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  Webbing for occupant restraint beltUSPTO Application #: 20070123128Title: Webbing for occupant restraint belt Abstract: A webbing for a seat belt comprises warp yarns and weft yarns made of synthetic filaments woven to extend perpendicular to each other. At least either of the warp yarns and the weft yarns are made of synthetic filaments having thermal adhesiveness, which include a bundle of first filaments and a second filaments. The second filament is attached to an outer surface of the first filament and has melting point lower than that of the first filament. The second filaments melt when heated at a temperature of 150° C. or more and a process time of 180 seconds or more so that the filament bodies are welded to each other. The webbing has a weight of 60 g/m or less, tensile strength of 25 kN or more, and retention rate after hexagonal bar abrasion of 70% or more. The occupant restraint belt is sufficiently stiff and has a reduced weight. (end of abstract) Agent: Foley And Lardner LLP Suite 500 - Washington, DC, US Inventors: Sadayuki Shimazaki, Itsuo Tabayashi USPTO Applicaton #: 20070123128 - Class: 442199000 (USPTO) Related Patent Categories: Fabric (woven, Knitted, Or Nonwoven Textile Or Cloth, Etc.), Woven Fabric (i.e., Woven Strand Or Strip Material), Strand Material Is Composed Of Two Or More Polymeric Materials In Physically Distinct Relationship (e.g., Sheath-core, Side-by-side, Islands-in-sea, Fibrils-in-matrix, Etc.) Or Composed Of Physical Blend Of Chemically Different Polymeric Materials Or A Physical Blend Of A Polymeric Material And A Filler Material The Patent Description & Claims data below is from USPTO Patent Application 20070123128. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND [0001] The present invention relates to a technology for developing an occupant restraint belt used for restraining an occupant in a vehicle in the event of a collision. [0002] For example, Japanese Unexamined Patent Publication No. 2004-315984, which is incorporated by reference herein in its entirety, discloses a conventional technology for developing such an occupant restraint belt. Japanese Unexamined Patent Publication No. 2004-315984 discloses a technology which relates to a seat belt that can have improved retractability and comfort by improving filament bundle and weaving arrangement thereof. SUMMARY OF THE INVENTION [0003] One embodiment of the invention relates to a webbing material for an occupant restraint belt that restrains a vehicle occupant. The webbing material comprises warp yarns and weft yarns woven together to form the webbing. The warp yarns and weft yarns being made of synthetic filaments such that the warp yarns and weft yarns extend perpendicular to each other. At least either of the warp yarns and the weft yarns are made of synthetic filaments with thermal adhesiveness. The synthetic filaments are formed by bundling a plurality of filament bodies. Each of the filament bodies includes a first filament and a second filament attached to an outer surface of the first filament. The second filament has a melting point lower than a melting point of the first filament. The second filaments melt when heated to temperature of 150.degree. C. or more and a process time of 180 seconds or more such that the filament bodies are welded to each other. The webbing has a weight of 60 g/m or less, tensile strength of 25 kN or more, and retention rate after hexagonal bar abrasion of 70% or more. [0004] Another embodiment of the invention relates to a seat belt. The seat belt comprises a webbing material that is configured to restrain an occupant in a vehicle. The webbing includes warp yarns and weft yarns woven together to form the webbing. The warp yarns and weft yarns are made of synthetic filaments such that the warp yarns and weft yarns extend perpendicular to each other. At least either of the warp yarns and the weft yarns are made of synthetic filaments with thermal adhesiveness. The synthetic filaments are formed by bundling a plurality of filament bodies. Each of the filament bodies includes a first filament and a second filament attached to an outer surface of the first filament. The second filament has a melting point lower than a melting point of the first filament. The second filaments melt when heated to a temperature of 150.degree. C. or more and a process time of 180 seconds or more such that the filament bodies are welded to each other. The webbing has a weight of 60 g/m or less, tensile strength of 25 kN or more, and retention rate after hexagonal bar abrasion of 70% or more. [0005] Yet another embodiment of the invention relates to a seat belt apparatus. The seat belt apparatus comprises a seat belt comprising a webbing material, a seat belt retractor capable of winding and unwinding the seat belt, a buckle fixed to a vehicle, and a tongue attached to the seat