Load bearing fabric assembly and method of making a load bearing fabric assembly

Abstract

A load bearing fabric assembly having a frame, a carrier and a load bearing fabric. The load bearing fabric is attached directly to the carrier. The frame defines view ports to enable visual inspection of the junction between the carrier and the load bearing fabric after the carrier and fabric have been mounted to the frame. A method of manufacturing the carrier for such a load bearing fabric assembly includes the steps of: (a) placing the fabric inside a mold with at least a portion of the fabric directly engaging the surface of the mold; (b) injecting a molten thermoplastic elastomer into the mold to form the carrier, the molten thermoplastic elastomer having a melt point greater than that of the fabric; and (c) permitting the molten thermoplastic elastomer to cure to form a carrier directly on the fabric. In one embodiment, the fabric is positioned so that the entry of molten thermoplastic elastomer urges the fabric against a surface of the mold cavity.

1 . A load bearing fabric assembly comprising: 
 a carrier;    a load bearing fabric attached to said carrier; and    a component receiving said carrier and said fabric, said component defining a first view port for viewing a junction between said carrier and said fabric.    
   
   
       2 . The load bearing fabric assembly of  claim 1  wherein said component defines a second view port for viewing said junction.  
   
   
       3 . The load bearing fabric assembly of  claim 2  wherein said first view port and said second view port are defined in said component in different planes.  
   
   
       4 . The load bearing fabric assembly of  claim 3  wherein said component is further defined as a frame, and said first view port and said second view port being defined as apertures in said frame.  
   
   
       5 . The load bearing fabric assembly of  claim 4  where said frame has an interior and said first view port is located on said interior.  
   
   
       6 . A load bearing fabric assembly comprising: 
 a frame;    a carrier, said carrier intersecured with said frame;    a load bearing fabric attached to said carrier along a line; and    wherein said frame defines a plurality of view ports for viewing at least portions of said line.    
   
   
       7 . The load bearing fabric assembly of  claim 6  where said plurality of view ports are aligned with said line.  
   
   
       8 . The load bearing fabric assembly of  claim 7  where said plurality of view ports are contained within more than one plane.  
   
   
       9 . The load bearing fabric assembly of  claim 8  where said plurality of view ports are spaced equidistant about said frame.  
   
   
       10 . The load bearing fabric assembly of  claim 8  where said frame defines a channel, said carrier being fitted within said channel, said view ports extending through said frame to said channel to permit viewing of said line.  
   
   
       11 . A method of manufacturing a carrier assembly comprising: 
 supplying a load bearing fabric having a melt temperature, the load bearing fabric having a terminus;    placing the terminus into a mold cavity, the cavity being defined by at least one mold surface;    insuring that a portion of the fabric within the mold cavity is against the mold surface;    supplying molten thermoplastic elastomer to the cavity, the molten thermoplastic elastomer having a substantially higher melt temperature than the load bearing fabric; and    cooling the molten thermoplastic elastomer.    
   
   
       12 . The method of  claim 11  further comprising the step of holding at least a portion of the load bearing fabric against the mold surface.  
   
   
       13 . The method of  claim 12  wherein the thermoplastic elastomer has a thermoplastic elastomer melt point and the load bearing fabric has elastomeric elements with a load bearing fabric melt point, and the thermoplastic elastomer melt point is greater than the load bearing fabric melt point.  
   
   
       14 . The method of  claim 13  where the step of placing the terminus into the chamber further comprises positioning the load bearing fabric such that the molten thermoplastic elastomer moved into the chamber urges at least a portion of the load bearing fabric against the desired mold surface.  
   
   
       15 . A method of manufacturing a carrier assembly, the carrier assembly having a carrier, comprising the steps of: 
 providing a first thermoplastic elastomer material having a first melt point;    providing a load bearing fabric having a thermoplastic elastomer material with a second melt point, the first melt point being higher than the second melt point;    forming a carrier from the first thermoplastic elastomer material in a mold while the first thermoplastic material is above the first melt point; and    attaching the load bearing fabric to the first thermoplastic elastomer material while the first thermoplastic elastomer material is above first melt point, at least a portion of the load bearing fabric engaging a surface of the mold, whereby the mold cools at least a portion of the load bearing fabric during said forming step.    
   
   
       16 . The method of  claim 15  further comprising the step of: 
 maintaining the temperature of at least a portion of the load bearing fabric in contact with the thermoplastic elastomer material below the second melt point while the thermoplastic elastomer material is at a temperature above the first melt point.    
   
   
       17 . The method of  claim 16  further comprising the step of: 
 cooling the thermoplastic elastomer material.    
   
   
       18 . A load bearing fabric assembly comprising: 
 a frame;    a carrier assembly secured to said frame, said carrier assembly including a load bearing fabric intersecured with a carrier, said carrier assembly manufactured by the steps of (a) placing a portion of said load bearing fabric in a mold with at least a portion of said load bearing fabric directly engaging a surface of said mold, (b) introducing a molten material into said mold in direct contact with said load bearing fabric, said molten material having a melt point greater than a melt point of the load bearing fabric and (c) permitting said molten material to cure in said mold in direct contact with said load bearing fabric.    
   
   
       19 . The assembly of  claim 18  wherein at least a portion of said load bearing fabric is fused with said carrier.  
   
   
       20 . The assembly of  claim 19  wherein said fabric includes a peripheral marginal portion, said carrier extending along at least a portion of said peripheral marginal portion.  
   
   
       21 . The assembly of  claim 20  wherein said carrier includes an outer surface, said fabric being integrally molded to at least a portion of said carrier along at least a portion of said outer surface.  
   
   
       22 . The assembly of  claim 19  wherein said fabric joins said carrier along a line of encapsulation, said fabric remaining along said outer surface of said carrier for a distance from said line of encapsulation.  
   
   
       23 . The assembly of  claim 22  wherein said distance is at least 0.20 inches.  
   
   
       24 . The assembly of  claim 23  wherein said distance is at least 0.25 inches.  
   
   
       25 . A load bearing fabric assembly comprising: 
 a carrier manufactured from a first thermoplastic elastomer, said first thermoplastic elastomer having a first melt temperature, said carrier having an outer surface; and    a load bearing fabric attached to said carrier, said load bearing fabric manufactured at least in part from a second thermoplastic elastomer, the second thermoplastic elastomer having a second melt temperature, wherein the first melt temperature is higher than the second temperature, said load bearing fabric being encapsulated along said outer surface of said carrier.    
   
   
       26 . The load bearing fabric assembly of  claim 25  further including a frame, said carrier being interfitted with said frame.  
   
   
       27 . The load bearing fabric assembly of  claim 26  wherein said load bearing fabric and said carrier are attached at a junction, and said carrier has a first view port for viewing said junction at a first location to permit visual inspection of the said junction.  
   
   
       28 . The load bearing fabric assembly of  claim 27  wherein said carrier has a second view port for viewing said junction at a second location different from said first location.  
   
   
       29 . The load bearing fabric assembly of  claim 28  wherein said first view port and said second view port are generally on a common plane.  
   
   
       30 . The load bearing fabric assembly of  claim 28  wherein said first view port and said second view port are in different planes.  
   
   
       31 . The load bearing fabric assembly of  claim 28  wherein said frame defines a channel, said carrier being fitted within said channel.  
   
   
       32 . The load bearing fabric assembly of  claim 21  wherein said first view port and said second view port extend through said frame to said channel.  
   
   
       33 . The load bearing fabric assembly of  claim 32  wherein said frame includes an interior surface, said first view port and said second view port being located along said interior surface.