HK1051224A - Inflatable fabrics comprising basket-woven attachment points between fabric panels - Google Patents

Description

Inflatable fabric comprising basket weave attachment points between fabric faces

Reference to related applications

This application is a continuation of U.S. patent application Ser. No. 09/406,264, filed 24/9 1999.

Technical Field

The present invention relates to a fully woven inflatable fabric comprising a double layer fabric region and attachment points or "seams" forming a single layer fabric. The single layer fabric is composed of only a basket weave pattern. These particular single layer fabrics reduce the permeability of air throughout the fabric article in a relatively efficient manner by reducing the likelihood of yarn migration upon inflation of the inflatable fabric. Alternatively, the presence of at least one second single-layer fabric section adjacent to the first single-layer fabric and separated by a narrow double-layer fabric can further reduce the likelihood of yarn migration in the first single-layer fabric section. Such fabrics may be used in a variety of applications where an inflatable fabric is required or necessary. In particular, the fabric of the present invention may be incorporated into an airbag cushion.

Technical Field

All U.S. patents cited herein are incorporated by reference in their entirety.

An inflatable protection cushion for a passenger vehicle is an integral part of a relatively complex passive restraint protection system. The main elements of these systems are: a crash sensing system, an ignition system, a propellant material, an attachment device, a system housing, and an inflatable protective cushion. Upon sensing the impact, the propellant is ignited, causing an explosion, releasing gas to fill the cushion body, leaving the cushion body in a deployed state that cushions the forward motion of the body from the impact and dissipates its energy by rapidly venting the gas. The entire process of event occurrence is within 30 milliseconds. In the undeployed state, the cushion is stored in or near the steering column, the instrument panel, in the door, or is positioned on the back of the front seat nearest the person or thing to be protected.

Inflatable cushion systems generally refer to airbag systems that have been used in the past to protect the driver and passengers of motor vehicles. Systems for protecting the driver of a motor vehicle are generally installed in the steering column tube of the motor vehicle and have employed cushion structures that can be deployed directly to the driver. These driver-side bolsters are generally simpler in construction because they function over a relatively small well-positioned area between the driver and the steering column. One such structure is disclosed in U.S. patent 5,533,755 to Nelson et al, the contents of which are incorporated herein by reference.

Inflatable cushions for protecting occupants from collisions from the front or sides generally have a more complex structure, since the position of the occupant in the vehicle may not be well defined, and there is a significant distance between the occupant and the surface of the vehicle, which distance results in the occupant being thrown away in the event of a strong impact. Existing mats for such a case are disclosed in the following patents: bishop U.S. Pat. No. 5,520,414, Krickl U.S. Pat. No. 5,454,594, Hawthornen et al U.S. Pat. No. 5,423,273, Yamaji et al U.S. Pat. No. 5,316,337, Wehner et al U.S. Pat. No. 5,310,216, Watanabe U.S. Pat. No. 5,090,729, Wallner et al U.S. Pat. No. 5,087,071, Backhaus U.S. Pat. No. 4,994,529, and Buchner et al U.S. Pat. No. 3,792,873.

The primary commercial restraint protective liners are made of woven fabric materials employing multifilament synthetic yarns of materials such as polyester, nylon 6 or nylon 6,6 polymers. Representative fabrics for such use are disclosed in the following patents: U.S. Pat. No. 4,921,735 to Bloch, U.S. Pat. No. 5,093,163 to Krummbeuer et al, U.S. Pat. No. 5,110,666 to Menzel et al, U.S. Pat. No. 5,236,775 to Swoboda et al, Sollars, U.S. Pat. No. 5,277,230 to Jr, U.S. Pat. No. 5,356,680 to Krummbeuer et al, U.S. Pat. No. 5,477,890 to Krummbeuer et al, U.S. Pat. No. 5,508,073 to Krummbeuer et al, U.S. Pat. No. 5,503,197 to Bower et al. U.S. patent 5,651,395 to Graham et al discloses a double-weave construction (two-way construction) airbag cushion, but does not discuss the importance of a single layer fabric of narrow basket weave.

