CN1153698C - 包含缝合加固接缝的焊接气囊垫体 - Google Patents

包含缝合加固接缝的焊接气囊垫体 Download PDF

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CN1153698C
CN1153698C CNB00812924XA CN00812924A CN1153698C CN 1153698 C CN1153698 C CN 1153698C CN B00812924X A CNB00812924X A CN B00812924XA CN 00812924 A CN00812924 A CN 00812924A CN 1153698 C CN1153698 C CN 1153698C
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R���ߵ���ɳ�ؿ�
R·凯沙瓦拉伊
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
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    • B60R21/16—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
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    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
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    • B29C66/232—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations said joint lines being multiple and parallel, i.e. the joint being formed by several parallel joint lines
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    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
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    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
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    • B60R2021/23504—Inflatable members characterised by their material characterised by material
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  • Engineering & Computer Science (AREA)
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  • Treatment Of Fiber Materials (AREA)
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Abstract

本发明涉及一种应用焊接的方法，用缝合接缝加固，将两相邻织物粘结在一起，形成一个可充气垫体。虽然缝合接缝在多层织物之间提供了更好且更容易制造的附着点，不用说这种改进的方式减少了空气或气体在这些附着点的渗透，邻近这些焊接区域的缝合接缝的应用提供了更强的加固，因而形成更可靠的非渗透性织物。接缝焊接通常涉及使织物下侧的薄膜与第二层膜处理过的织物相接触并处于高频能量下，从而在两层织物之间的附着点处形成聚合材料焊珠。如果形成的聚合材料焊珠的尺寸足以使织物层之间彻底地密封和附着的话，使用低数量的缝合接缝即可产生充分的加固。本发明包含该具体的加固织物以及大尺寸焊珠焊接的气囊织物。

