Coated multi-layered woven textile fabrics for use in air-holding vehicle restraint system

• US 6,458,724 B1
• Filed: 01/28/2000
• Issued: 10/01/2002
• Est. Priority Date: 06/07/1999
• Status: Expired due to Term

• 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:
  US09/493,628
• Time in Patent Office: 977 Days
• Field of Search: 428/12, 428/33, 428/34.1, 428/34.3, 428/34.5, 428/34.6, 428/34.7, 428/35.2, 428/36.1, 428/36.2, 428/57, 428/58, 428/192, 442/67, 442/71, 442/76, 442/149, 442/157, 442/164, 442/172, 442/218, 280/728.1, 280/729, 280/733
• 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 2067/00 Use of polyesters or derivatives thereof, as moulding material
• 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 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 1/00 Layered products having a non-planar shape
• CPC Class Codes: B32B 2250/02 2 layers
• CPC Class Codes: B32B 2250/20 All layers being fibrous or filamentary
• CPC Class Codes: B32B 2255/02 on fibrous or filamentary layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2255/28 Multiple coating on one surface
• CPC Class Codes: B32B 2262/0261 Polyamide fibres
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2307/306 Resistant to heat
• CPC Class Codes: B32B 2307/50 having particular mechanical properties
• CPC Class Codes: B32B 2307/7242 : Non-permeable
• CPC Class Codes: B32B 2307/748 : Releasability
• CPC Class Codes: B32B 2571/00 : Protective equipment
• CPC Class Codes: B32B 2605/00 : Vehicles
• CPC Class Codes: B32B 3/08 : characterised by added members at particular parts layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18
• CPC Class Codes: B32B 3/26 : characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205; characterised by an apertured layer
• CPC Class Codes: B32B 3/30 : characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/026 : Knitted fabric
• CPC Class Codes: B32B 5/06 : characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 7/05 : the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection using interposed adhesives or bonding materials applied in spaced arrangements B32B7/14
• CPC Class Codes: B60R 2021/23514 : coated fabric
• CPC Class Codes: B60R 21/235 : characterised by their material
• CPC Class Codes: D06N 3/128 : with silicon polymers
• CPC Class Codes: D06N 3/14 : with polyurethanes
• CPC Class Codes: D06N 3/183 : the layers are one next to the other
• CPC Class Codes: D06N 3/186 : one of the layers is on one surface of the fibrous web and the other layer is on the other surface of the fibrous web
• CPC Class Codes: D10B 2505/124 : Air bags
• CPC Class Codes: F16L 59/026 : Mattresses, mats, blankets or the like
• CPC Class Codes: Y10T 428/13 : Hollow or container type article [e.g., tube, vase, etc.]
• CPC Class Codes: Y10T 428/1307 : Bag or tubular film [e.g., pouch, flexible food casing, envelope, etc.]
• CPC Class Codes: Y10T 428/1314 : Contains fabric, fiber particle, or filament made of glass, ceramic, or sintered, fused, fired, or calcined metal oxide, or metal carbide or other inorganic compound [e.g., fiber glass, mineral fiber, sand, etc.]
• CPC Class Codes: Y10T 428/1317 : Multilayer [continuous layer]
• CPC Class Codes: Y10T 428/1321 : Polymer or resin containing [i.e., natural or synthetic]
• CPC Class Codes: Y10T 428/1334 : Nonself-supporting tubular film or bag [e.g., pouch, envelope, packet, etc.]
• CPC Class Codes: Y10T 428/1362 : Textile, fabric, cloth, or pile containing [e.g., web, net, woven, knitted, mesh, nonwoven, matted, etc.]
• CPC Class Codes: Y10T 428/1366 : Textile, fabric, cloth, or pile is sandwiched between two distinct layers of material unlike the textile, fabric, cloth, or pile layer
• CPC Class Codes: Y10T 428/19 : Sheets or webs edge spliced or joined
• CPC Class Codes: Y10T 428/192 : Sheets or webs coplanar
• CPC Class Codes: Y10T 428/24777 : Edge feature
• CPC Class Codes: Y10T 442/2066 : Different coatings or impregnations on opposite faces of the fabric
• CPC Class Codes: Y10T 442/2098 : At least two coatings or impregnations of different chemical composition
• 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 442/2738 : Coating or impregnation intended to function as an adhesive to solid surfaces subsequently associated therewith
• CPC Class Codes: Y10T 442/2803 : Polymeric coating or impregnation from a silane or siloxane not specified as lubricant or water repellent
• CPC Class Codes: Y10T 442/2861 : Coated or impregnated synthetic organic fiber fabric
• CPC Class Codes: Y10T 442/2926 : Coated or impregnated inorganic fiber fabric
• CPC Class Codes: Y10T 442/3301 : Coated, impregnated, or autogenous bonded

