Laminated multi-denier mixed fabrics for use in inflatable vehicle restraint systems

• US 20030060104A1
• Filed: 08/30/2002
• Published: 03/27/2003
• Est. Priority Date: 06/07/1999
• Status: Active Grant

• Current Assignee: Bradford Coatings, Llc
• Original Assignee: Bradford Industries, Inc.
• Inventors: Veiga, Manuel J.
• Granted Patent: US 6,734,125 B2
• Time in Patent Office: Days
• US Class Current: 442/76
• CPC Class Codes: B29C 65/04 Dielectric heating, e.g. high-frequency welding , i.e. radio frequency welding of plastic materials having dielectric properties, e.g. PVC
• CPC Class Codes: B29C 65/08 using ultrasonic vibrations non-plastics element to plastics elements B29C65/645
• CPC Class Codes: B29C 65/10 using hot gases (e.g. combustion gases) or flames coming in contact with at least one of the parts to be joined
• CPC Class Codes: B29C 66/7292 coated B29C66/72941 takes precedence
• CPC Class Codes: B29K 2071/00 Use of polyethers , e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2077/00 Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2267/00 Use of polyesters or derivatives thereof as reinforcement
• CPC Class Codes: B29K 2313/00 Use of textile products or fabrics as reinforcement B29K2105/06 takes precedence
• CPC Class Codes: B29L 2031/3038 Air bag covers
• CPC Class Codes: B32B 27/04 as impregnant, bonding, or embedding substance not used
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/40 comprising polyurethanes
• CPC Class Codes: B60R 2021/0018 Roll-over
• CPC Class Codes: B60R 2021/23514 coated fabric
• CPC Class Codes: B60R 21/232 Curtain-type airbags deploying mainly in a vertical direction from their top edge
• CPC Class Codes: B60R 21/235 characterised by their material
• CPC Class Codes: D03D 1/02 Inflatable articles
• CPC Class Codes: D03D 11/00 Double or multi-ply fabrics not otherwise provided for
• CPC Class Codes: D03D 15/283 synthetic polymer-based, e.g. polyamide or polyester fibres cellulose-based artificial fibres D03D15/225
• CPC Class Codes: D06N 2209/128 : Non-permeable
• CPC Class Codes: D06N 2211/26 : Vehicles, transportation
• CPC Class Codes: D06N 3/0002 : characterised by the substrate
• CPC Class Codes: D06N 3/128 : with silicon polymers
• CPC Class Codes: D06N 3/14 : with polyurethanes
• CPC Class Codes: D06N 3/145 : two or more layers of polyurethanes
• CPC Class Codes: D06N 3/183 : the layers are one next to the other
• CPC Class Codes: D10B 2201/02 : Cotton
• CPC Class Codes: D10B 2331/021 : aromatic polyamides, e.g. aramides
• CPC Class Codes: D10B 2331/04 : polyesters, e.g. polyethylene terephthalate [PET]
• CPC Class Codes: D10B 2401/063 : high strength
• CPC Class Codes: D10B 2505/124 : Air bags
• CPC Class Codes: F16L 59/026 : Mattresses, mats, blankets or the like
• CPC Class Codes: Y10T 442/2139 : Coating or impregnation specified as porous or permeable to a specific substance [e.g., water vapor, air, etc.]
• CPC Class Codes: Y10T 442/2361 : Coating or impregnation improves stiffness of the fabric other than specified as a size
• CPC Class Codes: Y10T 442/2369 : Coating or impregnation improves elasticity, bendability, resiliency, flexibility, or shape retention of the fabric
• CPC Class Codes: Y10T 442/2402 : Coating or impregnation specified as a size
• CPC Class Codes: Y10T 442/2861 : Coated or impregnated synthetic organic fiber fabric
• CPC Class Codes: Y10T 442/2893 : Coated or impregnated polyamide fiber fabric
• CPC Class Codes: Y10T 442/30 : Woven fabric [i.e., woven strand or strip material]
• CPC Class Codes: Y10T 442/3008 : Woven fabric has an elastic quality
• CPC Class Codes: Y10T 442/3016 : Including a preformed layer other than the elastic woven fabric [e.g., fabric or film or foil or sheet layer, etc.]
• CPC Class Codes: Y10T 442/3065 : Including strand which is of specific structural definition
• CPC Class Codes: Y10T 442/3179 : Woven fabric is characterized by a particular or differential weave other than fabric in which the strand denier or warp/weft pick count is specified
• CPC Class Codes: Y10T 442/3203 : Multi-planar warp layers
• CPC Class Codes: Y10T 442/3211 : Multi-planar weft layers
• CPC Class Codes: Y10T 442/322 : Warp differs from weft
• CPC Class Codes: Y10T 442/3301 : Coated, impregnated, or autogenous bonded
• CPC Class Codes: Y10T 442/3854 : Woven fabric with a preformed polymeric film or sheet