Description

包含缝合加固接缝的焊接气囊垫体
技术领域
本发明涉及一种应用焊接的方法，用缝合接缝加固，将两相邻织物粘结在一起，形成一个可充气垫体。虽然缝合接缝在多层织物之间提供了更好且更容易制造的附着点，不用说这种改进的方式减少了空气或气体在这些附着点的渗透，邻近这些焊接区域的缝合接缝的应用提供了更强的加固，因而形成更可靠的非渗透性织物。接缝焊接通常涉及使织物下侧的薄膜与第二层膜处理过的织物相接触并处于高频能量下，从而在两层织物之间的附着点处形成聚合材料焊珠。
如果形成的聚合材料焊珠的尺寸足以使织物层之间彻底地密封和附着的话，使用低数量的缝合接缝即可产生充分的加固。本发明包含该具体的加固织物以及大尺寸焊珠焊接的气囊织物。
现有技术背景
应用于客车的可充气保护垫体是相对复杂的被动约束保护系统的组成部分。这些系统的主要元件是：碰撞感应系统、点火系统、推进材料、附着装置、系统罩壳和可充气保护垫体。通过感知碰撞，推进剂被点燃，产生爆炸，释放出气体充满垫体，使垫体呈展开状态，该状态可缓冲身体向前运动的碰撞并通过快速排泄气体而耗散其能量。事件发生的整个过程在30毫秒以内。在未展开状态下，该垫体贮存在转向柱管、仪表板中或其附近，门中，或者设置在前排座位的背部最靠近要保护的人或物的位置。
可充气垫体系统通常是指过去被用于保护机动车的驾驶员和乘客的气囊系统。保护机动车驾驶者的系统一般安装在机动车的转向柱管中，并已经采用可向驾驶者直接展开的垫体结构。这些司机侧垫体一般构造比较简单，因为它们在司机和转向柱管之间相当小的良好定位的区域之上发挥作用。在Nelson等的美国专利5,533,755中公开了一种这样的结构，其内容在此引入作为参考。
用于从前面或侧面保护乘客免受碰撞的可充气垫体一般具有更为复杂的结构，因为机动车中乘客的位置可能是没有被明确限定的，在乘客和机动车的表面存在很大的距离，此距离导致在强烈撞击事故中，乘客可能被抛出去。在如下专利中公开了用于此种情况下的现有的垫体：Bishop的美国专利5,520,416、Krickl的美国专利5,454,594、Hawthorn等的美国专利5,423,273、Yamaji等的美国专利5,316,337、Wehner等的美国专利5,310,216、Watanabe的美国专利5,090,729、Wallner等的美国专利5,087,071、Backhaus的美国专利4,994,529和Buchner等的美国专利3,792,873。
主要的商用约束保护衬垫以机织物材料制成，该材料采用例如聚酯、尼龙6或尼龙6，6聚合物等材料的复丝合成纱。这种用途的代表性织物在以下专利中公开：Bloch的美国专利4,921,735、Krummbeuer等的美国专利5,093,163、Menzel等的美国专利5,110,666、Swoboda等的美国专利5,236,775、Sollars，Jr的美国专利5,277,230、Krummbeuer等的美国专利5,356,680、Krummbeuer等的美国专利5,477,890、Krummbeuer等的美国专利5,508,073、Bower的美国专利5,503,197和Bower等的美国专利5,704,402。
正如将会意识到的，在确定碰撞事件后充气和随后快速放气的速率时，垫体结构的透气性是一个重要因素。不同的气囊垫体应用于不同的目的。例如，一些气囊被安装在汽车的转向柱管内的充气设备里，以保护驾驶员。另一些被设置在仪表板的工具箱内或周围和/或乘客座位前的仪表板上，以保护前排座位上的乘客。还有一些研制为在长持续时间的碰撞(诸如翻转碰撞)时保护所有乘客。在这些碰撞中，目标气囊垫体必须在高压(诸如在大约40到50psi之间)下快速地充气、并且在相对高压下保持充气，以对乘客提供最大程度的保护。