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

• US 6,455,449 B1
• Filed: 09/03/1999
• Issued: 09/24/2002
• Est. Priority Date: 09/03/1999
• Status: Expired due to Fees

• Current Assignee: Bradford Coatings, Llc
• Original Assignee: Bradford Industries, Inc.
• Inventors: Veiga, Manuel J., Satin, Richard J.
• Primary Examiner(s): Morris, Terrel
• Assistant Examiner(s): SINGH-PANDEY, ARTI R
• Application Number:
  US09/389,711
• Time in Patent Office: 1,117 Days
• Field of Search: 442/60, 442/76, 442/79, 442/85, 442/86, 442/208, 442/203, 442/209, 442/210, 442/211, 442/212, 442/213, 442/214, 442/215, 442/216, 442/217, 442/218, 442/219, 442/220, 280/728.1, 280/729, 280/736, 280/742, 280/737, 428/36.91
• US Class Current: 442/218
• CPC Class Codes: B60R 2021/23514 coated fabric
• CPC Class Codes: B60R 21/235 characterised by their material
• CPC Class Codes: D03D 1/02 Inflatable articles
• CPC Class Codes: D03D 15/283 synthetic polymer-based, e.g. polyamide or polyester fibres cellulose-based artificial fibres D03D15/225
• CPC Class Codes: D03D 15/43 with differing diameters
• CPC Class Codes: D06N 2201/02 Synthetic macromolecular fibres
• CPC Class Codes: D06N 2201/0263 Polyamide fibres
• CPC Class Codes: D06N 2201/0272 Aromatic polyamide fibres
• CPC Class Codes: D06N 2201/087 Carbon fibres
• CPC Class Codes: D06N 2209/106 Roughness, anti-slip, abrasiveness
• CPC Class Codes: D06N 2209/128 Non-permeable
• CPC Class Codes: D06N 2211/268 Airbags
• CPC Class Codes: D06N 3/0002 characterised by the substrate
• CPC Class Codes: D06N 3/042 Acrylic polymers D06N3/045 takes precedence
• CPC Class Codes: D06N 3/125 with polyamides
• CPC Class Codes: D06N 3/14 with polyurethanes
• 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: Y10T 428/1393 : Multilayer [continuous layer]
• CPC Class Codes: Y10T 442/2008 : Fabric composed of a fiber or strand which is of specific structural definition
• 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 442/2164 : Coating or impregnation specified as water repellent
• CPC Class Codes: Y10T 442/2213 : Coating or impregnation is specified as weather proof, water vapor resistant, or moisture resistant
• CPC Class Codes: Y10T 442/2221 : Coating or impregnation is specified as water proof
• 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 442/322 : Warp differs from weft
• CPC Class Codes: Y10T 442/3228 : Materials differ
• CPC Class Codes: Y10T 442/3236 : Including inorganic strand material
• CPC Class Codes: Y10T 442/3244 : Including natural strand material [e.g., cotton, wool, etc.]
• CPC Class Codes: Y10T 442/3252 : Including synthetic polymeric strand material
• CPC Class Codes: Y10T 442/326 : Including synthetic polymeric strand material
• CPC Class Codes: Y10T 442/3268 : Including natural strand material
• CPC Class Codes: Y10T 442/3276 : Including polyamide strand material
• CPC Class Codes: Y10T 442/3285 : Including polyester strand material
• CPC Class Codes: Y10T 442/3293 : Warp and weft are identical and contain at least two chemically different strand materials
• CPC Class Codes: Y10T 442/3301 : Coated, impregnated, or autogenous bonded
• CPC Class Codes: Y10T 442/3309 : Woven fabric contains inorganic strand material
• CPC Class Codes: Y10T 442/3317 : Woven fabric contains synthetic polymeric strand material

Abstract

A coated woven textile fabric is disclosed which is formed of synthetic yarns of more than one denier preferably synthetic filamentary yarns of differing deniers. A polymeric coating such as polyurethane is layered on at least one side thereof, but may also be provided on both sides. The combination of yarns of different deniers provides a superior adhesion surface for the polymeric coating. The yarns and the polymeric coating are preselected respectively in deniers and thickness so as to render the fabric substantially impermeable to fluid under pressure, while maintaining superb packageability and antiblocking properties for use in vehicle occupant restraint systems. A flexible lightweight air bag for receiving and containing fluid under pressure for use in a vehicle air restraint system is also disclosed, incorporating the woven textile fabric of the invention.

Claims

1. A flexible lightweight air bag for receiving and containing fluid under pressure for use in a vehicle air restraint system, which comprises a textile fabric woven of synthetic yarns of at least two different deniers, and a polymeric coating on at least one side of said fabric, said yarns and said polymeric coating being preselected respectively in deniers and thickness so as to render said air bag capable of receiving and retaining fluid under pressure in a vehicle air restraint system, said polymeric coated fabric being substantially impermeable to the fluid.

2. The air bag according to claim 1, wherein said fabric is comprised of warp yarns of about 315D nylon and fill yarns of about 210D nylon.

3. The air bag according to claim 2, wherein said fabric is comprised of warp yarns of about 420D nylon and fill yarns of about 315D nylon.

4. The air bag according to claim 3, wherein said 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.

5. The air bag according to claim 4, wherein said fabric is comprised of warp yarns of at least two different deniers and fill yarns of at least two different deniers.

