CN1612819A - 由低抗张强度的纱线制成的气袋 - Google Patents
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Abstract
一种具有新型接缝结构的气袋缓冲垫,包括一个三针脚折边接缝结构或一个双针脚折边接缝结构。该新型接缝结构允许利用在约40cN/tex至65cN/tex范围内的低抗张强度的纱线制造气袋缓冲垫。
Description
发明背景
气袋系统是使用一个传感器,检测碰撞事件而工作的。碰撞触发一个充气器部件,使气袋缓冲垫在高压下膨胀。这个过程的结果使得气袋缓冲垫受到突然和猛烈的气体压力增加的作用,然后又受到汽车内的乘客作用在气袋缓冲垫上的外部压力的影响。为了使气袋缓冲垫能保护汽车内的乘客,气袋必需具有高的爆裂强度。
以前,作过各种尝试来制造强度高,耐用性好,和爆裂强度大的气袋缓冲垫。制造这种缓冲垫的一个通常采用的方法是使用抗张强度大于8.0克/旦尼尔(g/den)的高抗张强度的复丝。
日本未经审查的专利公开号4-5145号公布了一种非圆形的气袋,它由空心的织造织物制成,该织物在与经纱方向成45°偏角的方向上的轴线长度,相当于在经纱和纬纱方向上的轴线长度的70-95%。
日本未经审查的专利公开号4-43143号公布了一种由非圆形的空心织造织物件制成的气袋。该织物件的在与经纱或纬纱方向成一个偏角倾斜的方向上的轴线,比在织物件的经纱方向上的轴线长。
这些想法是根据这样的思路:即气袋缓冲垫爆裂的开始点在缓冲垫的圆周边缘部分的接缝连接部分上;并提供了由非圆形的机织织物件制成的缓冲垫。该织物件在偏移方向的轴线,比在经线或纬线方向上的轴线短,以增加接缝部分的爆裂强度。
美国专利5470106号说明了在包围充气器连接的区域上使用机织织物围裙,经改善爆裂强度。其他改善爆裂强度的措施包括使用粘接剂装置以增强气袋的较弱区域。美国专利5296278号提出,纱线拉伸强度小于8.0(g/den)(大约70cN/tex或厘牛顿/tex)的袋性能不好。这个文献还提出了在接缝处涂硅酮橡胶的方法,以防止涂层织物磨损,防止在接缝处破坏。
大多数改善气袋缓冲垫的爆裂强度的措施都集中在使用抗张强度高的纱线上,有时与一些增加接缝强度的其他装置或方法结合。然而,没有一种现有技术提供了具有新型接缝和低抗张强度纱线综合来形成高爆裂强度的气袋缓冲垫。在气袋缓冲垫应用中使用抗张强度低的纱线的一个优点是,一般抗张强度低的纱线的制造和购买成本比抗张强度高的纱线低。
发明目的
因此,本发明的一个目的是要提供一种使用抗张强度小于70cN/tex(厘牛/特),同时保持高的爆裂强度的纱线制造的气袋缓冲垫。
本发明的另一个目的是要提供一种具有新型的接缝结构的气袋缓冲垫,该结构可以利用低抗张强度纱线制造气袋缓冲垫,而不牺牲可接受的爆裂强度。
本发明还有一个目的要提供一种使用抗张强度小于70cN/tex,同时保持高的爆裂强度的纱线制造气袋缓冲垫的方法。
本发明再一个目的是要提供一种制造成本低,和克服其他气袋缓冲垫的某些常见缺点的气袋缓冲垫。
附图说明
参考以下的说明,附加的权利要求书和附图,将会更好地理解本发明的这些和其他特点,方面和优点。其中,
图1A为气袋缓冲垫上所用的传统的接缝结构的侧视图;
图1B为图1A所示的传统接缝结构的横截面图;
图1C为图1B所示的传统的接缝结构的放大的横截面图;
图2A为具有新型的三针脚折边的接缝结构的气袋缓冲垫的侧视图;
图2B为表示图2A所示的新型三针脚折边的接缝结构的横截面图;
图2C为图2B所示的新型三针脚折边的接缝结构的放大的横截面图;
图3A为图2A-2C所示的气袋缓冲垫的另一个实施例的侧视图。其中接缝方向相反;
图3B为表示方向相反的新型三针脚折边的接缝结构的横截面图;
图3C为表示方向相反的新型三针脚折边的接缝结构的放大的横截面图;
图4A为具有新型的三针脚折边的接缝的气袋缓冲垫的另一个实施例,其中,接缝的折边的部分在气袋的内面部分上;
