METHOD FOR MANUFACTURING A PROTECTION DEVICE

Abstract

A method for manufacturing a protection device is described. The protection device comprises an inflatable element configured to assume an active inflated condition and a rest deflated condition. The inflatable element includes a knitted body having a closed structure on at least four sides or walls and/or having at least a partially tubular shape, and defining an inner area or inner chamber. The knitted body includes also union threads crossing the inner chamber.

Claims

1. A method for manufacturing a protection device to be worn by a user, the method comprising: knitting an inflatable three-dimensional unitary knitted body having an inner chamber that is configured to assume an inflated condition for protection of the user, and a deflated condition at rest, the inflatable three-dimensional unitary knitted body being knitted by a rectilinear knitting machine, wherein: in the inflated condition, the inner chamber is defined by at least a partially tubular shape; in the deflated condition, the inner chamber is defined by overlapping opposite regions of said inflatable three-dimensional unitary knitted body; and the knitting comprises forming a plurality of union threads in said inflatable three-dimensional unitary knitted body by said rectilinear knitting machine, the plurality of union threads occupying the inner chamber and connecting the overlapping opposite regions.

2. The method according to claim 1, wherein the knitting further comprises: adjusting a length of the union threads according to a region of the inflatable three-dimensional unitary knitted body.

3. The method according to claim 2, wherein the adjusting comprises shortening the length of the union threads in a region of the inflatable three-dimensional unitary knitted body away from a central area of said knitted body.

4. The method according to claim 1, wherein the forming of the union threads comprises: continuously extending a thread in an alternate manner between the overlapping opposite regions of the inflatable three-dimensional unitary knitted body.

5. The method according to claim 4, wherein the thread extends in the alternate manner, in a zigzag or a sinusoidal pattern, between said overlapping opposite regions.

6. The method according to claim 1, wherein the knitting further comprises: knitting on a first needle bed, a first portion of the overlapping opposite regions via a first thread carried by a first thread guide; knitting on a second needle bed, a second portion of the overlapping opposite regions via the first thread carried by the first thread guide; and connecting by knitting the first portion of the overlapping opposite regions on the first needle bed with said second portion on the second needle bed via a second thread carried by a second thread guide, wherein the rectilinear knitting machine includes at least the first needle bed and the second needle bed.

7. The method according to claim 6, wherein the first thread is made of a different material than the second thread.

8. The method according to claim 7, wherein the first thread is made of a material that is softer and less resistant to tensile strength compared to a material of the second thread.

9. The method according to claim 1, further comprising: covering or coating an outer surface of said an inflatable three-dimensional unitary knitted body.

10. The method according to claim 1, wherein the inflatable three-dimensional unitary knitted body is included in a garment or a sub-garment.

11. The method according to claim 1, wherein the inflatable three-dimensional unitary knitted body is shaped as a garment or a sub-garment.

12. The method according to claim 1, wherein the inflatable three-dimensional unitary knitted body is a closed body that defines a closed casing.

13. The method according to claim 1, wherein the knitting further comprises: forming mesh openings of said inflatable three-dimensional unitary knitted body that are at least partially closed or covered to retain at least temporarily an inflating fluid in said knitted body.

14. The method according to claim 1, further comprising: covering an outer surface of said knitted body with a covering layer or a cover sheet.

15. The method according to claim 14, wherein the covering layer or the cover sheet is made of a material comprising a resin.

16. The method according to claim 14, further comprising: arranging the inflatable three-dimensional unitary knitted within an outer covering casing made of a material capable to resist a predetermined gas pressure.

17. The method according to claim 1, wherein: the protection device is a wearable garment producible by the rectilinear knitting machine, and the method further comprises: programming the rectilinear knitting machine for forming in an area of the wearable garment a double layer of tissue corresponding to said overlapping opposite regions of the inflatable three-dimensional unitary knitted body with the plurality of union threads, and coating said area of the wearable garment with a cover apt to retain an inflating fluid.

18. The method according to claim 17, wherein said area of the wearable garment is part of a pocket of the wearable garment.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0051] The figures of the enclosed drawings will be referred to, wherein:

[0052] FIG. 1 shows a top view of a protection device rested on a plane and manufactured according to the present disclosure;

[0053] FIG. 2 shows a section view according to the line II-II of FIG. 1;

[0054] FIG. 3 shows a detail III of FIG. 2;

[0055] FIG. 4 shows a detail IV of FIG. 2;

[0056] FIG. 5 shows a top view of a knitted body according to the present disclosure;

[0057] FIG. 6 shows a view of a step for manufacturing a protection device according to the present disclosure wherein a knitted body is associated to a cover.