As will be appreciated, the air permeability of the cushion structure is an important factor in determining the rate of inflation and subsequent rapid deflation following a collision event. Different airbag cushions are used for different purposes. For example, some airbags are installed in an inflator in a steering column tube of an automobile to protect a driver. Others are mounted in or around the instrument box of the instrument panel and/or on the instrument panel in front of the passenger seats to protect the passengers in the front seats. Still others have been developed to protect all occupants during long duration crashes, such as rollover crashes. In these collisions, the target airbag cushion must inflate rapidly at high pressure (such as between about 10 and 40 psi) and remain inflated at relatively high pressure to provide maximum protection to the occupant. Moreover, such long lasting airbag cushions preferably comprise a "pillow" form by joining together at least two different fabrics or warp yarns of the fabrics in a sealed, sewn or similar manner. When inflated, the free spaces between the attachment points inflate to create the desired "pillow" structure of the cushion. In the prior art, U.S. Pat. No. 5,788,270 to Halano et al discloses such a long duration "pillow" configuration air bag cushion. However, in order to provide a suitable and effective airbag fabric, as well as a cushion body that includes two or more attachment points between the fabric or fabric warp yarns, improvements in the overall structure of the seams at these attachment points are needed to prevent unwanted or potential risk of gas or air leakage from the target airbag cushion body. The prior art has discussed coating of sewn seams at the attachment points to seal off potentially loose portions of these seams and/or to keep individual yarns of the airbag fabric secured at the attachment points from moving and possibly creating openings for air or gas leakage. However, such coatings are actually complementary to the seam structure to provide the necessary insulation from air or gas. A strong, effective, and efficient weave structure is the primary method of initially producing an effective airbag fabric that is incorporated into the body of an airbag cushion.

Previous efforts have been made to produce inflatable fabrics containing "pillow-type" chambers (e.g., side panels, etc.) that are made solely by a weaving process, which exhibit reduced air permeability in the woven structure (i.e., the fabric is not sewn together to form the inflatable structure). For example, U.S. patent 5,011,183 to Thornton et al is the closest prior art, which discloses an inflatable fabric structure comprising at least two different regions of different fabric layers. Patentees discuss two-layer fabrics woven in a plain weave and a single layer construction of a variety of different weave patterns. The junction between two different fabric layer regions must have at least three different fabric densities (which are determined by the weave structure) with two relatively loose structures (double layer plain weave and single layer basket weave) separated by one relatively tight structure (single layer plain weave). Such an integral inflatable fabric structure may have the air permeability necessary for the proper function of a side curtain airbag cushion (especially when coated with standard airbag coating compositions); however, many variations in fabric density also apply different pressures at discrete areas of the fabric (particularly at or near the junctions between different fabric layer regions), so that yarn migration is highly likely to occur upon inflation, which can cause discontinuities in the overall coating, thereby compromising the long-term air permeability required for certain airbag applications.

Previous efforts have been made to improve such fabrics; these efforts, however, have resulted in an increase in the number of different fabric density regions on the fabric, rather than a decrease in such different regions. For example, a plain weave structure has been used in a double layer region adjacent to a transition weave pattern that is joined to an Oxford weave pattern, and then a basket weave or plain weave structure is used on the fabric for the remainder of the single layer region. A first problem encountered is that such complex patterns are difficult to produce on weaving equipment. Second, attempts have been made to use an Oxford weave area to prevent the problems encountered with plain weave patterns (which are highly undesirable due to the difficulty of making such high density single layer fabrics with double layer numbers of yarns). However, if the single layer area of the fabric is not substantially straight, it must conform to a curved structure, and thus the Oxford weave will eventually become a plain weave, at least in the area around the curved seam. In such a case, the junction between the two different layers of the fabric will be irregular, always producing an undesirable and/or irregular number of floats (floats) (i.e., passing over or under a certain number of vertically oriented yarns; if greater than three, it will be difficult to avoid yarn migration, as just one example). Thus, the barrier to air permeability of the finished fabric itself is very unsatisfactory, although coatings may be used to improve this performance. Third, the individual yarns in the seam between the bi-layer and mono-layer regions, which would be placed under significant tension during inflation (as described by Thornton et al), would most likely cause the yarns to move. Because of this yarn movement, the permeability benefits (if any) are most likely to be compromised again, and the resulting airbag fabric will not perform as desired.

