METHOD OF REINFORCING A SEAM AND A PRODUCT WITH A REINFORCED SEAM IN ACCORDANCE WITH THE METHOD

Abstract

A method of reinforcing a seam on a body involves folding a seam allowance into a series of accordion folds to form a series of parallel reinforcement layers. The parallel reinforcement layers are of similar size and form a ridge. A ridge cap of flexible material is placed over the ridge. The ridge cap provides at least one further parallel reinforcement layer. The method involves securing the ridge cap and parallel reinforcement layers together with rows of stitching, with the stitching extending through all of the parallel reinforcement layers.

Claims

1. A method of reinforcing a seam on a body, comprising: positioning two edges of flexible material together to form a seam allowance and positioning a first row of stitching on the seam allowance spaced from the body; folding the seam allowance into a series of accordion folds to form the seam allowance into a series of parallel reinforcement layers, with the reinforcement layers being of similar size and forming a ridge; positioning a ridge cap of flexible material over the ridge, with the ridge cap providing at least one further parallel reinforcement layer of the series of parallel reinforcement layers; and securing the ridge cap and parallel reinforcement layers together with further rows of stitching positioned between the first row of stitching and the body, with the stitching extending through all of the parallel reinforcement layers.

2. The method of claim 1, wherein the series of accordion folds, comprises: a first accordion fold oriented in a first direction and forming a first reinforcement layer of the series of parallel reinforcement layers, the first reinforcement layer being secured parallel to the seam allowance by a second row of stitching, a second accordion fold oriented in a second direction and forming a second reinforcement layer of the series of parallel reinforcement layers, the second reinforcement layer being secured parallel to the first reinforcement layer and the seam allowance by a third row of stitching.

3. The method of claim 2, wherein a remote end of the seam allowance is folded over the ridge and oriented in the first direction to serve as a ridge cap, while forming a third reinforcement layer of the series of parallel reinforcement layers, the third reinforcement layer being secured by at least one of the third row of stitching or a fourth row of stitching.

4. A product, comprising: a body made from flexible material, with two edges of the flexible material positioned together to form a seam allowance, with a first row of stitching on the seam allowance spaced from the body; the seam allowance having a series of accordion folds to form the seam allowance into a series of parallel reinforcement layers, with the parallel reinforcement layers being of similar size and forming a ridge; a ridge cap of flexible material positioned over the ridge, with the ridge cap providing at least one further parallel reinforcement layer of the series of parallel reinforcement layers; and the ridge cap and parallel reinforcement layers being secured together with further rows of stitching positioned between the first row of stitching and the body, with the stitching extending through all of the parallel reinforcement layers.

5. The product of claim 4, wherein the series of accordion folds, comprises: a first accordion fold oriented in a first direction and forming a first reinforcement layer of the series of parallel reinforcement layers, the first reinforcement layer being secured parallel to the seam allowance by a second row of stitching, and a second accordion fold oriented in a second direction and forming a second reinforcement layer of the series of parallel reinforcement layers, the second reinforcement layer being secured parallel to the first reinforcement layer and the seam allowance by a third row of stitching.

6. The product of claim 5, wherein a remote end of the seam allowance is folded over the ridge and oriented in the first direction, thereby forming a third reinforcement layer of the series of parallel reinforcement layers, the third reinforcement layer being secured by at least one of the third row of stitching or a fourth row of stitching.

7. A method of reinforcing a seam on a body, comprising: folding a seam allowance into a series of accordion folds to form a series of parallel reinforcement layers, the parallel reinforcement layers being of similar size which forms a ridge; placing a ridge cap of flexible material over the ridge, the ridge cap providing at least one further parallel reinforcement layer; and securing the ridge cap and parallel reinforcement layers together with rows of stitching, with the stitching extending through all of the parallel reinforcement layers.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] These and other features will become more apparent from the following description in which reference is made to the appended drawings, the drawings are for the purpose of illustration only and are not intended to be in any way limiting, wherein:

[0015] FIG. 1 is a first end elevation view, in section, showing a first step of fabricating a seam on an inflatable tube of an air frame.

