Seatbelt system having seamless inflatable member

Abstract

A passenger restraint system ( 100 ) for an occupant of a vehicle ( 102 ) includes an inflatable belt portion comprising a seamless hollow inflatable textile member that becomes inflated upon the occurrence of a collision. The inflatable textile member may vary in size and construction along its length. The belt portion ( 104, 112 ) tightens against the occupant's body when the inflatable belt portion becomes inflated.

What is claimed is:  
     
         1 . In a combination for protecting an occupant in a vehicle in the event of a collision involving the vehicle, the vehicle ( 102 ) having a support structure ( 106 ,  125 ) and having a seat ( 108 ) for the occupant with an inboard side and an outboard side and having a first retainer means ( 122 ) at the inner side of the occupant's seat and having second retainer means ( 124 ) at the outer side of the occupant's seat, 
 a unitary belt ( 100 ) including an inflatable belt portion ( 104 ) and a lap belt portion ( 112 ),    the inflatable belt portion ( 104 ) extending diagonally across the chest of the occupant, the inflatable belt portion having first and second opposite ends and being constructed to be attached at the first end to the support structure ( 106 ) in the vehicle ( 102 ), the inflatable belt portion comprising a seamless hollow textile structure ( 200 ,  210 ,  220 ),    the lap belt portion ( 112 ) having first and second ends and being attached at the first end to the second end of the inflatable belt portion and extending across the lap of the occupant from the second end of the inflatable belt portion ( 104 ), the second end of the lap belt portion having a coupling member ( 116 ) for coupling to the first retainer means ( 122 ) in the vehicle,    the lap belt portion ( 112 ) having a second coupling member at a position near the inflatable belt portion for coupling to the second retainer means ( 124 ) in the vehicle, and    means ( 124 ,  116 ) operatively coupled to the lap belt portion ( 112 ) for extending the lap belt portion upwardly in the direction of the inflatable belt portion ( 104 ) and for providing for a tightening of the lap belt portion against the lap of the occupant when the inflatable belt portion becomes inflated.    
     
     
         2 . In a combination as set forth in  claim 1 , wherein the textile structure ( 104 ,  112 ,  160 ,  220 ,  210 ,  220 ) is a continuously woven member that is pleated prior to inflation.  
     
     
         3 . In a combination as set forth in  claim 1 , wherein the textile structure ( 104 ,  112 , 160 ,  220 ,  210 ,  220 ) is a continuously woven member of varying diameter when inflated, the textile structure having a center portion ( 204 ,  214 ,  225 ) between first end portions ( 201 ,  211 ,  221 ) and second end portions ( 203 ,  213 ,  223 ), the inflated diameter of the end portions being less than that of the center portion, the first end portion being constructed to be attached to the support structure ( 106 ,  125 ) in the vehicle ( 102 ), and the second end portion being constructed to be attached to the lap belt portion ( 112 ,  160 ).  
     
     
         4 . In a combination as set forth in  claim 1 , wherein the textile structure ( 104 ,  112 ,  160 ,  220 ,  210 ,  220 ) is a continuously woven member of varying diameter when inflated, the textile structure having first end portions ( 201 ,  211 ,  221 ) and second end portions ( 203 ,  213 ,  223 ) and a center portion ( 204 ,  214 ,  225 ), the diameter of the end portions being less than that of the center portion, the number of warp ends ( 205 ,  216 ) per unit of textile circumference decreasing as the diameter of the textile structure increases, the first end portion being constructed to be attached to the support structure ( 106 ,  125 ) in the vehicle ( 102 ).  
     
     
         5 . In a combination as set forth in  claim 1 , wherein the textile structure ( 104 ,  112 ,  160 ,  220 ,  210 ,  220 ) is a continuously woven member having first end portiosn ( 201 ,  211 ,  221 ) and second end portions ( 203 ,  213 ,  223 ) joined to a center portion ( 204 ,  214 ,  225 ), at least some of the weft members ( 206 ) adjacent the second end portion being of plastically extensible filamentary material ( 202 ).  
     