To date, there is no method or fabric structure that can both remedy this problem and efficiently knit with a single step process. Thus, there is a clear need for improved inflatable fabrics.

Disclosure of Invention

In view of the foregoing, it is a general object of the present invention to provide an inflatable fully woven fabric having a full grain weave seam at the single/double layer junction within the fabric. It is a more specific object of the present invention to provide a fully woven inflatable fabric (to form a "pillow-type" chamber) having a double fabric region and a single fabric region that includes up to two fabric densities throughout the fabric structure. Moreover, it is an object of the present invention to utilize such an inflatable fabric as an airbag cushion in an automotive restraint system. The term "vehicle restraint system" refers to inflatable restraint cushion devices and mechanochemical devices such as inflators, igniters, propellants and the like.

To achieve these and other objects, and in accordance with the purpose of the present invention, as embodied and broadly described herein, there is provided an inflatable fabric comprising at least two layers of fabric at certain discrete areas of the fabric, at least one narrow single layer fabric at the discrete areas within said fabric, wherein said at least one narrow single layer fabric is formed of a basket weave pattern of even number yarns only, having a width of at most 12 yarns. As is well known to those skilled in the textile industry, the weave structure of the single layer fabric is preferably a 2 x 2 basket weave pattern with a maximum length of 4 to 8 yarns. Furthermore, the present invention encompasses an inflatable fabric comprising at least two layers of fabric in certain discrete areas of the fabric, at least one single layer of fabric in which the discrete areas comprise, wherein the weave pattern has no more than three unfilled cells in any row or column in succession. Furthermore, the present invention relates to an inflatable fabric comprising at least two layers of fabric in certain discrete areas of the fabric and at least one single layer of fabric in said discrete areas of the fabric, wherein only two different fabric densities are present in the overall fabric structure.

The term "inflatable fabric" is intended to encompass any fabric that is made up of at least two layers of fabric that can be sealed to form a bag. The inflatable fabric of the present invention must therefore include a double layer of fabric to satisfy the inflation, and a single layer of fabric to act as a seal for the fabric face ends or to provide "pillow-type" cells within the target fabric when inflated. The term "fully woven" for the fabric of the present invention requires that the inflatable fabric, having either a double or single layer, can be manufactured separately on a loom. Any type of loom may be used for this purpose, such as water jet, air jet, dobby looms, and the like. However, jacquard weaving and dobby weaving are most preferred.

The resulting fabric may have a balanced or unbalanced weft/warp count, the weave construction essentially requiring that the individual basket patterns be provided in the individual layer regions of the inflatable fabric. These patterns are made by arranging at least one warp (or weft) yarn on the same side of two adjacent weft (or warp) yarns within the weave pattern. The same weft (or warp) yarns are arranged on the opposite side in close proximity so that the resulting pattern is "basket-like". This basket weave pattern may include warp yarns (or weft yarns) arranged on the same side of any even number of weft yarns (or warp yarns). Preferably up to about six at a time.

