One-piece woven, side impact airbag having two layer coating

Patent metadata

Field	Value
Publication number	US-10619281-B2
Application number	US-201514833392-A
Country	US
Kind code	B2
Filing date	Aug 24, 2015
Priority date	Aug 24, 2015
Publication date	Apr 14, 2020
Grant date	Apr 14, 2020

Abstract

An airbag textile containing a woven textile having an inner side and an outer side, a primer layer on the outer side of the textile and a gas barrier layer on the primer layer. The primer layer contains a first thermoplastic polymer and has a surface roughness and a plurality of holes extending at least partially through the thickness of the primer layer. The gas barrier layer contains a second thermoplastic polymer and at least partially fills in the surface roughness and holes of the primer layer.

First claim

What is claimed is:

1. A one-piece woven, side impact airbag comprising:
a) a one-piece woven textile substrate having an inner side and an outer side, wherein the one-piece woven textile substrate comprises a plurality of yarns, the yarns comprising polyester or polyamide fibers having a linear density of about 110 dtex or greater, and wherein the textile substrate has a cover factor less than 2000;
b) a primer layer on at least a portion of the outer side of the textile substrate having a first thickness, wherein the primer layer comprises a first thermoplastic polymer, and wherein the primer layer has a surface roughness and a plurality of holes extending at least partially through the thickness of the primer layer, and wherein the inner side of the textile substrate is essentially free of the first thermoplastic polymer; and,
c) a gas barrier layer on the primer layer and having a second thickness, wherein the gas barrier layer comprises a second thermoplastic polymer, wherein the gas barrier layer at least partially fills in the surface roughness and holes of the primer layer, wherein the second thickness is greater than the first thickness, and wherein the inner side of the textile substrate is essentially free of the second thermoplastic polymer.

2. The one-piece woven, side impact airbag of claim 1 , wherein the first thermoplastic polymer and the second thermoplastic polymer is the same type of thermoplastic polymer.

3. The one-piece woven, side impact airbag of claim 1 , wherein the first thermoplastic polymer is a thermoplastic polymer selected from the group consisting of polyurethane, polyacrylate, acrylic co-polymer, polyurethane-polyacrylate hybrid, acrylic, vinyl acetate, vinyl chloride, vinyl alcohol, urethane, styrene butadiene, acrylonitrile, ethylene vinyl acetate, and ethylene vinyl chloride, vinylidene chloride, polyvinyl chloride, and polyvinyl butyral.

4. The one-piece woven, side impact airbag of claim 1 , wherein the second thermoplastic polymer is a thermoplastic polymer selected from the group consisting of polyurethane, polyacrylate, acrylic co-polymer, polyurethane-polyacrylate hybrid, acrylic, vinyl acetate, vinyl chloride, vinyl alcohol, urethane, styrene butadiene, acrylonitrile, ethylene vinyl acetate, and ethylene vinyl chloride, vinylidene chloride, polyvinyl chloride, and polyvinyl butyral.

5. The one-piece woven, side impact airbag of claim 1 , wherein the primer layer is foam coated onto the first side of the woven textile.

6. The one-piece woven, side impact airbag of claim 1 , wherein the primer layer further comprises at least one of an additive selected from the group consisting of flame retardant, pigment, stabilizing surfactant, filler, thickening agent, antioxidants, and stabilizers.

7. The one-piece woven, side impact airbag of claim 1 , wherein the gas barrier layer further comprises at least one of an additive selected from the group consisting of flame retardant, pigment, surfactant, filler, thickening agent, antioxidants, stabilizers, and anti-blocking agents.

8. The one-piece woven, side impact airbag of claim 1 , wherein the gas barrier layer is further crosslinked with crosslinked selected from the group consisting of isocyanates, reactive epoxy resin, carbodiimides, melamine resin, and silanes.

9. A vehicle comprising the one-piece woven, side impact airbag of claim 1 .

10. The one-piece woven, side impact airbag of claim 1 , wherein the cover factor is 1885.

11. The one-piece woven, side impact airbag of claim 1 , wherein the primer layer is further crosslinked with crosslinked selected from the group consisting of isocyanates, reactive epoxy resin, carbodiimides, melamine resin, and silanes.