6. The air bag according to claim 5, wherein said fabric is comprised of warp yarns of from about 210D to about 315D nylon and fill yarns of about 210D nylon.

7. The air bag according to claim 6, wherein said synthetic yarns are selected from the group consisting of nylon, polyester, aramid and graphite and combinations thereof.

8. The coated woven textile fabric according to claim 7, wherein said polymeric coating is comprised of at least one of polyurethane, polysiloxane, polyamide and acrylic type polymers.

9. The coated woven textile fabric according to claim 8, wherein said woven textile fabric is coated on a second side.

10. The coated woven textile fabric according to claim 9, wherein said coating on said second side of said woven textile fabric is at least one of polyurethane, polysiloxane, polyamide and acrylic type polymers.

11. The coated woven textile fabric according to claim 10, wherein each of said coatings has a thickness of from about 0.001 inch to about 0.020 inch.

12. A coated woven textile air bag fabric, which comprises synthetic yarns of at least two different deniers, and a polymer coating on at least one side thereof, said yarns and said polymeric coating being preselected respectively in deniers and thickness so as to render said fabric substantially inpermeable to fluid under pressure.

13. The coated woven textile air bag fabric according to claim 12, wherein said fabric is comprised of warp yarns of about 315D nylon and fill yarns of about 210D nylon.

14. The coated woven textile air bag fabric according to claim 12, wherein said fabric is comprised of warp yarns of about 420D nylon and fill yarns of about 315D nylon.

15. The coated woven textile air bag fabric according to claim 12, wherein said 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.

16. The coated woven textile air bag fabric according to claim 12, wherein said fabric is comprised of warp yarns of at least two different deniers and fill yarns of at least two different deniers.

17. The coated woven textile air bag fabric according to claim 12, wherein said fabric is comprised of warp yarns of from about 210D to about 315D nylon and fill yarns of about 210D nylon.

18. The coated woven textile air bag fabric according to claim 12, wherein said synthetic yarns are selected from the group consisting of nylon, polyester, aramid and graphite and combinations thereto.

19. The coated woven textile air bag fabric according to claim 12, wherein said polymeric coating is comprised of at least one of polyurethane, polysiloxane, polyamide and acrylic polymers.

20. The coated woven textile air bag fabric according to claim 19, wherein said woven textile fabric is coated on a second side.

21. The coated woven textile air bag fabric according to claim 20, wherein said coating on said second side of said woven textile fabric is at least one of polyurethane polysiloxane, polyamide and acrylic polymer.

22. The coated woven textile air bag fabric according to claim 21, wherein each of said coatings has a thickness of from about 0.001 inch to about 0.20 inch.

23. A coated woven textile air bag fabric, which comprises synthetic yarns of at least two different deniers and more than one synthetic filamentary material, and a polymeric coating on at least one side thereof, said yarns and said polymeric coating being preselected respectively in deniers and thickens so as to render said fabric substantially impermeable to fluid under pressure, said filamentary materials being selected to provide predetermined weight and strength for use in inflatable vehicle restraint systems.

24. The coated woven textile air bag fabric according to claim 23, wherein said fabric is comprised of warp yarns of about 315D nylon and fill yarns of about 210D nylon.

25. The coated woven textile air bag fabric according to claim 24, wherein said fabric is comprised of warp yarns of about 420D nylon and fill yarns of about 315D nylon.

26. The coated woven textile air bag fabric according to claim 25, wherein said fabric is comprised of warp yarns of about 315D to about 420D nylon and A fill yarns of from about 195D to about 380D aramid.

27. The coated woven textile air bag fabric according to claim 26, wherein said fabric is comprised of warp yarns of at least two different deniers and fill yarns of at least two different deniers.

28. The coated woven textile air bag fabric according to claim 27, wherein said fabric is comprised of warp yarns of from about 210D to about 315D nylon and fill yarns of about 210D nylon.

29. The coated woven textile air bag fabric according to claim 28, wherein said synthetic yarns are selected from the group consisting of nylon, polyester, aramid and graphite and combinations thereof.

30. The coated woven textile air bag fabric according to claim 29, wherein said polymeric coating is comprised of at least one of polyurethane, polysiloxane, polyamide and acrylic type polymers.

31. The coated woven textile air bag fabric according to claim 30, wherein said woven textile fabric is coated on a second side.

32. The coated woven textile air bag fabric according to claim 31, wherein said coating on said second side of said woven textile fabric is at least one of polyurethane, polysiloxane, polyamide and acrylic type polymers.

33. The coated woven textile air bag fabric according to claim 32, wherein each of said coatings has a thickness of from about 0.001 inch to about 0.20 inch.

34. A flexible air bag, which comprises a fabric having synthetic yarns of at least two different deniers, and a polymer coating on at least one side thereof, said yarns and said polymeric coating being preselected respectively in deniers and thickness so as to render said fabric substantially, impermeable to fluid under pressure.

35. A flexible air bag, which comprises a coated woven textile fabric having synthetic yarns of at least two different deniers and more than one synthetic filamentary material, and a polymeric coating on at least one side thereof, said yarns said polymeric coating being preselected respectively in deniers and thickness so as to render said fabric substantially impermeable to fluid under pressure, said filamentary materials being selected to provide predetermined weight and strength for use in inflatable vehicle restraint systems.