This use of the basket weave pattern alone in the single layer region produces heretofore undiscovered benefits in inflatable fabric construction. For example, such basket weave patterns may provide a constant "seam" width and weave pattern throughout a single layer region, even when the region is curved. As mentioned above, the common standard Oxford weave does not maintain the same weave pattern around the curved seam and they will become a plain weave pattern. Moreover, this basket weave seam pattern provides the inflatable fabric structure with only plain weave double layer fabric areas, and a single layer "seam" with no "floats" greater than three picks throughout the fabric structure. Such a fabric will not have discrete areas of air permeability substantially greater than the remainder of the fabric. In general, the prior art (e.g., "supra" by Thornton et al) sometimes produces floats of up to six or seven picks at a time. While there are methods in the textile industry to "fill in" these floats within the weave pattern, this process takes time and still does not continuously provide a fabric with substantially uniform air permeability throughout the structure. To prevent irregularities in the weave structure (e.g., a large number of floats) at the junction between the single and double layer fabrics (as shown in figure 2 below), a basket weave structure must be arranged in the single layer fabric in the fabric structure. Another benefit to the user of the basket weave pattern is the ability to create more than one single fabric region (i.e., another "seam" in the fabric) adjacent to a first "seam". This second seam provides a means to dissipate the pressure from each yarn of the two seams and transfer the load. Thus, the benefits are: by applying a strictly woven textile structure (i.e. without the need for simultaneous coating), detrimental yarn movement is reduced in case of inflation. Previously disclosed or applied inflatable fabrics having double or single fabric regions did not disclose the possibility of using such a two-basket weave pattern seam. Moreover, the two-seam construction does not require weaving a large single fabric region within the target inflatable fabric. Prior art fabrics for airbag cushions having "pillow-type" chambers, such as side panels, are formed by weaving an entire single layer of fabric (which is not itself actually a seam). This process is both time consuming and difficult to implement. In this embodiment, the inflatable fabric of the present invention requires only at least two very narrow single layer fabrics (seams) woven into the fabric structure (another preferred embodiment uses only one seam of a single layer fabric); the remaining portion of the fabric in these two regions may be double layered if desired. In this way, the fabric of the present invention enables an improved and cost effective method of manufacturing a "pillow-type" inflatable fabric.

The inflatable fabric itself is preferably made of fully synthetic fibers, such as polyester and polyamide, although natural fibers may also be used in some cases. Preferably, the fabric is made of 6, 6-nylon. Each yarn used in the fabric substrate must generally have a thickness of from about 40 to about 840 denier; preferably from about 100 to about 630.

As mentioned above, a coating should be applied to the surface as a necessary supplement to the air permeability of the fabric of the present invention. Because one preferred application of the fabric of the present invention is as a side curtain airbag, which must maintain very low air permeability throughout a crash (e.g., rollover, the curtain must protect the occupant for an extended period of time), there is a pressing need to reduce air permeability. Any standard coating such as silicone, polyurethane, polyamide, polyester, rubber (e.g., neoprene), etc. may be used for this purpose, and any standard method may be used to apply any standard amount to the fabric surface.

Additional objects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. 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 scope of the invention, as claimed.

Drawings

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several possible preferred embodiments of the invention and together with the description, serve to explain the principles of the invention:

FIG. 1 is a cross-sectional view of a fully woven inflatable fabric of the present invention showing the preferred double and single layer regions comprising two spaced single layer regions.

FIG. 2 is a weave pattern showing a possible preferred repeating weft yarn pattern formed by a four-weft yarn arrangement that repeats a plain weave and basket weave.

Detailed Description

Referring now to the drawings, FIG. 1 is a cross-sectional view of a preferred construction showing the double layer fabric 12, 14, 18, 20, 24, 26 and the single layer fabric 16, 22 of the fabric 10 of the present invention. Each of the fabric layer areas 12, 14, 16, 18, 20, 22, 24, 26 has a weft yarn 28 therein over or under which a respective warp yarn 38, 40, 42, 44 is woven. The double layer fabrics 12, 14, 18, 20, 24, 26 are woven in a plain weave pattern. The single layer fabrics 16, 22 are woven in a basket weave pattern. In the preferred construction, every fourth weft yarn forms a repeating basket weave pattern. However, any two to twelve weft yarns may be used in the single fabric regions (seams) 16, 22. The middle double fabric regions 18, 20 each contain only four weft yarns 28 in a plain weave pattern. The number of such intermediate weft yarns 28 between the single fabric regions 16, 22 must be a multiple of 2 to provide maximum compression resistance within the two seams 16, 22, thereby minimizing the likelihood of yarn migration at the junction of the seams 16, 22 and the double fabric regions 12, 14, 24, 26 when inflated.