belt and latched to the seat belt buckle when the seat belt is worn by a vehicle occupant. The webbing material comprises warp yarns and weft yarns woven together to form the webbing. The warp yarns and weft yarns are made of synthetic filaments such that the warp yarns and weft yarns extend perpendicular to each other. At least either of the warp yarns and the weft yarns are made of synthetic filaments with thermal adhesiveness. The synthetic filaments are formed by bundling a plurality of filament bodies. Each of the filament bodies includes a first filament and a second filament attached to an outer surface of the first filament. The second filament has a melting point lower than a melting point of the first filament. The second filaments melt when heated to a temperature of 150.degree. C. or more and a process time of 180 seconds or more such that the filament bodies are welded to each other. The webbing material has a weight of 60 g/m or less, tensile strength of 25 kN or more, and retention rate after hexagonal bar abrasion of 70% or more. [0006] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only, and are not restrictive of the invention as claimed. BRIEF DESCRIPTION OF THE DRAWINGS [0007] These and other features, aspects, and advantages of the present invention will become apparent from the following description, appended claims, and the accompanying exemplary embodiments shown in the drawings, which are briefly described below. [0008] FIG. 1 is an illustration schematically showing the structure of a seat belt apparatus according to an embodiment. [0009] FIG. 2 is a table indicating weaving conditions and webbing properties of seat belt webbing composing a seat belt shown in FIG. 1 with regard to examples (Example 1 through Example 4) and a comparative example. [0010] FIG. 3 is an illustration showing a brief overview of the low melting point polyester filaments (thermal adhesion yarns). DETAILED DESCRIPTION [0011] When designing a seat belt of this kind, it is required to apply stiffness to the seat belt in order to restrain the occupant in the event of a vehicle collision. In addition, taking into consideration the occupant's comfort while wearing the seat belt and the ease of withdrawing the seat belt from a retractor, it is also required to reduce the weight of the seat belt (which is a long belt). To reduce the weight of the seat belt, the number of filaments in the filament yarns of the seat belt can be reduced. Though the technique of simply reducing the number of filaments achieves the reduction in weight, the technique has a risk of causing the reduction in stiffness according to the reduction in the number of filaments. In this case, it is difficult to achieve the desired performance of restraining the occupant. [0012] An object of the present invention is provide a technology which is effective both for applying stiffness and for reducing the weight of an occupant restraint belt to be installed in a vehicle. [0013] Embodiments of the present invention can be typically adapted to a seat belt or a safety belt as a mechanism for restraining an occupant in a vehicle, such as an automobile. [0014] The webbing for occupant restraint belt of a first embodiment is used for an occupant restraint belt (such as a seat belt), which is a long belt to be wound and unwound by a seat belt retractor, and a safety belt for an aircraft. The webbing for occupant restraint belt is webbing which is woven from warp yarns and weft yarns made of synthetic filaments such that the warp yarns and the weft yarns extend perpendicular to each other. [0015] In the webbing for an occupant restraint belt, at least either of the warp yarns and the weft yarns are made of synthetic filaments having thermal adhesiveness which are made by bundling a plurality of filament bodies each of which comprises a first filament and a second filament which is attached to the outer surface of the first filament and has a melting point lower than that of the first filament. The second filaments are melted when heated under a condition of a temperature of 150.degree. C. or more and a process time of 180 seconds or more so that the filament bodies are welded. The configuration of the filament bodies used here includes an embodiment in which the second filament is attached partially to the outer surface of the first filament and an embodiment in which the entire outer surface of the first filament is enclosed by a layer of the second filament, that is, a double layer structure. The synthetic filaments having thermal adhesiveness can be called "thermal welding type synthetic filaments" or "thermal adhesion yarns". In one alternative, either of the warp yarns and the weft yarns are made of synthetic filaments having thermal adhesiveness. In another alternative, both the warp yarns and the weft yarns are made of synthetic filaments having thermal adhesiveness. In this case, parts