
`Int. Cl.
`(200701)
`360R 21/23
`(2007.01)
`B60R 21/213
`(52) U.s. Cl.
`................................... .. 280/743.2; 280/730.2
`
`(57)
`
`ABSTRACT
`
`GREENVILLE’ SC 29602-1449 (US)
`
`Air bags for Vehicles and processes for making the air bags
`
`<7»
`
`(21) Appl. No‘,
`
`.
`
`I
`'
`gles’ nc
`11/504,214
`
`(22)
`
`Filed;
`
`Aug_ 15, 2006
`
`Related US, Application Data
`
`(60) Provisional application No. 60/708,204, filed on Aug.
`15, 2005.
`
`bag to the other side of the air bag and control the inflation
`characteristics ofthe bag. The tethers are integral with the air
`bag such that they are integrated into a woven pattern used
`to form the bag. The tethers can comprise yarn tethers or
`fabric tethers. In one embodiment, for instance, a one-piece
`air bag is disclosed that is formed from warp yarns and fill
`yarns that are not only used to construct the woven air bag
`but are also used to construct tethers incorporated into the
`bag.
`
`10
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`INTEX EXHIBIT 2024, Pg. 1
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`Bestway v. Intex; PGR2017-00003
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`INTEX EXHIBIT 2024, Pg. 1
`Bestway v. Intex; PGR2017-00003
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`

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`Patent Application Publication Feb. 22, 2007 Sheet 1 of 5
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`US 2007/0040368 A1
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`INTEX EXHIBIT 2024, Pg. 2
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`Bestway v. Intex; PGR2017-00003
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`INTEX EXHIBIT 2024, Pg. 2
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`

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`Bestway v. Intex; 0000000000 03
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`INTEX EXHIBIT 2024, Pg. 3
`Bestway v. Intex; PGR2017-00003
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`Bestway v. Intex; 0000000000 03
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`INTEX EXHIBIT 2024, Pg. 4
`Bestway v. Intex; PGR2017-00003
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`Patent Application Publication Feb. 22, 2007 Sheet 4 of 5
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`US 2007/0040368 A1
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`"“‘“”1:
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`Patent Application Publication Feb. 22, 2007 Sheet 5 of 5
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`US 2007/0040368 A1
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`10
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`FIG. 6
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`INTEX EXHIBIT 2024, Pg. 6
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`Bestway v. Intex; PGR2017-00003
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`INTEX EXHIBIT 2024, Pg. 6
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`

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`US 2007/0040368 A1
`
`Feb. 22, 2007
`
`ONE-PIECE WOVEN AIRBAG WITH TETHERS
`
`RELATED APPLICATIONS
`
`[0001] The present application is based upon and claims
`priority to U.S. Provisional Patent Application having Ser.
`No. 60/708,204, filed on Aug. 15, 2005.
`
`BACKGROUND OF THE DISCLOSURE
`
`[0002] Within a passenger compartment of a vehicle,
`many occupant restraint systems can be utilized, such as
`seatbelts and air bag systems. For instance, air bag systems
`can supplement the protection offered by seatbelts. Air bag
`systems typically comprise at least one folded air bag and an
`inflation gas. The air bag system is designed to inflate the air
`bag with the inflation gas when a collision between the
`vehicle and another object is detected.
`
`[0003] Traditional air bag systems include driver side air
`bags, passenger side airbags, and side-impact air bags.
`Driver side air bags are normally located in the steering
`column of the vehicle and passenger side air bags are
`typically located in the dash board. Side-impact air bags
`include side cushion air bags,
`typically mounted in the
`outboard side of the seat, and side curtain air bags, which are
`usually stored in the roof line and connected along the door
`frame.
`
`[0004] Driver side and passenger side air bags often
`include vent holes to expel
`the inflation gas relatively
`quickly after inflation. Side-impact air bags,
`in contrast,
`remain inflated over long periods of time in order to offer
`prolonged protection in events such as roll-over crashes.
`
`[0005] Usually, air bags are made of a woven fabric due to
`the substantial force the air bag must sustain from the
`inflating gas during deployment. Many different materials,
`either coated or uncoated, have been utilized in the manu-
`facture of air bags, for example as described in U.S. Pat.
`Nos. 5,881,776 and 6,632,753, both of which are incorpo-
`rated by reference herein.
`
`[0006] Air bags in the past have been made using various
`techniques and processes. For example, in some applica-
`tions, air bags are made by sewing together various panels.