     
         6 . In a combination as set forth in  claim 1  wherein the inflatable textile structure ( 104 ,  112 ,  160 ,  220 ,  210 ,  220 ) is a continuously woven member having a portion ( 228 ) that is plastically expansible in diameter without rupture in response to inflation gas pressure in excess of a predetermined value  
     
     
         7 . In a combination as set forth in  claim 6 , wherein the inflatable textile structure ( 104 ,  112 ,  160 ,  220 ,  210 ,  220 ) has a first end portion ( 201 ,  211 ,  221 ) and a second end portion ( 203 ,  213 ,  223 ) which are resistant to increase in diameter when inflated in response to inflation gas pressure in excess of a predetermined value and a center portion ( 204 ,  214 ,  225 ) which plastically expands in diameter without rupture in response to inflation gas pressure in excess of said predetermined value.  
     
     
         8 . In a combination as set forth in  claim 6 , wherein the inflatable textile structure ( 104 ,  112 ,  160 ,  220 ) has a first end portion ( 221 ) and a center portion ( 225 ) which are resistant to an increase in diameter when inflated in response to inflation gas pressure in excess of a predetermined value and a second end portion ( 228 ) which plastically expands in diameter without rupture in response to inflation gas pressure in excess of said predetermined value.  
     
     
         9 . In a combination as set forth in  claim 1 , wherein the textile structure ( 104 ,  112 ,  160 ,  200 ,  210 ,  220 ) is a continuously woven member of varying diameter, the textile structure having first end portions ( 201 ,  211 ,  221 ) and second end portions ( 203 ,  213 ,  223 ) and a center portion ( 204 ,  214 ,  225 ), the diameter of the end portions when inflated being less than that of the center portion when inflated, the center portion extending diagonally across the chest of the occupant.  
     
     
         10 . In a combination as set forth in  claim 1 , wherein the textile structure ( 104 ,  112 ,  160 ,  200 ,  210 ,  220 ) is a continuously woven member of varying diameter, the textile structure having first end portions ( 201 ,  211 ,  221 ) and second end portions ( 203 ,  213 ,  223 ) and a center portion ( 204 ,  214 ,  225 ), the diameter of the end portions when inflated being less than that of the center portion when inflated, the center portion extending diagonally across the chest of the occupant and across the outboard side of the neck and the head of the occupant.  
     
     
         11 . In a combination for protecting a human occupant in a vehicle ( 102 ) in the event of a collision involving the vehicle, the vehicle having a support structure ( 106 ,  125 ) and having a seat for the occupant with an inboard side and an outboard side, 
 a unitary belt ( 100 ,  160 ) including an inflatable belt portion ( 104 ,  160 ) comprising a seamless hollow textile member ( 180 ,  200 ,  210 ,  220 ) extending across the body of the occupant, the inflatable belt portion ( 104 ,  160 ,  180 ) having first and second opposite ends extending between the inboard side and the outboard side of the seat ( 108 ) and being constructed to be attached to the support structure ( 106 ,  125 ) in the vehicle ( 102 ), the construction of the inflatable belt portion providing for a tightening of the belt against the occupant when the inflatable belt portion becomes inflated, and    inflator means ( 10 ) disposed relative to the first end of the inflatable belt portion providing gas inflation of the inflatable belt portion when the vehicle is in a collision.    
     
     
         12 . In a combination as set forth in  claim 11 , wherein the seamless hollow textile member ( 180 ,  200 ,  210 ,  220 ) is a continuously woven member that is pleated prior to inflation.  
     
     
         13 . In a combination as set forth in  claim 12 , wherein the pleated textile member ( 104 ) is encased in a frangible cover ( 105 ) that is ruptured upon inflation of the pleated textile member.  
     
     
         14 . In a combination as set forth in  claim 11 , wherein the inflatable textile member ( 180 ,  200 ,  210 ,  220 ) is a continuously woven member which is of varying size along its length when inflated, the inflatable textile member having first end portions ( 201 ,  211 ,  221 ) and second end portions ( 203 ,  213 ,  223 ) joined to a center portion ( 204 ,  214 ,  225 ), the inflated size of the end portions being less than that of the center portion.  
     
     
         15 . In a combination as set forth in  claim 11 , wherein the inflatable textile member ( 180 ,  200 ,  210 ,  220 ) is a continuously woven member that is of varying size along its length when inflated, the number of warp ends ( 205 ,  216 ) per unit of textile circumference decreasing as the size of the textile member increases.  
     
     
         16 . In a combination as set forth in  claim 11 , wherein the inflatable belt portion ( 104 ,  160 ) includes an integrally woven stiffener ( 193 ) comprising larger warp members ( 194 ) that contact the occupant and resist twisting of the inflatable belt portion and carry most of the load when the belt is tensioned in a collision.  
     