而且，如此长时间持续的气囊垫体优选为包含“枕头”形式，该形式通过将至少两个不同的织物或织物的经纱以密封、缝合或类似方式结合在一起。在充气时，附着点之间的自由空间充气膨胀，从而产生希望的垫体“枕头”结构。在现有技术中，Halano等的美国专利5,788,270公开了这样的长持续时间的“枕头化”(pillowed)结构的气囊垫体。然而，为了提供合适及有效的气囊织物，以及在织物或织物经纱之间包含两个或以上的附着点的垫体，需要对在这些附着点上的接缝的整体结构进行改进，以防止气体或空气从目标气囊垫体中不希望的泄漏或有泄漏的潜在危险。现有技术已经讨论了在附着点上的缝合接缝处涂层，以密封这些接缝的潜在的松动部分、和/或保持在附着点的气囊织物的单个纱线固定，以防止纱线移动而可能产生的使空气或气体泄漏的开口。然而，不能证明这样的涂层完全有能力提供这样的好处。大多数涂层包含硅，其实际上倾向于作为纱线润滑剂，因而非但不能阻止，反而会导致有害的纱线移动。而且，这种涂层所需的数量和/或厚度也相对较高，这在织物部分储存于可充气设备中时产生了厚度问题。当气囊垫体紧紧地包装在这样的封闭部分中时，涂层可能趋于增加相接触的织物部分之间的粘附性，从而可能难以展开垫体。更进一步，这样的厚涂层费用实在很高，总价格的提高超出了消费者的承受力。最近几年，已在大力推动生产高效气囊垫体同时降低此产品的价格。因而，需要提供合适的、性能良好的、费用经济的在气囊织物或气囊织物经纱之间的附着点，以符合上述工业要求。目前，现有技术还没有实现这样的性能和价格改进，以适应气囊垫体市场。
发明概述
鉴于以上所述，本发明的总的目的是提供一种应用在汽车约束保护系统中的引入气囊垫体内部的有效的、加强的、焊接的气囊织物。术语“汽车约束保护系统”(vehicle restraint system)是指可充气的约束保护垫体装置和机械化学装置(诸如充气装置、点火装置、推进剂等等)。本发明的一个特定的目的是提供一种气囊织物，其中，加固接缝被缝合在邻近焊接接缝的区域。本发明的另一目的是提供一种气囊织物，其包括通过使用相对大的聚合物焊珠连接并定位的附着点。
根据本发明的目的，为实现这些和其它目的，如在此具体化的和宽泛地描述的，本发明提供一种包含在气囊垫体内的气囊织物，其包括至少一条焊接接缝作为两层织物面板之间的附着点，其中所述气囊织物还包括至少一条位于所述焊接接缝附近的缝合接缝。此发明还包含一种气囊织物，其包含在包括有至少一条作为两层织物经纱之间的附着点的焊接接缝的气囊垫体内，其中所述焊接接缝包括一个平均厚度为大约2到40mils的聚合物焊珠。
术语“焊接接缝”(welded seam)包括任何在两层织物面板之间通过应用焊接工艺形成的附着点。一般地，此工艺包括：用极性热塑性聚合材料在织物面板上涂膜；接触该涂膜面板；在织物的指定区域上放置一高强度放电模具，在织物内将产生一条焊缝；把这一高强度电场应用到涂膜织物面板上，随后在极热塑性材料内产生出电子，从一极移动到另一极，从而产生摩擦，其最终产生出热量；以及通过处于该热量下，形成伸长的聚合物焊珠，其粘附二织物面板并填充织物面板之间的空隙(术语“织物面板”(fabric panel)指通过此焊接工艺连接在一起的两个不同的独立的织物片，或者一个织物的两个不同的经纱)。此聚合物焊珠承受附着点上充气产生的高压负载。然而，在焊珠和织物面板之间的接触区域实质上仅包含此焊珠的顶部。所以，由于这样的低接触表面区域，仍然存在使聚合物焊珠在该焊珠位置从面板上撕下的可能性。
因此，虽然焊接接缝(其在Kesh等的美国专利09/326,368中被全面地讨论)产生出卓越的、坚固的附着接缝，基本上防止了气囊织物面板在充气时被撕裂，但是由于织物焊珠不完全牢固，损害了聚合物焊珠产生的密封结构。本发明的织物通过使更多织物在被伸长和冷却(焊接)进入织物结构之后围绕在焊珠周围，而改善了此潜在的问题。缝合接缝必须存在于邻近焊接接缝的区域。邻近，是指缝合接缝产生于二个不同的附着点之间(因而产生了焊接接缝之间的接缝)，或者，如果仅存在一条焊接接缝，产生于比焊接接缝更为接近的织物面板边缘，而且足够近，以增加与焊接接缝的聚合物焊珠接触的织物的数量。一般地，该距离为约0.1-5cm；优选约0.1-3cm；更优选约0.5-2cm；最优选约0.5-1cm。虽然需要足够的长度以确保聚合物焊珠与织物之间有足够的接触，但接缝的长度并不重要。长度太短将不能产生足够的接触表面；太长会妨碍气囊织物的剩余部分的性能。术语“缝合接缝”(sewn seam)是指包括用诸如使用针缝合(needle stitches)、超声波缝合(ultrasonic stitches)等重复缝制制造出的任何类型的接缝。