Figure 2 shows a weave pattern 30 of the fabric of the present invention comprising two irregularly shaped concentric circles as the seam. This pattern also provides a general indication of the need to select basket weave pattern alignment criteria within the fabric itself. Three different pattern types are shown with different shading. The first 32 represents a repeating plain weave pattern throughout the double layer fabric (e.g., 12, 14, 18, 20, 24, 26 of fig. 1) that must always be aligned starting with the warp direction 4X +1 (where X represents the number of weft yarns aligned in the pattern) and the weft direction 4X +1 (whereby the weft yarns comprising a particular two layer plain weave flag 32 are aligned starting with two directions of the four empty spaces beneath it). The third type 34 represents an "over-under" basket weave pattern wherein, when a seam (such as 16 and 22 in FIG. 1) is desired (thus, including the pattern associated with the designation "over-under" block 34, including a void block within the basket weave weft yarn arrangement in the four spaces warp and weft thereunder), the basket weave pattern must have a void block and always begin with positions 4X +1 in the warp direction (where X represents the number of weft yarns that are repeatedly arranged in the pattern) and 4X +1 in the weft direction. The remaining pattern is essentially a "under-over" basket weave pattern in a single layer fabric (e.g., 16 and 22 in fig. 1), represented by the particular shaded blocks 36. When a seam is desired, the pattern must always be arranged starting with either the warp direction 4X +1 and weft direction 4X +3, or the warp direction 4X +3 and weft direction 4X + 1. This particular arrangement of the different "up-down" basket weave 34 and "down-up" basket weave 36 patterns is necessary to achieve continuity and repetition of the basket weave structure while not exceeding the presence of three floats (i.e., void pieces) in the target fabric structure. Moreover, there is believed to be no disclosure or discovery of this principle in the prior art of inflatable fabrics.

While particular embodiments of the present invention have been illustrated and described, it will be understood, however, that the invention is not limited thereto since various modifications and other arrangements consistent with the principles of the invention will no doubt occur to those skilled in the art. This modification includes, without limitation, the reverse, symmetrical or offset (offset) etc. versions of the two pattern combinations of the inventive fabric described above. It is therefore contemplated by the appended claims to cover any such modifications and other arrangements incorporating the features of the invention which fall within the spirit and scope of the claims.

Claims (69)

1. An inflatable fabric comprising at least two layers of fabric in certain discrete areas of the fabric, and at least one narrow single layer of fabric in discrete areas within said fabric, wherein said at least one narrow single layer of fabric is formed from a basket weave pattern of only an even number of yarns, having a width of at most 12 yarns.

2. The fabric of claim 1, wherein said at least two layers of fabric within the inflatable fabric are formed from only one weave pattern, wherein said weave pattern is not a basket weave pattern.

3. The fabric of claim 2 wherein the weave pattern of said at least two layers of fabric within said inflatable fabric is a plain weave pattern.

4. The fabric of claim 1 wherein within said inflatable fabric there are discrete narrow regions of at least two single layer fabrics, wherein said at least two single layer fabrics are separated by a double layer fabric region, wherein each single layer has a length of 4 to 8 yarns.

5. The fabric of claim 4 wherein said at least two single fabric regions are seams in the inflatable fabric that are parallel to each other.

6. The fabric of claim 4 wherein said at least two single layer fabric regions are comprised of only basket weave patterns, each basket weave pattern comprising at least two yarns and at most four yarns.

7. The fabric of claim 5 wherein the double fabric separation region between the two single fabric regions comprises an even number of weft yarns.

8. The fabric of claim 7 wherein the double layer fabric separation region comprises at most 12 picks and at least 2 picks.

9. The fabric of claim 8 wherein said at least two single layer fabrics consist of only a 2 x 2 basket weave pattern and said double layer fabric spacer region comprises four weft yarns.

10. An inflatable fabric comprising at least two layers of fabric in certain discrete areas of the fabric and at least one single layer of fabric in discrete areas within said fabric, wherein the weave pattern of the fabric has no more than three continuous unfilled blocks in any row or column.

11. An inflatable fabric comprising at least two layers of fabric in certain discrete areas of the fabric and at least one single layer of fabric in discrete areas within said fabric, wherein only two different weave densities are present throughout the fabric structure.

12. An inflatable fabric comprising at least two layers of fabric in certain discrete areas of the fabric and at least one narrow single layer of fabric in at least two discrete areas within said fabric, wherein said at least one narrow single layer of fabric is formed only from a basket weave pattern having an even number of yarns, wherein within said inflatable fabric there are at least two discrete narrow areas of single layer fabric, wherein said at least two single layer fabric areas are separated by at least two layers of fabric area and each single layer has a width of 4 to 8 yarns.