or all of the warp yarns and the weft yarns may be made of synthetic filaments having thermal adhesiveness. As a specific example of the synthetic filament having thermal adhesiveness, polyester filament may be employed. [0016] In the webbing of an occupant restraint belt, at least either of the warp yarns and the weft yarns are made of synthetic filaments having thermal adhesiveness which are made by bundling a plurality of filament bodies in which the second filaments are melted when heated under a condition of a temperature of 150.degree. C. or more and a process time of 180 seconds or more so that the filament bodies are welded to each other, whereby the second filaments (low melting point filaments) having lower melting point in the synthetic filaments having thermal adhesiveness are preferentially melted when heated under the aforementioned condition so that the adjacent filament bodies, i.e. the first filaments which are high melting point filaments, are welded to each other. That is, the second filaments having low melting point in the synthetic filaments having thermal adhesiveness exhibits works and effect as a binder for connecting the first filaments. Therefore, since the filament bodies are welded to each other, the overall stiffness of the webbing is enhanced. Thus, since the stiffness of the webbing is enhanced because of the yarns including the synthetic filaments having thermal adhesiveness, it allows reduction in number of filaments of warp yarns and weft yarns so as to achieve the weight saving. Accordingly, webbing for occupant restraint belt having weight of 60 g/m or less, tensile strength of 25 kN or more, and retention rate after hexagonal bar abrasion of 70% or more is obtained, thereby providing a seat belt having both sufficient stiffness and light weight properties. The measurement of tensile strength (force) of webbing was carried out by a method according to JIS L1096 8.12.1A and the measurement of retention rate after hexagonal bar abrasion of webbing was carried out by a method according to JIS D4604. [0017] The webbing for occupant restraint belt in a second embodiment of the invention has the same structure the first embodiment and is adapted such that the weft density is 20 picks per inch or less. [0018] As for the sectional configuration of webbing of this kind, the warp yarns are curved so as to form "crimps (ruffling)", while weft yarns extend linearly. This is a phenomenon unique to a weaving method (weaving structure) of woven fabric in which weft yarns are inserted into portions formed by spacing warp yarns alternately. In such an arrangement, the wavy profile of the crimps as curves of warp yarns can be smoothened by reducing weft density to 20 picks per inch or less, preferably 17 or less, thereby reducing stress concentration on the curves. Therefore, with regard to satisfaction of both stiffness and weight saving of webbing, a further improvement of performance can be obtained. [0019] The webbing for occupant restraint belt of the third embodiment has the same structure the first or second embodiments and is adapted such that at least either of the warp yarns and the weft yarns are made of filament yarn material of twist yarns or filament yarn material made of entangled non-twist yarn. In one alternative, the warp yarns or the weft yarns are made of filament yarn material of twist yarns or filament yarn material made of entangled non-twist yarn. In another alternative, both the warp yarns and the weft yarns are made of filament yarn material of twist yarns or filament yarn material made of entangled non-twist yarn. This increases the tangles of filaments so as to improve the cohesion thereof, thereby enhancing the stiffness of the webbing. Especially, using the filament yarn material made of entangled non-twist yarn contributes lower material cost than a case using the filament yarn material of twist yarns, thereby reducing the manufacturing cost of the webbing for occupant restraint belt. [0020] The seat belt of the fourth embodiment is an occupant restraint belt which comprises the webbing for occupant restraint belt as disclosed in any one of the first, second, or third embodiments. This arrangement allows satisfaction of both stiffness and weight saving of the seat belt. Continue reading... Full patent description for Webbing for occupant restraint belt Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Webbing for occupant restraint belt patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Webbing for occupant restraint belt or other areas of interest. ### Previous Patent Application: Flame-resistant material Next Patent Application: Upholstery for a passenger seat Industry Class: Fabric (woven, knitted, or nonwoven textile or cloth, etc.) ### FreshPatents.com Support Thank you for viewing the Webbing for occupant restraint belt patent info. 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