`In other applications, instead of being made from separate
`panels, the air bags are made in a single weaving operation
`using, for instance, a Jacquard loom. Jacquard looms, for
`example, are capable of weaving together an air bag includ-
`ing a first side separated from a second side joined by a
`woven seam in one single operation. Such air bags are
`known in the art as “one-piece woven” air bags.
`
`[0007] Air bags often require the inclusion of some feature
`that is present to shape the air bag into a desired dimension
`upon inflation. For instance, air bags often include tethers to
`limit the volume the air bag encompasses upon deployment.
`Tethers are utilized to prevent the air bag from “ballooning”
`in undesired areas. The tethers may be located internally or
`externally. Normally, the tethers are sewn into the air bag,
`either between the air bag layers or on the surface, after the
`air bag has been sewn.
`
`[0008] Typically, air bags incorporating tethers are con-
`structed by a cut and sew method. For example, in order to
`incorporate tethers into air bags, tethers are typically sewn
`
`into the bag manually. Thus, the incorporation of tethers into
`air bags tends to be not only labor intensive, but also requires
`a significant amount of time.
`
`[0009] Lobes are often utilized to shape the air bags also.
`In lobed air bags, a seam is sewn or woven at various
`locations along the air bag sealing the first side to the second
`side in order to restrict the volume of the air bag upon
`deployment. Although incorporating lobes into air bags may
`be useful in some applications, the lobes have a tendency to
`form a non-uniform product when inflated. Thus, some
`lobed air bags do not create a uniform surface for contact
`with a passenger during vehicle accidents thus possibly
`reducing the amount of protection provided to the passenger.
`
`In addition, the seams that are woven into the air
`[0010]
`bags to form the lobes can create stress points in the product
`during inflation. These concentrated stress areas may cause
`unwanted gas leakage along the seams. Thus,
`in some
`embodiments,
`it
`is desirable to reduce or eliminate the
`number of seams contained within the product.
`
`In view of the above, a need currently exists for an
`[0011]
`improved air bag in which tethers are constructed integral
`with the bag. Specifically, a need exists for an air bag
`containing tethers and for a process for producing the air bag
`in which the tethers are woven into the product as the bag
`itself is being woven. In this manner, the air bag may be
`formed containing tethers without any separate processing
`steps, such as a separate cut and sew process.
`
`SUMMARY
`
`In general, the present disclosure is directed to an
`[0012]
`air bag that has tethers that have been integrally formed with
`the air bag. The tethers can be, for instance, yarn tethers or
`fabric tethers. The air bag can be made from a one-piece
`woven fabric in which the tethers are integrated into the
`weave pattern used to form the bag.
`
`In one embodiment, for instance, the present dis-
`[0013]
`closure is directed to an air bag including a first side spaced
`from a second side defining a gas inflatable volume ther-
`ebetween. The first side and the second side, for instance,
`may comprise woven materials. In accordance with the
`present disclosure, at least one tether extends from the first
`side of the air bag to the second side. The tether is integral
`with the first and second sides.
`
`[0014] For example, in one embodiment, the tether can be
`attached to the first side of the air bag by at least one tack
`point and can also be attached to the second side of the air
`bag by at least one tack point. The tether may comprise a
`yarn tether. For instance, in one embodiment, the air bag can
`be made from warp yarns and fill yarns and can include a
`plurality of tethers that are constructed from the fill yarns
`only, from the warp yarns only, or from a combination of fill
`yarns and warp yarns. When present, the yarn tethers can be
`uniformly distributed across the interior of the air bag.
`Alternatively, however, the yarn tethers may be non-uni-
`formly distributed across the bag and may be concentrated
`in certain areas.
`
`In addition to yarn tethers, air bags can be made
`[0015]
`according to the present disclosure including woven fabric
`tethers. In this embodiment, for instance, the air bag can
`have a one-piece construction and can be made from warp
`yarns and fill yarns. The warp yarns and fill yarns that are
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`US 2007/0040368 A1
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`Feb. 22, 2007
`
`used to form the air bag can also be used to form woven
`fabric tethers within the bag. In one particular embodiment,
`the air bag comprises a Jacquard woven bag.
`
`[0016] Air bags made according to the present disclosure
`may be uncoated or coated. In one embodiment, for instance,
`a coating may be applied to the exterior surface of the air bag
`in order to reduce the permeability of the first and second
`sides. In general,
`for instance,
`the air bag can have a
`permeability of less than about 4 cfm, such as from about 0.5
`cfm to about 3 cfm.