13. The fabric of claim 12 wherein said two single fabric regions are seams in the inflatable fabric that are parallel to each other.

14. The fabric of claim 12 wherein said at least two single layer fabric regions are comprised of only basket weave patterns, each basket weave pattern comprising at least two yarns and at most four yarns.

15. The fabric of claim 12 wherein the double fabric separation region between the two single fabric regions comprises an even number of weft yarns.

16. The fabric of claim 15 wherein said double layer fabric separation region comprises at most 12 picks and at least 2 picks.

17. The fabric of claim 16 wherein said at least two single layer fabrics consist of only a 2 x 2 basket weave pattern and said double layer fabric spacer region comprises four weft yarns.

18. The fabric of claim 12, wherein said fabric has three different types of patterns: the first pattern is a repeating plain weave pattern through at least two layers of fabric which must always be arranged starting from the 4X +1 position in the warp direction and the 4X +1 position in the weft direction, where X represents the number of weft yarns arranged in the weave pattern, such that the weft yarn arrangement comprising a particular two layer plain weave pattern patch starts from two directions with four spaces therebelow; the second pattern is an "over-under" basket weave pattern in which a void piece must be present when a seam is desired, and which always starts with a warp direction of 4X +1 and a weft direction of 4X +1, where X represents the number of weft yarns that are repeatedly arranged in the pattern, such that the pattern containing the "over-under" piece includes a void piece in the basket weave weft yarn arrangement in its lower warp and weft spaces; the third pattern is primarily a "bottom-top" basket weave pattern for a single layer fabric, which must always be aligned from 4X +1 in the warp direction and 4X +3 in the fill direction, or 4X +3 in the warp direction and 4X +1 in the fill direction, when a seam is desired; this particular arrangement of the different "up-down" basket weave and "down-up" basket weave patterns is necessary to achieve continuity and repetition of the basket weave structure while at the same time there are no more than three floats or void blocks in the target fabric structure.

19. A fabric according to claim 12 wherein there are weft yarns in each fabric section, and warp yarns are woven over or under the fabric section, and the at least two fabric sections are woven in a plain weave pattern, and the single fabric section is woven in a basket weave pattern, with every fourth weft yarn constituting a repeating basket weave pattern, however, any two to twelve weft yarns may be used in the seams of the single fabric section, and the middle double fabric section contains only four weft yarns per layer in a plain weave pattern, such that the number of intermediate weft yarns between the single fabric sections must be a multiple of two to provide maximum compression resistance in the two seams of the at least two fabric sections.

20. The fabric of claim 12 wherein each of the at least two discrete stenotic regions of the single layer fabric form at least one of a seam and a seal.

21. The fabric of claim 12 wherein at least one of the at least two discrete stenotic regions of the single layer fabric forms at least one of a non-linear seam and a seal.

22. The fabric of claim 12 wherein the at least two discrete constriction regions and the at least two fabric regions of the single layer of fabric form at least one pillow-type chamber.

23. The fabric of claim 12, wherein said fabric is formed on at least one of a jacquard loom and a dobby loom.

24. The fabric of claim 12 wherein said fabric is sealed to form a pouch.

25. An improved inflatable fully woven fabric airbag cushion comprising at least two layers of fabric at certain discrete areas of the fabric and at least one single layer of fabric at the discrete areas of the fabric that forms at least one of a seam and a seal, wherein the fabric has no more than three picks present.

26. The airbag cushion of claim 25, wherein there are only two different weave densities throughout the fabric structure.

27. The airbag cushion of claim 25, wherein at least two layers of fabric within said inflatable fabric are formed from only one weave pattern, wherein said weave pattern is not a basket weave pattern.

28. The airbag cushion of claim 27, wherein the weave pattern of said at least two layers of fabric in said inflatable fabric is a plain weave pattern.

29. The airbag cushion of claim 25, wherein a weave pattern having rows and columns of fabric fill or unfilled does not have more than three consecutive unfilled blocks in any row or column.