可以应用任何类型的结实的工业用线，以向焊接接缝提供所需的加强强度。因而，可以应用从大约40#到200#的任何尺寸的线。接缝优选为单针缝合；然而，也可以用多针缝合。
另一种增加焊接接缝强度的方法是增加由此工艺产生的聚合物焊珠的总厚度。此厚度增加将增加焊珠和织物之间的接触表面，同时填充更多的空隙，最终降低了空气或气体从气囊织物中泄漏的可能性。已发现这种标准RF-焊接技术改进，是生产具有更好的抗泄漏性能织物的仅有方式。理论上，此聚合物焊珠的几何形状改变也将导致目标织物之间有更好的接触；然而，此几何形状改变很难实现，因为在焊接过程中，聚合物层更易于将自身确定为圆形，而不是其它构型。因此，需要的焊珠厚度至少是涂覆在目标织物上的聚合物层的厚度的四倍，以达成所需的伸长和焊珠和织物的粘结生成物。因为此聚合物涂层的平均厚度为约0.5-10mil，优选的焊珠平均厚度应为约2-约40mil，优选约5-约40mil；更优选约10-约30mil；最优选约20-约30mil。为生产如此厚的焊珠，必须使用自身的厚度大于织物表面涂层厚度2000倍的焊接头，较薄的焊珠结构在目标织物内产生不一致的焊接强度，因为熔化的聚合物流过织物表面的方向非常难以控制，尤其是在织物面板的附着点位置的弯曲区域或者直线区域不一致时。较厚焊珠的产品通过提供更多的聚合物表面供大量的织物-焊珠相接触，而基本上减少了这些织物结构中的不一致问题。在焊接并填充织物面板的开放空间时，以及在覆盖织物面板上更宽的区域时，焊珠将变形，尤其是在附着点周围变形。使用上述接缝焊接技术，这种在覆盖表面和填充空间的增加，将产生更为结实的接缝。
虽然使用这种改进的接缝生产方法，由于焊珠-织物接触不充分，织物内还存在松脱、撕裂、或接缝失效的可能性。如前所述，这种潜在的问题可以通过应用邻近焊接接缝的缝合接缝来解决。
本发明的优选实施例
下面的实例用于说明落于本发明范围内的具体的优选实施方案：
                      实施例1
二编织织物，每个包含420丹尼尔6，6-尼龙纱线，且在每英寸结构中具有39×39纬纱/经纱，在目标织物的一侧的每一织物上涂覆以2.4盎司的标准聚氨酯气囊涂层及粘合促进剂。然后使涂覆表面相互接触，将焊接头放置在二织物复合物之上。高频电磁场以超过每秒2700万次(27MHz)倒转，最终加热了位于二织物之间的焊接目标位置的薄膜。通过此方法生成的焊珠产生出宽度接近3mm、跨越二织物的整个长度的焊接接缝，从而在一个位置连接了织物。在冷却之后，将织物转移到缝纫机。用138#线穿过单个140#针缝合出一个接缝，每100mm约为20针脚，接缝长度平行于焊接接缝，并离焊接接缝大约5mm。二接缝的撕裂强度超过标准气囊产品的要求(即，大于每英寸275磅)。
                      实施例2
二编织织物，每个包含210丹尼尔6，6-尼龙纱线，且在每英寸结构中具有55×55纬纱/经纱，在目标织物的一侧的每一织物上涂覆以2.7盎司的标准聚氨酯气囊涂层及粘合促进剂。然后使涂覆表面相互接触，将焊接头放置在二织物复合物之上。高频电磁场以超过每秒2700万次(27MHz)倒转，最终加热了位于二织物之间的二相邻焊接目标位置的薄膜。通过此方法生成的焊珠产生出宽度接近3mm、距离接近3mm的跨越二织物的整个长度的两个分开的焊接接缝，从而在一个位置连接了织物。在冷却之后，将织物转移到缝纫机。用92#线穿过单个140#针缝合出一个接缝，每100mm为约40针脚，接缝长度平行于焊接接缝，并离焊接接缝大约5mm。二接缝的撕裂强度超过标准气囊产品的要求(即，大于每英寸275磅)。