图4B为表示图4A所示的新型三针脚折边的接缝的横截面图;
图4C为表示图4B所示的新型三针脚折边的接缝结构的放大的横截面图;
图5A为具有新型的双针脚折边的接缝的气袋缓冲垫的另一个实施例的侧视图;
图5B为表示图5A所示的新型的双针脚折边接缝的放大的横截面图;
图5C为表示图5B所示的新型的双针脚折边的接缝结构的放大的横截面图。
说明
一般,气袋缓冲垫包括至少二块织物片,每一块都有所希望的形状,它们缝在一起,形成一个三维的结构。图1A-图1C表示传统的双针链式针脚接缝结构10,它通常用作将形成气袋缓冲垫的织物坯料连接在一起的方法。第一块织物坯料12利用内针脚16和外针脚18与第三块织物坯料14连接。过去使用该双针链式针脚结构,因为单针脚的接缝强度不够,并且使用这种接缝结构的气袋的爆裂强度因爆裂强度太低而受损害。
该双针链式针脚接缝结构的一个问题是,由气袋充气器引起的高压力使接缝容易被剥离打开(这里称为剥开模式的状态)。图1C表示剥开模式中,在应力作用下的双针链式针脚的接缝结构。当由于充气压力作用缓冲垫膨胀时,内针脚接受最大的应力。该应力有时使内针脚形成的针穿透的孔易于受到获得的充气气体的热腐蚀。剥开模式时的接缝强度只等于织物强度的大约60%-70%。
为了改善双针链式针脚接缝结构的接缝强度,从而增加气袋缓冲垫的爆裂强度,在该接缝结构上加入第三个针脚20,如图2A-2C所示。如图所示,如同内针脚16和外针脚18一样,第三个针脚20将第一和第二块织物坯料连接在一起,而且以折叠方式将第一块织物坯料反过来连接在本身上。这种结构将接缝结构上的应力状态从剥开模式转换至剪切模式,使应力负荷在接缝内的多个针脚上散布,而不是由单一一个针脚承受全部应力负荷。这里称这三针脚折边接缝(或三针脚)的接缝结构,在接缝处具有100%的织物强度,并可保护内针脚16和外针脚18不受热气体腐蚀。这样,气体可能泄露的唯一区域,即内针脚16和外针脚18之间,被双层织物覆盖。
在图3A-3C中表示了可选实施例,其中,第二块织物片本身被折边,而不是如图2A-2C所示那样,第一块织物片被折边。图4A-4C表示三针脚折边的接缝结构的另一个可选实施例,其中,第二块织物片本身折边,并且折叠部分在缓冲垫内侧,而不是在气袋缓冲垫的外侧。图5A-5C表示新型的接缝结构的另一个实施例,它是双针脚折边的接缝。在这个实施例中,如图所示,不是在折边步骤之前用两条平行接缝连接织物坯料,而是利用一条接缝将织物坯料连接,然后利用折边的接缝将织物的接缝折叠和连接。
如上所述,利用三针脚折边的接缝或双针脚折边的接缝使得可以用抗张强度低的纱线制造气袋缓冲垫,而在现有气袋缓冲垫的应用中,是不可能使用这种低抗张强度的纱线的。因为三针脚和双针脚折边的接缝(统称为“剪切接缝”)大大增加了缓冲垫的接缝的强度,没有必要再使用抗张强度高的纱线来保持可接受的爆裂强度。
一种优选的纱线为聚酯。优选的抗张强度范围约为60cN/tex-35cN/tex。第二个优选的范围大约为50cN/tex-40cN/tex。最优选的范围为大约55cN/tex-45cN/tex。虽然公布了一种特定的纱线形式,但应理解,任何适当的纱线都可以使用。
下面的例子表示与爆裂强度有关的接缝的效果:
例1:使用传统针脚的低抗张强度与高抗张强度的比较
在喷水织机上,以每英寸40×40根的纱线结构的平纹组织织造抗张强度为5.1g/den(45cN/tex)的复丝620d聚酯纱线。然后,将织物轧光使得表面平滑,并用硅酮橡胶涂层,使重量为0.74OZ/sqxd(0.74盎司/平方码)。这种抗张强度低的织物和一般的630d尼龙6,6硅酮涂层的气袋织物的物理性质比较表示在下表中。
表1 气袋织物的物理性质
630d尼龙6,6气袋织物 | 620d-PET低抗张强度织物 | ||
纱线抗张强度 | g/den | 9.3 | 5.1 |
织物结构,W/F | 每英寸 | 41/40 | 40/40 |