`
`[0017] The air bag can be made from any suitable mate-
`rials. For instance, in one embodiment, the air bag can be
`made from spun yarns, monofilament yarns, multifilament
`yarns, or combinations thereof. In one particular embodi-
`ment, for example, the air bag can be constructed from nylon
`multifilament yarns having a denier of from about 210 to
`about 630.
`
`[0018] The tethers that are integrated into the air bag can
`have any suitable length. For instance, the tethers can have
`a length of from about one-half inch to about 20 inches, such
`as from about 2 inches to about 12 inches. The number of
`
`tethers present within the air bag can also vary depending
`upon the particular application. In general, suflicient tethers
`should be incorporated into the bag so that the tethers can
`withstand the force of an inflation gas.
`
`[0019] Further aspects and features of the present disclo-
`sure are discussed in greater detail below.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`[0020] A full and enabling disclosure of the present inven-
`tion, including the best mode thereof to one of ordinary skill
`in the art, is set forth more particularly in the remainder of
`this specification, including reference to the accompanying
`figures in which:
`
`[0021] FIG. 1 depicts a perspective view of an inflated
`side-curtain air bag;
`
`[0022] FIG. 2 depicts a perspective view of one embodi-
`ment of the present disclosure with yarn tethers integrated
`into a one-piece air bag, woven between a first side and a
`second side.
`
`[0023] FIG. 3A depicts a cross-sectional view of one
`embodiment of the present disclosure illustrating yarn teth-
`ers integrated into a one-piece air bag, woven in the fill
`direction between a first side and a second side.
`
`[0024] FIG. 3B depicts a cut-away top view of one
`embodiment of the present disclosure illustrating yarn teth-
`ers integrated into a one-piece air bag, woven in the fill
`direction between a first side and a second side.
`
`[0025] FIG. 4A depicts a cross-sectional view of one
`embodiment of the present disclosure illustrating tethers
`integrated into a one-piece air bag, woven in the warp
`direction between a first side and a second side.
`
`[0026] FIG. 4B depicts a cut-away top view of one
`embodiment of the present disclosure illustrating yarn teth-
`ers integrated into a one-piece air bag, woven in the warp
`direction between a first side and a second side.
`
`[0027] FIG. 5A depicts a cross-sectional view of one
`embodiment of the present disclosure illustrating yarn teth-
`
`ers integrated into a one-piece air bag, woven in both the
`warp and fill directions between a first side and a second
`side.
`
`FIG. 5B depicts a cut-away top view of one
`[0028]
`embodiment of the present disclosure illustrating yarn teth-
`ers integrated into a one-piece air bag, woven in both the
`warp and fill directions.
`
`FIG. 6 depicts a perspective view of one embodi-
`[0029]
`ment of the present disclosure illustrating fabric tethers
`integrated into a one-piece air bag woven in either the warp
`or fill direction.
`
`DETAILED DESCRIPTION
`
`[0030] Reference now will be made in detail to various
`embodiments of the disclosure, one or more examples of
`which are set forth below. Each example is provided by way
`of explanation of the disclosure, not limitation of the dis-
`closure. In fact, it will be apparent to those skilled in the art
`that various modifications and variations can be made in the
`
`present disclosure without departing from the scope or spirit
`of the disclosure. For
`instance,
`features illustrated or
`described as part of one embodiment, can be used on another
`embodiment to yield a still further embodiment. Thus, it is
`intended that the present disclosure covers such modifica-
`tions and variations.
`
`In general, the present disclosure is directed to a
`[0031]
`one-piece woven air bag in which tethers are woven directly
`into the air bag between a first side and a second side by a
`weaving device. For example, in the one embodiment, the
`air bag is woven on a weaving device in which yarn or fabric
`tethers are woven between the two layers of the air bag. In
`this manner, the tethers become integral with the air bag as
`the air bag is being formed. In one embodiment, the air bag
`containing the tethers is formed by a Jacquard loom weaving
`device. It should be understood, however, that any suitable
`weaving device may be used that is capable of weaving a
`one-piece woven air bag with internally integrated tethers.