     
         17 . In a combination as set forth in  claim 11 , wherein the inflatable belt portion ( 104 ,  160 ,  180 ,  190 ) contains at least two integrally woven chambers ( 181 ,  182 ,  191 ,  192 ) that are inflatable.  
     
     
         18 . In a combination as set forth in  claim 17 , wherein one of the chambers ( 181 ,  191 ) is first inflated and another of the chambers ( 182 ,  192 ) is subsequently inflated by gas passing from said one chamber ( 181 ,  191 ).  
     
     
         19 . In a combination as set forth in  claim 11 , wherein the inflatable belt portion ( 104 ,  160 ,  180 ,  190 ) contains at least two integrally woven inflatable chambers ( 181 ,  182 ,  191 ,  192 ) are sequentially inflatable.  
     
     
         20 . In a combination as set forth in  claim 11 , wherein the inflatable textile member ( 200 ,  210 ,  220 ) is a continuously woven member that is of varying size along its length when inflated, the number of weft ends ( 206 ) per unit of textile length increasing as the size of the textile member increases.  
     
     
         21 . In a combination as set forth in  claim 20 , wherein the number of weft ends ( 206 ) per unit of textile length is greater in the center portion ( 204 ,  214 ,  225 ) than in the end portions ( 201 ,  211 ,  221 ,  203 ,  213 ,  229 ) of the inflatable textile member.  
     
     
         22 . In a combination as set forth in  claim 20 , wherein the center portion ( 214 ,  225 ) includes a greater number of warps ( 205 ,  216 ) than the end portions ( 211 ,  213 ,  221 ,  223 ) of the inflatable textile member.  
     
     
         23 . In a combination as set forth in  claim 20 , wherein the center portion ( 204 ) includes the same number of warps ( 205 ) as the end portions ( 201 ,  203 ) of the inflatable textile member ( 200 ).  
     
     
         24 . In a combination as set forth in  claim 20 , wherein at least some of the weft members ( 206 ) of the center portion ( 214 .  225 ) of the inflatable textile member ( 210 ,  220 ) are of plastically extensible filamentary material ( 202 ).  
     
     
         25 . In a combination as set forth in  claim 11 , wherein the inflatable textile member ( 210 ,  220 ) is a continuously woven member having a portion ( 214 ,  224 ) that is plastically expansible in size without rupture in response to inflation gas pressure in excess of a predetermined value that does not cause substantial plastic expansion of the remainder of the inflatable textile member.  
     
     
         26 . In a combination as set forth in  claim 20 , wherein the inflatable textile member ( 210 .  220 ) has a first end portion ( 211 ,  221 ) which does not substantially increase in size when inflated in response to inflation gas pressure in excess of a predetermined value and a second end portion ( 224 ) which plastically expands in size without rupture in response to inflation gas pressure in excess of said predetermined value.  
     
     
         27 . In a combination as set forth in  claim 20 , wherein the inflatable textile member ( 220 ) has a first end portion ( 221 ) and a second end portion ( 223 ) which are resistant to increase in size when inflated in response to inflation gas pressure in excess of a predetermined value and a center portion ( 225 ,  224 ) which plastically expands in size without rupture in response to inflation gas pressure in excess of said predetermined value.  
     
     
         28 . In a combination as set forth in  claim 11 , wherein the textile member ( 180 ,  200 ,  210 ,  220 ) is a continuously woven member that varies in size along its length when inflated, the textile member having first end portions ( 201 ,  211 ,  221 ) and second end portions ( 203 ,  213 ,  223 ) joined to a center portion ( 204 ,  214 ,  224 ), the size of the end portions when inflated being less than that of the center portion when inflated, the center portion extending diagonally across the chest of the occupant.  
     
     
         29 . In a combination as set forth in  claim 11 , wherein the textile member ( 180 ,  200 ,  210 ,  220 ) is a continuously woven member of varying size, the textile member having first end poritons ( 201 ,  211 ,  221 ) and second end portions ( 203 ,  213 ,  223 ) joined to a center portion ( 204 ,  214 ,  225 ), the size of the end portions when inflated being less than that of the center portion when inflated, the center portion extending diagonally across the chest of the occupant and across the outboard side of the neck and the head of the occupant.  
     