织物总重量 | 盎司/平方码 | 8.06 | 6.89 |
添加涂层 | 盎司/平方码 | 1.1 | 0.74 |
抓样拉力,W/F | 磅/英寸 | 611/585 | 487/499 |
伸长,W/F | % | 35.1/37.1 | 38.4/35.2 |
切口撕裂,W/F | 磅 | 50/55 | 42.5/53 |
可燃性 | 英寸/分 | 没有燃烧速率 | 没有燃烧速率 |
最大刚性 | 磅 | 2.4 | 1.9 |
织物模量 | 磅/英寸 | 960 | 720 |
52升容积的系绳司机气袋是利用图1所示的典型的接缝方法,由上述二种织物制成。沿着周边,利用双针链式针脚缝制二个圆形的片。当如图所示,将袋内面翻出后,周边接缝成为剥开模式。
利用传统的双针链式针脚缝制方法,使用上述织物(一个缓冲垫用抗张强度高的纱线制造,另一个用抗张强度低的纱线制造)制造的气袋缓冲垫,利用220Kpa的司机充气器,进行静态和在负载下试验。如预期那样,尼龙6,6袋工作正常,但低抗张强度聚酯袋在周边接缝处受到热腐蚀,产生相当大的压力损失。
因为急剧的压力衰减(在45ms(毫秒)时<1.0磅/平方英寸),低抗张强度聚酯袋的有效约束功能丧失。尽管聚酯织物涂层,但纱线没有涂层的一侧很容易暴露在热作用下,因为抗张强度低的纱线接缝处伸长较大。另外,因为聚酯的热容量为1.5KJ/Kg.k,与之相比,尼龙的为1.7KJ/kg.k,因此希望保护接缝处纱线的没有涂层侧,并改善整个接缝。
例2:使用三针脚的缓冲垫性能(高抗张强度对低抗张强度)
在分别利用抗张强度低的聚酯纱丝和抗张强度高的尼龙6,6纱线织造的,由硅酮涂层织物制成的一组52升司机袋的基础上实现三针脚折边的接缝改造。如以前一样,利用同样的220Kpa司机充气器对这些袋进行静态和负荷下的试验。试验结果综合在下面的表2中。
表2 袋性能参数
袋形式 | 袋的平均峰值压力(磅/平方英寸) |
带有三针脚折边接缝的630d尼龙6,6(剪切接缝) | 10.85 |
630d尼龙6,6传统接缝(剥开接缝) | 9.5 |
带有三针脚折边接缝的620d PET(剪切接缝) | 11.9 |
620d PET传统接缝(剥开接缝) | <1.0 |
从能量吸收来看,用抗张强度低的纱线制成的新袋的约束功能等同于或好于由抗张强度高的纱线制成的传统气袋。肉眼检查袋没有发现在接缝处有热腐蚀的任何痕迹。
例3:落下试验
对于控制组,使用630d尼龙6,6以每英寸41×41根纱线的结构制造一组气袋缓冲垫;利用以每英寸40×40根纱线的结构,由抗张强度低(4.8g/den)的聚酯纱线620d织造的织物来制造第二组气袋缓冲垫。二组织物都在喷水织机上织造,并用硅酮涂层,涂层重量为0.7OZ/sq·yd(0.7盎司/平方码)。所有的聚酯缓冲垫具有如图3所示的三针脚折边接缝结构。这些试验所用的充气器为231Kpa充气器(在60升的容器中测试)。这种充气器在气袋工业中被认为是苛刻的充气器。
通过将一个重量为75磅的重块从6英尺高度落下到充气袋上,来进行对气袋的落下试验。面向该袋的重块的12英寸×24英寸的表面在水平面上,并且重块受约束,只能在垂直方向上下运动。记录重块的峰值减速度以及最大的回跳高度。
表3,利用充气器的落下试验(每次平均6个袋)
袋压力(Psi) | 最大的G | 回跳距离(英寸) | 压缩距离(英寸) | |
630d尼龙6,6气袋——传统接缝 | 10.2 | 20.8 | 27.5 | 5.84 |
620d低抗张强度PET气袋——三针脚折边接缝 | 11.4 | 16 | <10 | 5.43 |
确定气袋性能时,由气袋使其达到静止的物体所经历的峰值减速度是一个重要参数。用G(由重力引起的标准加速度的倍数)乘以物体重量测量的峰值减速度,给出了作用在物体上使其静止的力。另一个重要参数为在达到静止后,物体经受的回跳量。这个参数是对在物体达到静止后,由气袋给予物体的能量的量度,该参数在第二次可能的损伤(如颈椎受伤)中起作用。