`
`[0032] The term “one-piece woven” hereinafter refers to
`an air bag that is constructed on a weaving apparatus in
`essentially one process step. For example, one-piece air bags
`may be formed on a weaving device that is capable of
`continuously and simultaneously forming air bags having a
`first side joined with a second side by a seam. In accordance
`with the present disclosure,
`the one-piece air bags may
`further include tethers that are integrated into the air bag
`structure during the weaving process. One-piece air bags
`may be coated with a chemical composition or uncoated in
`order to control the permeability or other physical properties
`of the bag.
`
`[0033] The term “tethers” hereinafter refers to any fiber,
`yarn, or fabric attached to both the first side and the second
`side of the air bag, which serves the purpose for shaping the
`air bag to the desired dimensions upon inflation. Further-
`more, the term “yam tethers” further describes “tethers” that
`are formed from unwoven yarns. The term “fabric tethers”
`also further describes “tethers” indicating that the tethers are
`formed from a woven material.
`
`[0034] Referring to FIG. 1, one embodiment of a deployed
`side-curtain air bag 10 is illustrated that may be constructed
`according to the present disclosure. Directional arrows 3A
`and 4A are shown to illustrate the direction in which the
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`INTEX EXHIBIT 2024, Pg. 8
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`INTEX EXHIBIT 2024, Pg. 8
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`

`

`US 2007/0040368 A1
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`Feb. 22, 2007
`
`tethers are woven into the air bag as will be described in
`more detail below. In FIG. 1, 3A depicts the fill direction and
`4A depicts the warp direction.
`
`[0035] Air bags constructed in accordance with the present
`disclosure that contain tethers integral with the construction
`of the bag offer many advantages and benefits. One advan-
`tage is that production can be completed in fewer steps
`without having to incorporate the tether into the bags in a
`separate operation. Furthermore, since the tethers are inte-
`grated into the weave pattern, the process can be completely
`automated.
`
`In addition, one-piece woven air bags containing
`[0036]
`tethers that have been woven into the bag may be produced
`without containing any sewn seams. Sewn seams cannot
`only produce more of a weakened stress point in the bag but
`may also adversely affect the gas holding properties of the
`bag.
`
`In one embodiment, air bags can be constructed
`[0037]
`containing tethers without having to also utilize lobes to
`direct the air bag’s shape thus perhaps creating a flatter
`surface during impact. It should be understood, however,
`that lobes may also be present in the air bag in combination
`with the tethers.
`
`[0038] Referring to FIGS. 2, 3A and 3B, one embodiment
`of an air bag 10 containing yarn tethers 20 is illustrated. As
`shown,
`in this embodiment,
`the tethers 20 comprise
`unwoven yarn that extends in between a first side 22 and a
`second side 24 of the air bag 10.
`In the embodiment
`illustrated in FIGS. 2, 3A and 3B, the yarn tethers are woven
`into the air bag 10 in the fill direction Y between the first side
`22 and the second side 24.
`
`[0039] The first side 22 and second side 24 are joined by
`a seam along the perimeter of the air bag (not shown). In
`accordance with the present disclosure, the tethers 20 are
`formed in between the first side 22 and the second side 24
`
`of the air bag 10 while the air bag itself is being woven. For
`example, in one embodiment, the air bag 10 may comprise
`a one-piece air bag containing the tethers 20.
`
`[0040] The tethers 20 may be formed in the air bag 10
`using any suitable method or process. In one particular
`embodiment, for instance, the tethers 20 may be woven into
`the air bag 10 using a suitable weaving device, such as a
`Jacquard loom. A Jacquard loom utilizes a highly versatile
`pattern mechanism to permit the production of large, intri-
`cate weaves. A Jacquard loom is capable of controlling the
`action of individual warp yarns or relatively small groups of
`warp yarns during the passage of each pick or fill. In this
`manner, very complex weave patterns can be produced. In
`fact, weave patterns can be made that when removed from
`the loom have a 3-dimensional configuration in the X, Y, and
`Z-planes. In accordance with the present disclosure, with
`proper manipulation and designing of a weave pattern, a
`Jacquard loom can be utilized to weave a one-piece air bag
`with tethers integrated into the bag and extending in between
`the two sides of the bag.
`
`[0041] For example, the Jacquard loom can be placed in
`association with a controller. The controller, which may
`comprise a microprocessor such as a computer, may be
`preprogrammed with an appropriate Jacquard pattern for
`forming air bags in accordance with the present disclosure.
`
`Specifically, various software is commercially available that
`may be used in conjunction with a Jacquard weaving device.