30. The airbag cushion of claim 25, wherein the fabric is coated.

31. The airbag cushion of claim 25, wherein the at least one narrow single layer fabric forms an edge seal.

32. The airbag cushion of claim 25, wherein the at least one single-layer fabric region consists only of basket weave patterns, each basket weave pattern comprising at least two yarns and at most four yarns.

33. The airbag cushion of claim 25, wherein the at least two fabric regions comprise an even number of weft yarns.

34. The air bag cushion of claim 33 wherein the at least two fabric regions comprise at most 12 picks and at least 2 picks.

35. The airbag cushion of claim 34, wherein said at least one single layer fabric consists of only a 2 x 2 basket weave pattern and said at least two layer fabric region comprises four weft yarns.

36. The airbag cushion of claim 25, wherein the airbag cushion is a side curtain airbag.

37. The airbag cushion of claim 25, wherein the airbag cushion has pillow-shaped chambers.

38. The airbag cushion of claim 25, wherein the at least one narrow single layer fabric forms at least one of a non-linear seam and a seal.

39. The airbag cushion of claim 25, wherein the at least one narrow single-layer fabric region and the at least two-layer fabric region form at least one pillow-type chamber.

40. The airbag cushion of claim 25, wherein the fabric has three different types of patterns: the first pattern is a repeating plain weave pattern through at least two layers of fabric which must always be arranged starting from the 4X +1 position in the warp direction and the 4X +1 position in the weft direction, where X represents the number of weft yarns arranged in the weave pattern, such that the weft yarn arrangement comprising a particular two layer plain weave pattern patch starts from two directions with four spaces therebelow; the second pattern is an "over-under" basket weave pattern in which a void piece must be present when a seam is desired, and which always starts with a warp direction of 4X +1 and a weft direction of 4X +1, where X represents the number of weft yarns that are repeatedly arranged in the pattern, such that the pattern containing the "over-under" piece includes a void piece in the basket weave weft yarn arrangement in its lower warp and weft spaces; the third pattern is primarily a "bottom-top" basket weave pattern for a single layer fabric, which must always be aligned from 4X +1 in the warp direction and 4X +3 in the fill direction, or 4X +3 in the warp direction and 4X +1 in the fill direction, when a seam is desired; this particular arrangement of the different "up-down" basket weave and "down-up" basket weave patterns is necessary to achieve continuity and repetition of the basket weave structure while at the same time there are no more than three floats or void blocks in the target fabric structure.

41. The airbag cushion of claim 25, wherein there are weft yarns in each fabric section, and warp yarns are woven above or below the fabric section, the at least two fabric sections are woven in a plain weave pattern, the single fabric section is woven in a basket weave pattern, and every four weft yarns make up a repeating basket weave pattern, however, any two to twelve weft yarns may be used in the single fabric section seams, and the middle double fabric section contains only four weft yarns per layer in a plain weave pattern, such that the number of intermediate weft yarns between the single fabric sections must be a multiple of two to provide maximum compression resistance in the two seams of the at least two fabric sections.

42. The airbag cushion of claim 25, wherein there are at least two discrete narrow zones of single layer fabric within the inflatable fabric.

43. The airbag cushion of claim 42, wherein the at least two single-layer fabric regions are seams through the inflatable fabric.

44. The airbag cushion of claim 25, wherein the fabric is formed on at least one of a jacquard loom and a dobby loom.

45. An inflatable fully woven fabric for use as a pillow-type cell inflatable protection cushion in automotive passive restraint including systems such as side screens, comprising at least two layers of fabric at certain discrete areas of the fabric, and at least one narrow single layer of fabric at discrete areas within the fabric, wherein the at least one narrow single layer of fabric is formed of only a 2 x 2 basket weave pattern of even numbered yarns, having a width of at most 12 yarns.

46. The fabric of claim 45, wherein at least two layers of fabric within said inflatable fabric are formed from only one weave pattern, wherein said weave pattern is not a basket weave pattern.

47. The fabric of claim 46, wherein said weave pattern of said at least two layers of fabric in said inflatable fabric is a plain weave pattern.

48. The fabric of claim 45, wherein there are discrete narrow regions of at least two single layer fabrics within said inflatable fabric, wherein said at least two single layer fabrics are separated by a double layer fabric region, and wherein each single layer has a length of 4 to 8 yams.