12. A one-piece woven, side impact airbag comprising:
1) a one-piece woven textile substrate having an inner side and an outer side, wherein the one-piece woven textile substrate comprises a plurality of yarns, the yarns comprising polyester or polyamide fibers having a linear density of about 110 dtex or greater, and wherein the textile substrate has a cover factor less than 2000;
2) a primer layer on at least a portion of the outer side of the textile substrate having a first thickness, wherein the primer layer comprises a first thermoplastic polymer, and wherein the primer layer has a surface roughness and a plurality of holes extending at least partially through the thickness of the primer layer, wherein the inner side of the textile substrate is essentially free of the first thermoplastic polymer, wherein the primer layer is formed by the process of:
i) forming a foamed coating dispersion comprising the first thermoplastic and air, wherein the foamed coating dispersion comprises at least 50% by volume air;
ii) coating the foamed coating dispersion onto the outer side of the one-piece woven textile substrate forming a coated side and an uncoated side;
iii) collapsing and at least partially drying the foamed coating dispersion forming a primer layer;

3) a gas barrier layer on the primer layer and having a second thickness, wherein the gas barrier layer comprises a second thermoplastic polymer, wherein the gas barrier layer at least partially fills in the surface roughness and holes of the primer layer, wherein the second thickness is greater than the first thickness, and wherein the inner side of the textile substrate is essentially free of the second thermoplastic polymer.

13. The one-piece woven, side impact airbag of claim 12 , wherein the first thermoplastic polymer and the second thermoplastic polymer is the same type of thermoplastic polymer.

14. The one-piece woven, side impact airbag of claim 12 , wherein the first thermoplastic polymer is a thermoplastic polymer selected from the group consisting of polyurethane, polyacrylate, acrylic co-polymer, polyurethane-polyacrylate hybrid, acrylic, vinyl acetate, vinyl chloride, vinyl alcohol, urethane, styrene butadiene, acrylonitrile, ethylene vinyl acetate, and ethylene vinyl chloride, vinylidene chloride, polyvinyl chloride, and polyvinyl butyral.

15. The one-piece woven, side impact airbag of claim 12 , wherein the second thermoplastic polymer is a thermoplastic polymer selected from the group consisting of polyurethane, polyacrylate, acrylic co-polymer, polyurethane-polyacrylate hybrid, acrylic, vinyl acetate, vinyl chloride, vinyl alcohol, urethane, styrene butadiene, acrylonitrile, ethylene vinyl acetate, and ethylene vinyl chloride, vinylidene chloride, polyvinyl chloride, and polyvinyl butyral.

16. The one-piece woven, side impact airbag of claim 12 , wherein the primer layer is foam coated onto the first side of the woven textile.

17. The one-piece woven, side impact airbag of claim 11 , wherein the primer layer further comprises at least one of an additive selected from the group consisting of flame retardant, pigment, stabilizing surfactant, filler, thickening agent, antioxidants, and stabilizers.

18. The one-piece woven, side impact airbag of claim 12 , wherein the gas barrier layer further comprises at least one of an additive selected from the group consisting of flame retardant, pigment, surfactant, filler, thickening agent, antioxidants, stabilizers, and anti-blocking agents.

19. A vehicle comprising the one-piece woven, side impact airbag of claim 12 .

20. The one-piece woven, side impact airbag of claim 12 , wherein the cover factor is 1885.

21. The one-piece woven, side impact airbag of claim 12 , wherein the gas barrier layer is further crosslinked with crosslinked selected from the gro

Assignees

• Milliken & Co

Inventors

• Keshavaraj Ramesh

Classifications

• B60R2021/23542

  Weaving · CPC title

• D10B2505/124

  Air bags · CPC title

• B60R21/235 Primary

  characterised by their material · CPC title

• B60R2021/23528

  Metal · CPC title

• B32B2605/003

  Interior finishings · CPC title