`
`[0042] The Jacquard weaving device, in one embodiment,
`may include a plurality of cords which are in control of the
`warp yarns. In one embodiment, for example, each indi-
`vidual warp yarn or group of warp yarns may be connected
`to a separate and corresponding cord. The cords are adapted
`to lift selected warp yarns at predetermined times during the
`weaving operation. When selected warp yarns are lifted, a
`“shed” is formed through which the fill yarns are inserted.
`By controlling each individual warp yarn or group of warp
`yarns during the weaving process, intricate 3-dimensional
`woven patterns can be formed, such as one-piece air bags
`containing integrated tethers.
`
`In the embodiments illustrated in FIGS. 2, 3A and
`[0043]
`3B, the yarn tethers 20 comprise fill yarns that are woven
`into the air bag 10 in the cross-machine direction, opposite
`the direction of the warp yarns. As shown, the yarn tethers
`20 extend from the first side 22 to the second side 24. More
`
`particularly, each yarn tether 20 is woven into the first side
`22 of the air bag 10 for a predetermined distance to form a
`tack point and then extends to the second side 24 of the air
`bag 10. The yarn tether is then woven into the second side
`24 of the air bag 10 for a predetermined distance to form
`another tack point and is then once again directed to the first
`side 22. In this embodiment, this process is repeated causing
`the tether yarn 20 to extend in between the two sides of the
`air bag in a zig-zag pattern.
`
`[0044] During production of the air bag 10 as shown in
`FIG. 2, various fill yarns are selected to serve as the yarn
`tethers 20. For example, in one embodiment, from about
`every second fill yarn to about every fiftieth fill yarn or
`greater may be utilized as a yarn tether. For example, in one
`particular embodiment, approximately from every third yarn
`to every tenth yarn may be utilized as a yarn tether. In one
`particular embodiment, for example, approximately every
`fifth fill yarn may be utilized as a yarn tether.
`
`[0045] The yarn tethers 20 as shown in FIG. 2 may have
`any desired length. As used herein, the length of a tether
`refers to the distance the tether separates a first side of the
`air bag from a second side. The length of a tether may
`depend on various different factors, including the type of air
`bag being constructed and the amount of inflation that is
`desired. For instance, the tethers may have a length such that
`the air bag when inflated provides suflicient protection to an
`occupant. The tethers, however, may be limited in size so as
`not to require a relatively large amount of gas generation to
`properly pressurize the air bag for an unnecessarily larger
`volume. In general, the length of the yarn tethers may be
`from about one-half inch to about twenty inches in length.
`For instance, in one embodiment, the tethers may have a
`length of from about
`two inches to about eight
`inches
`between tack points.
`
`[0046] The number of yarn tethers may also vary dramati-
`cally depending upon the particular application and the
`desired results. In general, enough yarn tethers may be
`incorporated into the air bag so as to withstand the force of
`the inflation gas.
`
`FIG. 3B illustrates one embodiment in which the
`[0047]
`tethers are distributed relatively uniformly in the fill direc-
`tion Y throughout the air bag. However, since a Jacquard
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`US 2007/0040368 A1
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`Feb. 22, 2007
`
`loom has the ability to control each warp yarn or group of
`warp yarns, the tethers are not necessarily woven into the
`bag uniformly. Tethers may be placed at any position of the
`air bag in order to shape the air bag into any inflated
`dimension desired. Further, the tethers may be uniformly
`distributed across the thickness of the air bag as shown in
`FIGS. 2, 3A and 3B or may be present in the air bag in a
`non-uniforrn manner. For example, in one embodiment, a
`collection of yarn tethers may be concentrated at certain
`areas of the air bag surrounded by areas where no tethers
`exist.
`
`[0048] The materials used to construct the air bag 10 as
`shown in FIGS. 2, 3A and 3B may also vary depending upon
`the particular application. For instance, the air bag 10 may
`be woven from any suitable material such as natural fibers
`including cotton, wool, linen, rarnie, hemp, and the like or
`synthetic fibers including polyester, polyamides,
`rayon,
`polyolefin, acrylic, and the like. As used herein, the term
`“yam” may refer to a single filament yarn, a multi-filament
`yarn, a spun yarn, and the like.