49. The fabric of claim 45, wherein said at least two single fabric regions are seams running through the inflatable fabric.

50. The fabric of claim 45, wherein said fabric is formed on at least one of a jacquard loom and a dobby loom.

51. The fabric of claim 45, wherein the fabric is sealed to form a pouch.

52. The fabric of claim 4, wherein said fabric is formed on at least one of a jacquard loom and a dobby loom.

53. An improved passive restraint system for an automobile occupant comprising an inflatable protection cushion body comprising at least two layers of fabric at certain discrete areas of the fabric and at least one narrow single layer of fabric at discrete areas within said fabric, wherein said at least one narrow single layer of fabric is formed from a basket weave pattern of only an even number of yarns, a maximum width of 12 yarns, and at least one of a seam and a seal is formed, there being three picks or less of float.

54. An improved airbag comprising an inflatable protection cushion body comprising at least two layers of fabric in certain discrete areas of the fabric and at least one narrow single layer of fabric in discrete areas within said fabric, wherein said at least one narrow single layer of fabric is formed from a basket weave pattern of only an even number of yarns, a maximum width of 12 yarns, and at least one of seams and seals are formed, with float yarns present of three weft yarns or less.

55. An improved side curtain airbag comprising an inflatable protection cushion comprising at least two layers of fabric in certain discrete areas of the fabric and at least one narrow single layer of fabric in discrete areas within said fabric, wherein said at least one narrow single layer of fabric is formed from a basket weave pattern of only an even number of yarns, a maximum width of 12 yarns, and at least one of a seam and a seal is formed, there being three picks or less.

56. An inflatable fabric for use as an inflatable protection cushion in an occupant restraint protection system, comprising at least two layers of fabric in certain discrete areas of the fabric and at least one narrow single layer of fabric in discrete areas within said fabric, wherein said at least one narrow single layer of fabric is formed from a basket weave pattern of only an even number of yarns, has a maximum width of 12 yarns, and forms at least one of a non-rectangular seam and a seal.

57. An improved airbag cushion having a multi-layer portion and a single-layer portion, comprising:

a narrow single fabric seam edge, followed by a double fabric edge, followed by at least one additional narrow single fabric seam edge.

58. The airbag cushion of claim 57, wherein the narrow single layer fabric seam edge is less than or equal to 12 yarns.

59. The airbag cushion of claim 57, wherein the narrow single-layer fabric seam edge consists of a 2 x 2 plain weave pattern of 2-12 yarn widths.

60. The airbag cushion of claim 57, wherein the narrow single-layer fabric seam edge has floats of substantially no more than 3 picks.

61. An improved airbag cushion formed from a single knit having multiple layers and a single layer portion includes at least one seam comprising a narrow single layer fabric region between two double layer fabric regions.

62. The airbag cushion of claim 61, wherein the at least one narrow single-layer fabric seam has a width of less than or equal to 12 yarns.

63. The airbag cushion of claim 61, wherein the at least one narrow single-layer fabric seam consists of a 2 x 2 plain weave pattern of 2-12 yarn widths.

64. The airbag cushion of claim 61, wherein at least one narrow single-layer fabric seam has floats of substantially no more than 3 picks.

65. The airbag cushion of claim 61, wherein at least one narrow single-layer fabric seam has at least one curved portion.

66. The airbag cushion of claim 61, wherein the weave comprises a woven fabric having only two weave densities in at least one narrow single fabric seam region.

67. An inflatable fabric for use as an inflatable protection cushion body in an occupant restraint protection system, comprising at least two layers of fabric in certain discrete areas of the fabric and at least one narrow single layer of fabric in discrete areas within said fabric, wherein said at least one narrow single layer of fabric is formed from a basket weave pattern of only an even number of yarns, a maximum width of 12 yarns, and at least one of a seam and a seal is formed, there being three picks or less of float.

68. The fabric of claim 67, wherein at least two layers of fabric within said inflatable fabric are formed from only one weave pattern, wherein said weave pattern is not a basket weave pattern.

69. The fabric of claim 68, wherein said weave pattern of said at least two layers of fabric inside said inflatable fabric is a plain weave pattern.