     
         30 . In a combination as set forth in  claim 11 , wherein the textile member ( 180 ,  200 ,  210 ,  220 ) is a continuously woven member that varies in size along its length when inflated, the textile member having first end portions ( 201 ,  211 ,  221 ) and second end portions ( 203 ,  213 ,  223 ) joined to a center portion ( 204 ,  214 ,  225 ), the size of the end portions when inflated being less than that of the center portion when inflated, the center portion extending across the lap of the occupant.  
     
     
         31 . In a combination as set forth in  claim 30 , further including a coupling member ( 116 ) affixed to an end of the belt ( 112 ) and a retainer means ( 122 ) in the vehicle ( 102 ) for detachably receiving the coupling member, wherein the inflator means ( 10 ) is disposed within the inflatable belt portion and is electrically coupled to receive a triggering signal when the belt is coupled to its retainer means.  
     
     
         32 . In a combination as set forth in  claim 31 , wherein the inflator means ( 10 ) is disposed adjacent the end of the belt to be detachably coupled to its retainer.  
     
     
         33 . In a combination as set forth in  claim 31 , further including a retractor ( 124 ) for minimizing slack in the belt portion ( 112 ,  104 ) and for preventing the length of the belt portion from increasing when a force above a predetermined value is imposed on the belt portion for increasing the length of the belt portion, wherein the inflator means ( 10 ) is disposed between the retractor ( 124 ) and the end of the belt to be detachably coupled to its retainer means ( 122 ).  
     
     
         34 . In a combination as set forth in  claim 30 , further including length adjustment and locking means ( 124 ) positioned under the seat ( 108 ) operably connected to the lap belt portion ( 112 ) for adjustment of the length of the lap belt portion and for providing for a tightening of the lap belt portion against the lap of the occupant when the inflatable belt portion ( 104 ,  160 ) becomes inflated, wherein the belt extends beneath the seat, and the inflator means ( 10 ) is disposed between the length adjustment means ( 124 ) and the end of the belt to be detachably coupled to its retainer ( 122 ).  
     
     
         35 . In a combination as set forth in  claim 30 , wherein the inflator means ( 10 ) is disposed externally of the inflatable belt portion ( 104 ,  160 ).  
     
     
         36 . In a combination for protecting an occupant in a vehicle ( 102 ) in the event of a collision involving the vehicle, the vehicle having a support structure ( 106 ,  125 ) and having a seat ( 108 ) for the occupant with an inboard side and an outboard side and having a first retainer means ( 122 ) at the inner side of the occupant's seat and having second retainer means ( 124 ) at the outer side of the occupant's seat, 
 a unitary belt ( 100 ) including a lap belt portion ( 112 ) and an inflatable belt portion ( 104 ),    the lap belt portion ( 112 ) being disposed to extend across the lap of the occupant and having a first end for attachment to the first retainer ( 122 ), the lap belt portion having a second end opposite the first end,    the inflatable belt portion ( 104 ) extending diagonally across the chest of the occupant, the inflatable belt portion having first and second opposite ends and being constructed to be attached at the first end to the support structure in the vehicle ( 106 ), the inflatable belt portion comprising a seamless hollow textile member ( 180 ,  200 ,  210 ,  220 ), the inflatable belt portion ( 104 ) being attached to the lap belt portion ( 112 ) at the second end of the lap belt portion,    means disposed at the second end of the lap belt portion ( 112 ) for coupling to the second retainer ( 124 ) and for guiding the lap belt portion to the inflatable belt portion,    means disposed at the second end of the inflatable belt portion ( 104 ) for attaching the inflatable belt portion to the support structure, and a retractor ( 124 ) disposed relative to the lap belt portion near the second coupling member for minimizing slack in the lap belt portion upon attachment of the first coupling member to the first retainer ( 122 ) and for preventing the length of the lap belt portion from increasing when a force above a predetermined value is imposed on the lap belt portion for increasing the length of the lap belt across the lap of the occupant.    
     