`
`In one embodiment, the yarns of which the air bag
`[0049]
`is constructed may comprise multifilament nylon yarn. The
`multi-filament nylon yarns may have any suitable denier,
`such as a denier up to about 630. Adjusting the denier of the
`yarn affects various properties of the air bag. For example,
`smaller yarn sizes can produce an air bag that may be easier
`to pack in an air bag compartment of a vehicle. For instance,
`smaller yarn sizes may produce a fabric with better pack-
`ability properties. In addition to packability properties, the
`denier of the yarns may also impact the permeability of the
`material. For example, smaller yarn sizes generally tend to
`decrease the air permeability of the woven fabric.
`
`In one embodiment, the multi-filament nylon yarns
`[0050]
`have a size of less than about 630 denier such as from about
`
`630 denier to about 210 denier or less. For example, in
`various embodiments, the nylon yarn may have a size of
`approximately 315 denier with approximately 140 filaments,
`resulting in a denier per filament (DPF) linear density of
`approximately 2.25. Alternatively, a higher DPF linear den-
`sity air bag may be constructed of nylon yarns that have a
`size of approximately 315 denier with approximately 70
`filaments (6 DPF).
`
`[0051] The desired permeability of the first and second
`sides of the air bag may vary. For instance, a side-curtain air
`bag is required to remain inflated for longer than a driver-
`side or passenger-side air bag. This is to allow greater
`protection in side-impact crashes and during vehicle roll-
`overs.
`
`[0052] One test for permeability is referred to as the “leak
`down” test. During a leak down test, the air bag is inflated
`to a particular pressure. After a period of time, the pressure
`in the air bag is then recorded to determine the pressure drop
`during the time interval. For example, in one embodiment,
`a side curtain air bag may be inflated to a pressure of 13 psi.
`Seven seconds after being inflated to the above pressure, the
`remaining pressure in the bag may be determined. For side
`impact air bags, for instance, after seven seconds, the air bag
`should retain at least about 60% of the original pressure,
`such as at
`least about 80% of the original pressure. If
`desired, the air bag may be coated with a chemical compo-
`sition, such as a polymer, in order to control the permeability
`of the bag.
`
`In one embodiment, the weave construction of the
`[0053]
`first side 22 and second side 24 comprises about a 60x60
`plain weave for 315 denier nylon construction or about
`48><48 plain weave for 420 denier nylon construction. It
`should be understood, however, that the above described
`weave construction is merely exemplary and that various
`weave patterns, weave densities, yam sizes, and yarn mate-
`rials may be used to construct air bags in accordance with
`the present disclosure.
`
`[0054] Referring to FIGS. 4A and 4B, another embodi-
`ment of an air bag 10 made in accordance with the present
`disclosure is illustrated. In this embodiment, the air bag 10
`includes a first side 22 spaced from a second side 24 by a
`plurality of yarn tethers 30. The yarn tethers 30 instead of
`comprising fill yams in this embodiment comprise warp
`yarns. The warp yarn tethers 30 are woven into the air bag
`in the warp direction X.
`
`FIG. 4B illustrates one embodiment in which the
`[0055]
`tethers are distributed relatively uniformly throughout the air
`bag. Again, since a Jacquard loom has the ability to control
`each warp yarn or group of warp yarns, the tethers are not
`necessarily woven into the bag uniformly. Tethers could be
`placed at any position of the air bag in order to shape the air
`bag into any inflated dimension desired.
`
`[0056] When forming the air bag 10 as shown in FIGS. 4A
`and 4B, the warp yarns may be fed into the weaving process
`from a beam. When the warp yarns are used to form yam
`tethers, differences in tension across the warp beam may be
`experienced since the warp yarns used to form the tethers
`require less amounts of yarn than when the yarns are used to
`form the woven first side 22 and second side 24. Thus, when
`the warp yarns are used to form tethers, various processing
`techniques may be needed in order to ensure that the warp
`yarns are consumed by the weaving process at a similar rate
`over the repeat of the weave.
`
`In an alternative embodiment, each of the warp
`[0057]
`yarns may be used to form a yarn tether at different times in
`order to maintain constant tension. Alternating the yarns to
`form the yarn tethers ensures that equal amounts of warp
`yarn are used across the warp beam. Of course, in some
`embodiments, yarn tension may not be an issue during the
`weaving process.