[0058] By referring to the enclosed figures, with the reference number 1 a protection device according to the present disclosure is designated in agreement with a specific and exemplifying embodiment.

DETAILED DESCRIPTION

[0059] In particular, the protection device 1 comprises an inflatable element 2 apt to assume substantially a first rest condition or deflated condition, and a second active condition or inflated condition. The modes for inflating the inflatable element 2 will be described hereinafter in the description.

[0060] The protection device 1 comprises a knitted body 3 having in the example a closed structure, that is it is a substantially casing-like shaped body, that is a three-dimensional structure at least with tubular shape, and preferably mainly closed on five sides or on all sides and defining an inner area or chamber 4.

[0061] In the illustrated embodiment the knitted body 3 is a substantially bag-like shaped body having one single opening 6 allowing the access to the inner area 4.

[0062] The knitted body 3 then, when laid on a plane and pressed in such extended position, includes two opposite portions/faces or walls 3a, 3b and at least three side portions/faces 3c, 3d, only two thereof can be seen in FIGS. 2 and 4 extending without continuity solution between the two opposite portions 3a, 3b.

[0063] Thanks to the tubular shape, and still better thanks to the shape like closed bag or casing, the knitted body 3 has the advantage of being closed laterally on at least two sides (at the side portions 3c, 3d) and not requesting a seam at least on said two sides, as for example described in the above-mentioned International patent application.

[0064] In the example illustrated in the drawings, the inflatable element 2 has a shape with two side wings 8, 9 for covering the shoulders of a user, a central portion shaped substantially like a “C” 10 and a spinal portion 11, intended to protect the spine of the user. The knitted body 3 has a shape re-using and following the shape of the inflatable element 2 and it is implemented in one single body according to said shape to define a single inner area 4.

[0065] In FIG. 5 and in FIG. 6, the knitted body 3, in schematic way, show a substantially rectangular shape in order to show how this is coated and covered by means of a cover. It is to be meant, as said, that the knitted body 3 can have or show a shape corresponding to that of the inflatable element 2 to be obtained.

[0066] In the illustrated embodiment, the spinal portion 11 can have said access opening 6 to allow positioning inside the inner area 4 a gas generator under pressure 12. Practically, the gas under pressure is introduced starting from the spinal portion 11.

[0067] The knitted body 3 further includes a plurality of union threads 5 or pulling threads distributed in the inner chamber 4 and firmly connected to respective portions 3a, 3b of the knitted body 3, in particular to surface portions of the same.

[0068] The union thread 5 is an element or entity having the function of keeping united or constrained or fixed, being tensioned to tensile strength, two or more portions of the knitted body 3, at least when the latter is under inflated condition. It is noted that in the illustrated embodiment the plurality of union threads 5 is obtained starting from or belongs to one single thread, or one single filament constituted by at least two threads, wherein the single thread or the single filament is extended alternatively continuously by knitting between the first portion 3a and the second portion 3b of the knitted body 3. The thread thereof the union threads are made is a different thread or filament from that thereof the faces of the knitted body are made.

[0069] Still more in particular, the single thread or the single filament is arranged in a zigzag manner or according to a sinusoidal pattern between the first portion 3a and the second portion 3b of the knitted body 3 to cover or occupy a region of the inflatable element 2.

[0070] The union threads 5 are suitably sized so that, when the inflatable element 2 is under rest condition, preferably they are not subjected to tension and they are collapsed in the inner chamber 4, whereas when the inflatable element 2 is under inflated condition they are subjected to tension. The threads can be arranged so as to connect opposite portions 3a, 3b of the knitted body 3 or they can be arranged diagonally so as to connect not opposite portions of the knitted body 3.

[0071] The threads are distributed closely for example with a density of at least a pulling element each cm.sup.2 of surface of the inner chamber 4, still more preferably, still by way of example, with density comprised between 1 and 15 threads each cm.sup.2 of surface of the inflatable element 2, preferably between 4 and 6 threads each cm.sup.2. The distribution of the threads can be varied according to the protection device area wherein the threads are. The union threads 5 for example can be made of polyester or polyamide, with thickness comprised between about 500 and about 1000 decitex (length unit of a continuous thread or a yarn). Each thread 5 can include a beam of continuous fibres without twist which outgo from a single point of a respective mesh of the knitted body 3.