虽然,已参照了一些优选实施例详细地说明了本发明,但也可以采用其他实施例。因此,所附权利要求书的精神和范围不应限于在此所述的优选实施例的说明。
Claims (36)
1、一种气袋缓冲垫,包括:
至少一个织物坯料,所述坯料包括抗张强度不大于约60cN/tex的复丝纱线。
2、如权利要求1所述的气袋缓冲垫,其特征在于,所述复丝纱线的抗张强度不大于约55cN/tex。
3、如权利要求1所述的气袋缓冲垫,其特征在于,所述复丝纱线的抗张强度不大于约50cN/tex。
4、如权利要求1所述的气袋缓冲垫,其特征在于,所述复丝纱线的抗张强度不大于约45cN/tex。
5、如权利要求1所述的气袋缓冲垫,其特征在于,所述复丝纱线的抗张强度不大于约40cN/tex。
6、如权利要求1所述的气袋缓冲垫,其特征在于,所述复丝纱线包括聚酯连续长丝纱线。
7、如权利要求6所述的气袋缓冲垫,其特征在于,所述聚酯连续长丝纱线在大约100至大约800旦尼尔的连续长丝纱线范围内。
8、如权利要求6所述的气袋缓冲垫,其特征在于,所述聚酯连续长丝纱线包括多根线性密度在每根长丝为大约2至大约6旦尼尔范围内的长丝。
9、如权利要求6所述的气袋缓冲垫,其特征在于,所述聚酯连续长丝纱线包括多根线性密度在每根长丝为大约4至大约6旦尼尔范围内的长丝。
10、如权利要求1所述的气袋缓冲垫,其特征在于,所述气袋缓冲垫还包括涂在至少一个表面上的涂层。
11、如权利要求10所述的气袋缓冲垫,其特征在于,所述涂层包括大约为0.5至2.0盎司/平方码的量的至少70%的硅酮树脂。
12、如权利要求1所述的气袋缓冲垫,还包括至少一个剪切接缝。
13、如权利要求11所述的气袋缓冲垫,其特征在于,所述接缝为三针脚折边接缝。
14、如权利要求11所述的气袋缓冲垫,其特征在于,所述接缝为双针脚折边接缝。
15、如权利要求1所述的气袋缓冲垫,其中所述连续长丝纱线是大约150旦尼尔的连续长丝纱线或大约150旦尼尔的倍数的连续长丝纱线;并且其中所述复丝纱线包括线性密度在每根长丝约为2至6旦尼尔范围内的多根长丝。
16、如权利要求1所述的气袋缓冲垫,还包括涂在织物的至少一个表面上的涂层,其中所述涂层量大约为0.2盎司/平方码至2.0盎司/平方码。
17、一种具有三针脚折边接缝的气袋缓冲垫。
18、一种具有双针脚折边接缝的气袋缓冲垫。
19、一种制造气袋缓冲垫的方法,所述方法包括下列步骤:
提供至少一块织物坯料;
形成包括所述至少一块织物坯料的三维气袋缓冲垫结构,其中所述气袋缓冲垫结构包括至少一个接缝;
其中所述接缝是由三针脚折边的接缝结构形成的。
20、如权利要求19所述的方法,还包括下列步骤:
提供第二块织物坯料,并通过使所述第一块织物坯料与所述第二块织物坯料连接,形成所述的三维结构。
21、如权利要求19所述的方法,还包括将涂层加在所述气袋缓冲垫的至少一个表面上的步骤。
22、如权利要求21所述的方法,其特征在于,所述涂层包括大约0.5至2.0盎司/平方码的量的至少70%的硅酮树脂。
23、如权利要求19所述的方法,其特征在于,所述至少一种织物坯料包括抗张强度不大于约60cN/tex的复丝纱线。
24、如权利要求19所述的方法,其特征在于,所述至少一块织物坯料包括抗张强度不大于约55cN/tex的复丝纱线。
25、如权利要求19所述的方法,其特征在于,所述至少一块织物坯料包括抗张强度不大于约50cN/tex的复丝纱线。
26、如权利要求19所述的方法,其特征在于,所述至少一块织物坯料包括抗张强度不大于约45cN/tex的复丝纱线。
27、如权利要求19所述的方法,其特征在于,所述至少一块织物坯料包括抗张强度不大于约40cN/tex的复丝纱线。
28、一种制造气袋缓冲垫的方法,所述方法包括下列步骤:
提供至少一块织物坯料;
形成包括所述至少一块织物坯料的三维气袋缓冲垫结构,其中,所述气袋缓冲垫结构包括至少一个接缝;并且