     
         37 . In a combination for protecting an occupant in a vehicle ( 102 ) in the event of a collision involving the vehicle, the vehicle having a support structure ( 106 ,  125 ) and having a seat ( 108 ) connected to the support structure ( 125 ) for the occupant with a first side and a second side and having a first retainer means ( 122 ) at the first side of the occupant's seat and having second retainer means ( 124 ) at the occupant's seat, 
 a unitary belt ( 100 ) including an inflatable lap belt portion ( 112 ,  160 ) comprising a seamless hollow textile member ( 180 ,  200 ,  210 ,  220 ),    the inflatable lap belt portion ( 112 ,  160 ) being disposed to extend across the lap of the occupant and having a first end affixed to a first coupling member ( 116 ) for detachable attachment to the first retainer mean ( 122 ),    the lap belt portion ( 112 ) having a second end opposite the first end coupled to the second retainer means ( 124 ),    guide means ( 103 ) for guiding the lap belt portion ( 112 ) from the second side of the seat to extend across the lap of the occupant,    a retractor ( 124 ) disposed relative to the lap belt portion ( 112 ,  160 ) for minimizing slack in the lap belt portion upon attachment of the first coupling member ( 116 ) to the first retainer means ( 122 ) and for preventing the length of the lap belt portion from increasing when a force above a predetermined value is imposed on the lap belt portion for increasing the length of the lap belt across the lap of the occupant, and    inflator means ( 10 )disposed relative to the inflatable belt portion providing gas inflation of the inflatable belt portion when the vehicle is in a collision.    
     
     
         38 . In a combination as set forth in  claim 37 , wherein the retractor ( 124 ) and the inflator means ( 10 ) are disposed under the seat ( 108 ).  
     
     
         39 . In a combination for protecting an occupant in a vehicle ( 102 ) in the event of a collision involving the vehicle, the vehicle having a support structure ( 106 ,  125 ) and having a seat ( 108 ) connected to the support structure ( 125 ) for the occupant with a first side and a second side and having a first retainer means ( 122 ) at the first side of the occupant's seat and a second retainer means ( 103 ) at the second side of the occupant's seat, 
 a unitary belt ( 112 ) including an inflatable lap belt portion ( 160 ) comprising a seamless hollow textile member ( 160 ,  180 ,  200 ,  210 ,  220 ),    the inflatable lap belt portion ( 160 ) being disposed to extend across the lap of the occupant and having a first end affixed to a first coupling member ( 116 ) for detachable attachment to the first retainer means ( 122 ),    the lap belt portion having a second end opposite the first end coupled to the second retainer means ( 103 ,  124 ),    guide means ( 103 ) for guiding the lap belt portion ( 112 ,  160 ) from the second side of the seat to extend across the lap of the occupant,    and a retractor ( 124 ) disposed at the second side of the seat for minimizing slack in the lap belt portion upon attachment of the first coupling member to the first retainer means and for preventing the length of the lap belt portion from increasing when a force above a predetermined value is imposed on the lap belt portion for increasing the length of the lap belt across the lap of the occupant, and    inflator means ( 10 ) disposed relative to the inflatable belt portion providing gas inflation of the inflatable belt portion when the vehicle is in a collision.    
     
     
         40 . In a combination as set forth in  claim 36 , wherein the inflatable belt portion ( 160 ,  180 ,  200 ,  210 ,  200 ) is integrally woven with the lap belt portion ( 160 ).  
     
     
         41 . In a combination as set forth in  claim 36 , wherein the inflatable belt portion ( 190 ) includes an integrally woven stiffener ( 193 ) that resists twisting of the inflatable belt portion.  
     
     
         42 . In a combination as set forth in  claim 36 , wherein the inflatable belt portion ( 190 ) includes an integrally woven stiffener ( 193 ) comprising larger warp members ( 194 ) that contact the occupant and resist twisting of the inflatable belt portion and carry most of the load when the belt is tensioned in a collision.  
     
     
         43 . In a combination as set forth in  claim 36 , wherein the inflatable belt portion ( 160 ,  180 ,  190 ) contains at least two integrally woven chambers ( 181 ,  182 ,  191 ,  192 ) that are inflatable.  
     
     
         44 . In a combination as set forth in  claim 43 , wherein one of the chambers ( 181 ,  191 ) is first inflated and another of the chambers ( 182 ,  192 ) is subsequently inflated by gas passing from said one chamber ( 181 ,  191 ).  
     
     
         45 . In a combination as set forth in  claim 37 , wherein the inflatable belt portion ( 160 ,  180 ,  190 ) contains at least two integrally woven inflatable chambers ( 181 ,  182 ,  191 ,  192 ) are sequentially inflatable.