[0016] FIG. 2 is a second end elevation view, in section, showing a second step of fabricating a seam on the inflatable tube of FIG. 1.

[0017] FIG. 3 is a third end elevation view, in section, showing a third step of fabricating a seam on the inflatable tube of FIG. 2.

[0018] FIG. 4 is a fourth end elevation view, in section, showing a fourth step of fabricating a seam on the inflatable tube of FIG. 3.

[0019] FIG. 5 is a first end elevation view, in section, showing a first step of fabricating a seam on a load bearing surface.

[0020] FIG. 6 is a second end elevation view, in section, showing a second step of fabricating a seam on a load bearing surface of FIG. 5.

[0021] FIG. 7 is a third end elevation view, in section, showing a third step of fabricating a seam on a load bearing surface of FIG. 6.

[0022] FIG. 8 is a fourth end elevation view, in section, showing a fourth step of fabricating a seam on a load bearing surface of FIG. 7.

DETAILED DESCRIPTION

[0023] A method of reinforcing a seam on a body will now be described with reference to FIG. 1 through FIG. 8. FIG. 1 through 4 depict the method as applied to an inflatable tubular air frame. FIG. 5 through 8 depict the method as applied to a load bearing surface. There is a single method, the illustrations are simply intended to show that the method can apply to a tubular body, such as an inflatable tubular air frame or to planar abutting connections of load bearing surfaces on a body. The load bearing surface may occur in a wide variety of products, possible examples might be a dry bag or a backpack.

[0024] The method involves positioning two edges of flexible material together to form a seam allowance 16. Referring to FIG. 1, there is a single sheet of flexible material 10 having two edges 11. The single sheet of flexible material 10 is formed into a tubular body 12. A gas holding inner bladder 14 is positioned within tubular body 12. A first row of stitching 20 is placed on seam allowance 16 spaced from tubular body 12. First row of stitching 20 secures inner surfaces 18 of seam allowance 16 together. Referring to FIG. 5, a body, generally indicated by reference numeral 35, is intended to depict a portion of a load bearing surface. Body 35 has two sheets 36 of flexible material positioned in abutting relation with the edges 37 of sheets 36 forming a seam allowance 16. A first row of stitching 20 is placed on seam allowance 16 spaced from body 35. First row of stitching 20 secures inner surfaces 18 of seam allowance 16 together. Notwithstanding, the differences between FIG. 1 through FIG. 4 and FIG. 5 through FIG. 8, the manner of reinforcing first row of stitching 20 is identical.

[0025] In broad terms, the manner of reinforcing first row of stitching 20 involves folding seam allowance 16 into a series of accordion folds to form seam allowance 16 into a series of parallel reinforcement layers. The parallel reinforcement layers are of similar size and are secured together to protect first row of stitching 20.

[0026] The parallel reinforcement layers form a ridge. A ridge cap of flexible material is positioned over the ridge and secured to the parallel reinforcement layers and the seam allowance.

[0027] The preferred embodiments will now be described in detail with reference to the Figures Referring to FIG. 1, the series of accordion folds, described above includes a first accordion fold 22 oriented in a first direction (depicted as downward on the page), which forms a first reinforcement layer 23 of the series of parallel reinforcement layers described above. Referring to FIG. 2, first reinforcement layer 23 is secured parallel to seam allowance 16 by a second row of stitching 24. Referring to FIG. 2, a second accordion fold 26 is oriented in a second direction (depicted as upward on the page), which forms a second reinforcement layer 27 of the series of parallel reinforcement layers.