其中所述接缝是由双针脚折边的接缝结构形成的。
29、如权利要求28所述的方法,还包括下列步骤:
提供第二块织物坯料,并通过使所述第一块织物坯料与所述第二块织物坯料连接,形成所述的三维结构。
30、如权利要求28所述的方法,还包括将涂层加在所述气袋缓冲垫的至少一个表面上的步骤。
31、如权利要求30所述的方法,其特征在于,所述涂层包括大约0.5至2.0盎司/平方码的量的至少70%的硅酮树脂。
32、如权利要求28所述的方法,其特征在于,所述至少一种织物坯料包括抗张强度不大于约60cN/tex的复丝纱线。
33、如权利要求28所述的方法,其特征在于,所述至少一块织物坯料包括抗张强度不大于约55cN/tex的复丝纱线。
34、如权利要求28所述的方法,其特征在于,所述至少一块织物坯料包括抗张强度不大于约50cN/tex的复丝纱线。
35、如权利要求28所述的方法,其特征在于,所述至少一块织物坯料包括抗张强度不大于约45cN/tex的复丝纱线。
36、如权利要求28所述的方法,其特征在于,所述至少一块织物坯料包括抗张强度不大于约40cN/tex的复丝纱线。
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2002
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- 2002-12-18 EP EP02794313A patent/EP1463655A4/en not_active Withdrawn
- 2002-12-18 CN CNB028269497A patent/CN100423970C/zh not_active Expired - Lifetime
- 2002-12-18 JP JP2003559830A patent/JP2005514267A/ja active Pending
- 2002-12-18 AU AU2002359754A patent/AU2002359754A1/en not_active Abandoned
- 2002-12-18 KR KR10-2004-7010621A patent/KR20040068615A/ko not_active Application Discontinuation
- 2002-12-18 WO PCT/US2002/040668 patent/WO2003059702A1/en active Application Filing
-
2004
- 2004-03-24 US US10/808,198 patent/US7287478B2/en not_active Expired - Fee Related
Also Published As
Publication number | Publication date |
---|---|
EP1463655A1 (en) | 2004-10-06 |
AU2002359754A1 (en) | 2003-07-30 |
US20030134066A1 (en) | 2003-07-17 |
US20040232682A1 (en) | 2004-11-25 |
US7413214B2 (en) | 2008-08-19 |
KR20040068615A (ko) | 2004-07-31 |
EP1463655A4 (en) | 2010-10-27 |
WO2003059702A1 (en) | 2003-07-24 |
JP2005514267A (ja) | 2005-05-19 |
US7287478B2 (en) | 2007-10-30 |
CN100423970C (zh) | 2008-10-08 |
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