[0072] In an embodiment of the present disclosure, the yarns used to implement the union threads 5 are yarns of different type with respect to those used for implementing the casing-like body and the above-mentioned portions 3a, 3b, 3c, 3d. In particular the union threads are made of a material having greater resistance to tensile strength than the threads of the casing-like body. The threads of the casing-like body can be made of a softer material, so as to obtain an inflatable element which is soft as much as possible and has a light and flexible consistence which is of total comfort for a user wearing it.

[0073] The threads of the knitted body 3 can be made of a material variable and differentiated even based upon the area of the protection device wherein they are and upon the area of the body of a user to be protected, for example the union threads 5 have a shorter length in a region of the inflatable element adjacent to the third portion/face 3c and/or the fourth portion/face 3d with respect to a central area of the inflatable element far from the third portion/face 3c and/or the fourth portion/face 3d.

[0074] The knitted body 3 and the union threads 5 can be implemented with a machine for knitting, or rectilinear knitting machine of known type which includes two needle beds, that is two rows of needles intended to the working of the knitted body. A knitting machine of known type is a machine for gloves as the one with code SWG0991N by Shima Seiki.

[0075] The two needle beds have a field of needles having an extension or length corresponding to a shape size, such as for example width or shape length, of the inflatable element to be obtained, corresponding to one of the two portions 3a or 3b comprised between the portions 3c and 3d for example. The machine is equipped with a first thread guide supporting a first thread intended to form the knitted body 3 and a second thread guide carrying a second thread intended to form the union threads 5.

[0076] The machine can be programmed so as to implement the knitted body 3 by means of the first thread guide which works alternatively the thread on the first needle bed of needles and on the second needle bed of needles.

[0077] The machine can be programmed so as to unite two opposite areas 3a, 3b of the mesh by means of the second thread carried by the second thread guide, to form the union threads 5. For example the machine can be programmed to work some mesh ranks, so as to form some complete mesh turns, and subsequently to unite by means of the second thread guide, and then the second thread, determined needles of the first needle bed with determined needles of the second needle bed. Subsequently, some mesh turns are worked again to repeat then the knitting with the second thread forming the union threads.

[0078] In order to define a specific length of the union thread, it is possible to unite the meshes by means of diagonal union threads. In this case the second thread guide will interlace the union thread with determined needles of the first needle bed and of the second needle bed so that the union threads are arranged diagonally between the needles of a first needle bed and the needles of a second needle bed.

[0079] Alternatively, the mesh can be worked with a “needle-discarding” technique wherein, for each needle bed one provides using some needles as “operating” needles intended for knitting and then involved by the working of the meshes of the knitted body, and other “not operating” free needles, not involved by the knitting. Such kept-free “not operating” needles allow receiving temporarily the union thread. Practically, the union thread is “parked” momentarily on the “not operating” needle when it is worked between the first needle bed and the second needle bed. In particular, the union thread is knitted on an “operating” needle of the first needle bed intended for the working of the meshes, then it is “parked” on a “not operating” needle of the same first needle bed and subsequently it is worked on an “operating” needle of the second needle bed. In this way, by programming the distance between the first “operating” needle of the first needle bed, the not operating needle of the first needle bed and the “operating” needle of the second needle bed, it is possible establishing in advance the length of the union threads 5 when the knitted body is removed from the knitting machine.

[0080] It is to be meant that a person skilled in the use of the rectilinear knitting machines can be able to program the machine in the most optimum way to obtain the wished result.

[0081] Additional information about the working of a knitted body by means of union threads can be traced in the Italian patent application TO-2013-A-472, which describes the implementation of knitted bodies equipped with union threads.

[0082] It is further to be noted that the rectilinear knitting machine can further be programmed to vary the length of the union thread according to the area of the inflatable element to be implemented. For example, in an area of the knitted body 3 intended to be placed at the peripheral areas or areas 3c, 3d of the inflatable element 2, the union threads 5 can have a length which reduces gradually up to the minimum, in order to guarantee a tension of the union threads 5 even at the peripheral areas when the inflatable element 2 is inflated.

[0083] Furthermore, the rectilinear knitting machine can further be programmed to vary the mesh opening, for example by modifying the programming of the discarded needle, or when a closer mesh is required by using a double thread for implementing the mesh.

[0084] An important aspect deriving from the fact that the knitted body 3 is obtained in a single working step lies in the fact that it is not necessary to provide peripheral seams in the meshes as on the contrary it was provided in the above-mentioned International patent application.