`
`still another
`[0058] Referring to FIGS. 5A and 5B,
`embodiment of an air bag 10 made in accordance with the
`present disclosure is shown. Specifically, FIGS. 5A-5B
`illustrate a cross-sectional and cut-away view of an air bag
`10 according to the present invention in which yam tethers
`20 and 30 are woven into the air bag in both the fill and warp
`directions X and Y. FIG. 5B illustrates one embodiment in
`
`which the tethers are distributed relatively uniformly
`throughout the air bag. Again, since a Jacquard loom has the
`ability to control each warp yarn or group of warp yarns, the
`tethers are not necessarily woven into the bag uniformly.
`Tethers could be placed at any position of the air bag in order
`to shape the air bag into any inflated dimension desired or to
`provide additional strength in any needed areas.
`
`In addition to yarn tethers, air bags may be made
`[0059]
`according to the present invention containing fabric tethers.
`In this embodiment, the tethers comprise a woven fabric
`made from, for instance, a combination of warp and fill
`yarns. The fabric tethers may comprise a tightly woven
`
`INTEX EXHIBIT 2024, Pg. 10
`
`Bestway v. Intex; PGR2017-00003
`
`INTEX EXHIBIT 2024, Pg. 10
`Bestway v. Intex; PGR2017-00003
`
`

`

`US 2007/0040368 A1
`
`Feb. 22, 2007
`
`fabric or may comprise a mesh material. For example, FIG.
`6 illustrates one embodiment of the present disclosure in
`which fabric tethers 40 are integrated into the air bag 10,
`woven between a first side 22 and a second side 24 of the air
`
`bag. The fabric tethers 40 may be woven in either the warp
`direction or the fill direction.
`
`[0060] While the fabric tethers 40 are typically con-
`structed of the same material as sides 22 and 24, they are not
`necessarily woven in the same weave pattern. For instance,
`the weave may be a relatively loose weave in comparison to
`the weave of the air bag layers.
`
`[0061] While FIG. 6 illustrates the fabric tethers 40 woven
`in a relatively uniform pattern, the fabric tethers 40 may be
`placed at any position in the air bag in order to shape the air
`bag to a desired inflated dimension. In fact, fabric tethers
`may be able to withstand higher tensile forces than yarn
`tethers due to a higher density of material. As such, fewer
`fabric tethers may be required to withstand the overall
`tensile stress impacted on the tethers during the rapid
`inflation that occurs when the air bag is deployed.
`
`In another embodiment of the present invention,
`[0062]
`both yarn and fabric tethers 20 or 30 and 40 are woven
`directly into the air bag. Either the yarn or the fabric tethers
`may be woven into the air bag in either the warp or fill
`directions. For example, a combination of yarn tethers and
`fabric tethers may be used in order to provide an optimum
`combination of strength and air permeability.
`
`[0063] Upon construction of a one-piece woven air bag
`with woven tethers internally integrated, the air bag may be
`coated with any suitable coating if needed by any suitable
`method. Typical coating methods include spraying, printing
`such as
`rotogravure printing, dip-coating,
`slot-coating,
`extrusion, and the like. In general, any suitable chemical
`compound, such as a polymer, may be applied to the air bag
`to control air permeability. Typical coating compounds
`include silicon, urethane, neoprene, and the like. In one
`embodiment,
`the air bag is dip-coated with silicon after
`weaving.
`
`[0064] These and other modifications and variations to the
`present invention may be practiced by those of ordinary skill
`in the art, without departing from the spirit and scope of the
`present invention. In addition, it should be understood that
`aspects of the various embodiments may be interchanged
`both in whole or in part. Furthermore, those of ordinary skill
`in the art will appreciate that the foregoing description is by
`way of example only, and is not
`intended to limit the
`invention.
`
`What is claimed is:
`
`1. An air bag comprising:
`
`a first side spaced from a second side defining a gas
`inflatable volume therebetween, the first side and the
`second side comprising woven materials; and
`
`at least one tether extending from the first side to the
`second side, the tether being integral with the first and
`second sides.
`
`2. An air bag as defined in claim 1, wherein the air bag
`comprises a one-piece air bag.
`
`3. An air bag as defined in claim 1, wherein the tether is
`attached to the first side of the air bag by at least one tack
`point and is also attached to the second side of the air bag
`by at least one tack point.
`4. An air bag as defined in claim 3, wherein at least one
`tether comprises a warp yarn tether.
`5. An air bag as defined in claim 3, wherein at least one
`tether comprises a fill yarn tether.
`6. An air bag as defined in claim 3, wherein the air bag
`includes a plurality of yarn tethers, a first port