虽然说明并描述了本发明的具体实施方案，应该理解，其并非构成本发明的限制，因为毫无疑问，本领域的普通技术人员根据本发明的原理可以作出改进和其它实施方案。因此，预期所附的权利要求包括任何落入权利要求的实质和范围中的结合本发明特征的改进和其它
实施方案。

Claims (16)

1.一种包含在气囊垫体内的气囊织物，其包括至少一个作为两织物经纱之间附着点的焊接接缝，其中所述气囊织物还包括至少一条位于所述焊接接缝附近的缝合接缝，其中所述焊接接缝包括平均厚度为约2-约40mils的聚合物焊珠。
2.如权利要求1所述的气囊织物，其中所述焊接接缝包括平均直径为约5-约40mils的聚合物焊珠。
3.如权利要求2所述的气囊织物，其中所述焊接接缝包括平均直径为约10-约30mils的聚合物焊珠。
4.如权利要求3所述的气囊织物，其中所述焊接接缝包括平均直径为约20-约30mils的聚合物焊珠。
5.一种包括权利要求1所述的气囊织物的气囊垫体。
6.一种包括权利要求2所述的气囊织物的气囊垫体。
7.一种包括权利要求3所述的气囊织物的气囊垫体。
8.一种包括权利要求4所述的气囊织物的气囊垫体。
9.一种包含在气囊垫体内的气囊织物，其包括至少一个作为两织物经纱之间附着点的焊接接缝，其中所述气囊织物还包括至少一条缝合接缝，位于两个不同的附着点之间，或者，如果仅存在一条焊接接缝，产生于比所述焊接接缝更为接近所述至少两织物层的边缘，其中所述至少一条缝合加固接缝中的缝合同时穿过所述至少两个织物层的内部和外部；其中所述至少一条缝合加固接缝具有超过与标准气囊充气压力相关的撕裂强度，其中所述焊接接缝包括平均厚度为约2-约40mils的聚合物焊珠。
10.如权利要求9所述的气囊织物，其中所述缝合接缝由线缝合或超声波缝合形成。
11.如权利要求1所述的气囊织物，其中所述焊接接缝包括平均厚度为约2-约30mils的聚合物焊珠。
12.一种包括权利要求9-11任一项所述的气囊织物的气囊垫体。
13.一种气囊织物垫体，其中包含至少两个织物层，其中至少一条焊接接缝位于所述至少两个织物层之间的附着点，其中所述至少两个织物层均具有相对该气囊垫体的内部和相对该气囊垫体的外部，其中所述气囊垫体还包括至少一条位于所述焊接接缝附近的缝合加固接缝，其中所述至少一条缝合加固接缝中的缝合同时穿过所述至少两个织物层的内部和外部；其中所述至少一条缝加固接缝具有超过与标准气囊充气压力相关的撕裂强度。
14.如权利要求13所述的气囊垫体，其中所述缝合加固接缝由线缝合或超声波缝合形成。
15.一种气囊织物垫体，其中包含至少两个织物层，其中至少一条粘接接缝位于所述至少两个织物层之间的附着点，其中所述至少两个织物层均具有相对该气囊垫体的内部和相对该气囊垫体的外部，其中所述气囊垫体还包括至少一条位于所述粘接接缝附近的缝合加固接缝，其中所述至少一条缝合加固接缝中的缝合同时穿过所述至少两个织物层的内部和外部；其中所述至少一条缝加固接缝具有超过与标准气囊充气压力相关的撕裂强度。
16.如权利要求13所述的气囊垫体，其中所述缝合加固接缝由线缝合或超声波缝合形成。
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US6598902B2 (en) 2003-07-29
BR0014193A (pt) 2002-05-21
WO2001023219A1 (en) 2001-04-05
EP1216168A4 (en) 2005-04-27
JP2003510214A (ja) 2003-03-18
US20020067034A1 (en) 2002-06-06
DE60040750D1 (de) 2008-12-18
CN1374909A (zh) 2002-10-16
AU7371800A (en) 2001-04-30
CA2379610A1 (en) 2001-04-05
MXPA02001884A (es) 2002-08-20

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