[0085] The knitted body can be further coated and covered by a cover.

[0086] The cover can include two walls 15, 16 or sheets made of a sheet of soft and gas-tight material, for example of polyamide or polyurethane, which are opposite one with respect to the other one, and fastened peripherally along respective peripheral edges 20, 21.

[0087] The walls 15, 16 can be like those described in the above-mentioned International patent application and they can be made of a laminate, which is usually used as a garment lining and including a layer of fabric, in the example nylon 100% (representing about 65% in weight of the laminate) and a layer of glue, in the example a film of glue (representing about 35% in weight of the laminate), for example polyurethane glue, distributed onto the layer of fabric, by means of roller spreading.

[0088] The knitted body 3 is firmly fastened to the surface of the respective wall 15, 16, by means of a film of glue (not visible in the figures). In case of using the above-mentioned laminate, the film of glue is arranged in contact with the layer of glue of the laminate.

[0089] The just described protection device is implemented in the following way according to an embodiment.

[0090] The knitted body 3 is arranged under extended condition, so that the two opposite portions 3a, 3b are collapsed one onto the other one. The knitted body 3 in such configuration is arranged between two walls 15, 16 and fastened adhering to a respective wall 15, 16, for example by means of glue.

[0091] Subsequently, respective opposite peripheral edges 20, 21 of the walls 15 and 16 are overlapped one onto the other one along the periphery.

[0092] From the above-mentioned description it comes out that the two walls 15 are 16 substantially are two opposite elements or sheets of the inflatable element 2, fastened along the respective peripheral edges 20 and 21. In any case there is nothing to prevent the two walls 15 and 16 from being opposite portions of one single book-like folded sheet, and then having peripheral edges extended along a portion of the periphery and closed by means of sealing tape.

[0093] To implement the inflation of the inflatable element 2, in case of unforeseen fall and/or slide and/or impact by a user or a vehicle whereon he/she proceeds, the protection device 1 according to the present invention is apt to cooperate with suitable activation means operatively connected to inflation means, thereof in figures by purely way of illustration a compressed cold gas cylinder 12 is illustrated, connected by means of a duct or cannula to an intercept valve, fastened to the inflatable element 2, which allows inserting an inflating fluid into the inflatable element 2.

[0094] The gas cylinder 12, as above indicated, can be also included inside the inflatable element 2.

[0095] Alternatively, such inflating means can include gas generators of pyrotechnic type or hybrid type or other types known to the state of art.

[0096] Said inflating means is controlled by a control unit based upon the detection of the status of the vehicle/driver system; for example said control unit can implement a system for predicting the fall allowing to timely identify the fall event and a reliable prediction thereof by means of accelerometric sensors integral to the vehicle (or the driver) and a unit for processing the signals produced by the sensors themselves.

[0097] Alternatively, the device according to the present disclosure can also be applied by using an activation cable connected to a vehicle guided by a user, which cable controls the inflation of the inflatable element 2 after the removal of the user from the vehicle, for example, after a fall or an unforeseen impact.

[0098] In any case, the above-mentioned activating and inflating means can be integrated in the protection device 1 according to the present invention or placed outside the same.

[0099] It is to be also noted that the activation modes, even if they are an aspect of particular relevance for an effective operation of the device, will not be further described with greater detail as they are methods mainly already known to the person skilled in the art of the protection of a subject from unforeseen impacts.

[0100] The knitted body 3 can include even electric threads which can be knitted together with the knitted body for the connection of inner/outer sensors and/or managing electronics or valves or other electric devices.

[0101] It is further to be noted that the protection device can be included in a garment, or it can be integrating portion of a garment. In fact, there is nothing to prevent that, thanks to the programming potential of a rectilinear knitting machine, from implementing in one single producing step a knitted body together with a garment, that is that the knitted body is integrated in one single body with the garment, or even coincides with the garment. In fact for example the knitted body can have a vest-like or jacket-like shape and, for example, worked with a mesh density so as to allow an adequate fluid-tightness of the inflating gas.

[0102] In order to make the knitted body impermeable or at least with temporary fluid-tightness, the implementation of a localized cover of the knitted body, or the implementation of a closer mesh at the knitted body, can be provided.

[0103] Two covering layers can be provided on opposite sides of the knitted body, and such covering layers can be united by means of suitable openings provided around the knitted body.

[0104] The subject of the present disclosure has been so far described with reference to preferred embodiments. It is to be meant that other embodiments belonging to the same inventive core may exist, all within the protection scope of the here below enclosed claims.