[0028] Referring to FIG. 3, parallel reinforcement layers (first reinforcement layer 23, second reinforcement layer 27, and seam allowance 16) when secured together form a ridge 29. A remote end 28 of seam allowance 16 is folded over ridge 29 and oriented in the first direction (depicted as downward on the page) to serve as a ridge cap 30. Remote end 28 of seam allowance 16 also forms a third reinforcement layer 31 of the series of parallel reinforcement layers. This third reinforcement layer 31 is secured by third row of stitching 32 as depicted in FIG. 3 and, if required, a fourth row of stitching 34 as depicted in FIG. 4. The addition of ridge cap 30 and third reinforcement layer 31 serves to bury first row of stitching 20 within the reinforcement layers created by the accordion folds, distributing the hoop stress forces of inflation and pulling forces equally on both sides of the seam. It is to be noted that second row of stitching 24, third row of stitching 32 and fourth row of stitching 34 are all positioned between first row of stitching 20 and tubular body 12.

[0029] Referring to FIG. 5, the series of accordion folds, described above includes a first accordion fold 22 oriented in a first direction (depicted as downward on the page), which forms a first reinforcement layer 23 of the series of parallel reinforcement layers described above. Referring to FIG. 6, first reinforcement layer 23 is secured parallel to seam allowance 16 by a second row of stitching 24. Referring to FIG. 6, a second accordion fold 26 is oriented in a second direction (depicted as upward on the page), which forms a second reinforcement layer 27 of the series of parallel reinforcement layers.

[0030] Referring to FIG. 7, parallel reinforcement layers (first reinforcement layer 23, second reinforcement layer 27, and seam allowance 16) when secured together form a ridge 29. A remote end 28 of seam allowance 16 is folded over ridge 29 and oriented in the first direction (depicted as downward on the page) to serve as a ridge cap 30. Remote end 28 of seam allowance 16 also forms a third reinforcement layer 31 of the series of parallel reinforcement layers. This third reinforcement layer 31 is secured by third row of stitching 32 as depicted in FIG. 7 and, if required, a fourth row of stitching 34 as depicted in FIG. 8. The addition of ridge cap 30 and third reinforcement layer 31 serves to bury first row of stitching 20 within the reinforcement layers created by the accordion folds, distributing the hoop stress forces of inflation and pulling forces equally on both sides of first row of stitching 20. It is to be noted that second row of stitching 24, third row of stitching 32 and fourth row of stitching 34 are all positioned between first row of stitching 20 and body 35. This protects first row of stitching 20.

[0031] When forming this reinforced seam in accordance with the method, care must be taken to have seam allowance 16 long enough to create first reinforcement layer 23 with first accordion fold 22, second reinforcement layer with second accordion fold 26, leaving enough excess length to fold remote end 28 over ridge 29 to form ridge cap 30 and third reinforcement lawyer 31.

[0032] The manner of securement is shown as stitching. This is because only stitching extends through all the parallel reinforcement layers.

[0033] It will be appreciated that the same result can be accomplished with just three seams. Fourth row of stitching 34 has been added to disperse more load. It is to be noted that third row of stitching 32 and fourth row of stitching 34 secure all layers of material together. The resulting seam sits in balance receiving equal force on each side from forces such as Hoop Stress and pulling forces. First row of stitching 20 is buried within and protected by the accordion folds, which distribute the hoop stress forces of inflation equally on both sides of the seam.

ADVANTAGES

[0034] The innovation presented herein describes an innovative reinforced seam, which has proven to increase the seam strength by 20% or more, as compared to the current state of the art seam. This new strong seam can be used on all flexible materials such as, but not limited to woven and knit fabrics, monolithic films or composites of films, weaves and knits. This new seam has been particularly effective at withstanding the hoop stress forces applied to composite materials that use film layer to support underlying woven substrates as used to make inflatable structures such as inflatable kites, wings and tents.

[0035] In this patent document, the word “comprising” is used in its non-limiting sense to mean that items following the word are included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article “a” does not exclude the possibility that more than one of the element is present, unless the context clearly requires that there be one and only one of the elements.

[0036] The scope of the claims should not be limited by the illustrated embodiments set forth as examples, but should be given the broadest interpretation consistent with a purposive construction of the claims in view of the description as a whole.