Abstract

A woven textile fabric is disclosed which is formed of synthetic yarns of at least two different deniers to which a solid polymeric film is laminated. An adhesive polymeric coating is provided for adhering the solid polymeric film to the woven textile fabric. The combination of yarns of different deniers provides a superior adhesion surface for the polymeric film. The yarns and the polymeric coating are preselected respectively in deniers and thicknesses so as to render the fabric substantially impermeable to fluid under pressure, while maintaining superb packageability and anti-blocking properties for use in vehicle occupant restraint systems. An air bag incorporating the woven textile fabric of the invention and having two outer surfaces and pre-configured air holding cavities woven therein to which a solid polymeric film is bonded for receiving and containing fluid under pressure for use in a vehicle air restraint system is also disclosed. Air vents are provided for preventing entrapped air from forming bubbles in the lamination process.

Claims

1. An automotive protective device comprising a textile fabric woven of synthetic yarns of at least two different deniers, an adhesive polymeric coating layer on at least one surface of said fabric, and a solid polymeric film laminated thereto.

2. The automotive protective device according to claim 1, wherein said synthetic yarns are selected from the group consisting of nylon, polyester, aramid and graphite and combinations thereof.

3. The automotive protective device according to claim 2, wherein said solid polymeric film laminate is a polyamide, polyolefin or polyurethane film.

4. The automotive protective device according to claim 3, wherein said woven textile fabric is comprised of warp yarns of about 315D nylon and fill yarns of about 210D nylon.

5. The automotive protective device according to claim 3, wherein said woven textile fabric is comprised of warp yarns of about 420D nylon and fill yarns of about 315D nylon.

6. The automotive protective device according to claim 3, wherein said woven textile fabric is comprised of warp yarns of from about 315D to about 420D nylon and fill yarns of from about 195D to about 380D aramid.

7. The automotive protective device according to claim 3, wherein said woven textile fabric is comprised of warp yarns of from about 210D to about 315D nylon and fill yarns of about 210D nylon.

8. The automotive protective device according to claim 3, wherein said woven textile fabric is comprised of warp yarns of at least two different deniers and fill yarns of at least two different deniers.

18. The automotive protective device of claim 3 wherein said adhesive prime coat polyurethane layer is a composition comprising:

a polycarbonate based aliphatic polyurethane;

a hot melt composition comprising a polyester or polyether-based polyurethane, or copolymer blends of ethylene vinyl acetate; and

an isocyanate.

19. The automotive protective device of claim 18 wherein said adhesive prime coat polyurethane layer has a coating weight of from about 0.25 ounces per square yard to about 2.5 ounces per square yard.

20. The automotive protective device of claim 18 wherein said adhesive prime coat polyurethane layer has a coating weight of about 1.2 ounces per square yard.

21. The automotive protective device of claim 18 wherein said adhesive prime coat polyurethane layer has a solids content of from about 25% to about 45%.

22. The automotive protective device of claim 3 wherein said solid polymeric film laminate has a thickness of from about 0.2 mils to about 5.0 mils.

23. The automotive protective device of claim 3 wherein said solid polymeric film laminate has a thickness of from about 0.5 mils to about 1.0 mils.

9. An automotive protective device comprising a textile fabric woven of synthetic yams of at least two different deniers, an adhesive prime coat polyurethane layer coated on at least one surface of said woven textile fabric, and a solid polymeric film laminated thereto, said yarns and said solid polymeric film being preselected respectively in deniers and thickness so as to render said fabric substantially impermeable to fluid under pressure.

10. The automotive protective device according to claim 9, wherein said synthetic yams are selected from the group consisting of nylon, polyester, aramid and graphite and combinations thereof.

11. The automotive protective device according to claim 10, wherein said woven textile fabric is comprised of warp yarns of about 315D nylon and fill yarns of about 210D nylon.

12. The automotive protective device according to claim 10, wherein said woven textile fabric is comprised of warp yarns of about 420D nylon and fill yarns of about 315D nylon.

13. The automotive protective device according to claim 10, wherein said woven textile fabric is comprised of warp yarns of at least two different deniers and fill yarns of at least two different deniers.

14. The automotive protective device according to claim 10, wherein said fabric is comprised of warp yarns of from about 210D to about 315D nylon and fill yarns of about 210D nylon.

40. The automotive protective device according to claim 10, wherein said woven textile fabric is comprised of warp yarns of from about 315D to about 420D nylon and fill yams of from about 195D to about 380D aramid.

15. An automotive protective device comprising a textile fabric woven of synthetic yarns of at least two different deniers and more than one filamentary material, an adhesive prime coat polyurethane layer coated on at least one surface of said woven textile fabric, and a solid polymeric film laminated thereto, said synthetic yarns and said solid polymeric film being preselected respectively in deniers and thickness so as to render said fabric substantially impermeable to fluid under pressure.

16. The automotive protective device according to claim 15, wherein said synthetic yarns are selected from the group consisting of nylon, polyester, aramid and graphite and combinations thereof.

17. The automotive protective device according to claim 16, wherein said solid polymeric film laminate is a polyamide, polyolefin or polyurethane film.

24. An automotive protective device comprising a textile fabric woven of synthetic yarns of at least two different deniers and having two outer surfaces and preconfigured air holding cavities woven therein, each of said outer surfaces having an adhesive polyurethane prime coat layer and a solid polymeric film laminated thereto.

25. The automotive protective device according to claim 24, wherein said synthetic yarns are selected from the group consisting of nylon, polyester, aramid and graphite and combinations thereof.

26. The automotive protective device according to claim 25, wherein said solid polymeric film laminate is a polyamide, polyolefin or polyurethane film.

27. The automotive protective device according to claim 26, wherein said synthetic yarns are woven nylon.

28. The automotive protective device according to claim 26, wherein said polymeric film laminate has a thickness of from about 0.2 mils to about 5.0 mils.

29. The automotive protective device according to claim 26, wherein said polymeric film laminate has a thickness of from about 0.5 mils to about 1.0 mils.

30. The automotive protective device according to claim 26, wherein said adhesive prime coat layer has a thickness of from about 0.5 mils to about 5.0 mils.

31. The automotive protective device according to claim 26, wherein said adhesive prime coat layer has a thickness of from about 1.0 mils to about 1.5 mils.

32. The automotive protective device according to claim 26, wherein said adhesive prime coat layer comprises:

a polycarbonate based aliphatic polyurethane;

a hot melt composition comprising a polyester or polyether-based polyurethane, or copolymer blends of ethylene vinyl acetate; and

an isocyanate.

33. A woven textile fabric for use in the manufacture of an automotive protective device comprising a multi-layered textile fabric of synthetic yarns of at least two different deniers and having air vents woven into said fabric at preselected locations, an adhesive prime coat polyurethane layer coated on at least one surface of said woven textile fabric, and a solid polymeric film laminated thereto, said yarns and said solid polymeric film being preselected respectively in deniers and thickness so as to render said fabric substantially impermeable to fluid under pressure.

34. The automotive protective device of claim 33, wherein said synthetic yarns are selected from the group consisting of nylon, polyester, aramid and graphite and combinations thereof.

35. The automotive protective device of claim 34, in which said air vents comprise portions of the weave in which the fill yarns overlay the warp yarns in said textile fabric.

36. The automotive protective device according to claim 35, wherein said woven textile fabric is comprised of warp yarns of about 315D nylon and fill yarns of about 210D nylon.

37. The automotive protective device according to claim 35, wherein said woven textile fabric is comprised of warp yarns of about 420D nylon and fill yarns of about 315D nylon.

38. The automotive protective device according to claim 35, wherein said woven textile fabric is comprised of warp yarns of from about 315D to about 420D nylon and fill yams of from about 195D to about 380D aramid.

39. The automotive protective device according to claim 35, wherein said woven textile fabric is comprised of warp yarns of from about 210D to about 315D nylon and fill yams of about 210D nylon.