Abstract

The invention is directed to multi-layered textile fabrics having a plurality of polymeric coating layers of polyurethane and/or polysiloxane coated thereon. The coating layers are applied to such multi-layered woven textile fabric substrates having preconfigured air-holding cavities therein to form an improved air-holding vehicle restraint system, such as an air bag or side air curtain with superior air-holding characteristics. In certain instances, the multi-layered textile fabrics are coated on one side only, and in others they may be coated on both sides, i.e., opposed first and second surfaces. The layers of the multi-layered fabric can then be joined by means of heat sealing, RF welding or combinations thereof, for purposes of forming an air bag or side air curtain without the need for sewing or stitching. The coated fabrics facilitate manufacture of air bags, side curtains or the like with both reduced cutting and sealing steps than fabrics of the prior art.

Claims

1. A coated textile substrate for an air-holding vehicle restraint system which comprises:

a) a multi-layered textile substrate having opposed outer surfaces;

b) a first coating layer of an adhesive polyurethane on a first surface of said multi-layered textile substrate; and

c) at least a second coating layer of an elastomeric polysiloxane on said first coating layer.

2. A coated textile fabric for an air-holding vehicle restraint system, which comprises:

a) a multi-layered textile substrate having first and second opposed outer surfaces and preconfigured air-holding cavities therein;

b) at least a first coating layer of adhesive polyurethane coated on both said first and second opposed outer surfaces of said textile substrate; and

c) at least a second coating layer of a polymeric material coated on both of said first coating layers of adhesive polyurethane.

3. The coated textile fabric of claim 2 wherein said multi-layered textile substrate is a fabric constructed from synthetic material.

4. The coated textile fabric of claim 3 wherein said synthetic material is selected from the group consisting of polyamides and polyesters.

5. The coated textile fabric of claim 4 wherein said coated textile substrate is a woven nylon fabric.

6. The coated textile fabric of claim 4 wherein said first coating layer is selected from the group consisting of aromatic or aliphatic polyester polyurethanes and aromatic or aliphatic polyether polyurethanes.

7. The coated textile fabric of claim 2 wherein both said second coating layers are each coated with a third coating layer of elastomeric polyurethane or polysiloxane.

8. The coated textile fabric of claim 2 wherein one of said second coating layers is elastomeric polyurethane and said other of said second coating layers is polysiloxane.

9. A coated textile fabric for an air-holding vehicle restraint system, which comprises:

a) a multi-layered woven fabric substrate having first and second opposed outer surfaces and preconfigured air-holding woven cavities defined between said fabric layers;

b) at least a first coating layer of adhesive polyurethane coated on both said first and second outer surfaces of said textile substrate;

c) at least a second coating layer of elastomeric polyurethane or polysiloxane coated on said first coating layers of adhesive polyurethane; and

d) at least a third coating layer of a polymeric material coated on at least one of said second coating layer.

10. The coated textile fabric of claim 9 wherein said woven textile substrate is a fabric constructed from synthetic material.

11. The coated textile fabric of claim 10 wherein said synthetic material is comprised of synthetic filamentary material selected from the group consisting of polyamides and polyesters.

12. The coated textile fabric of claim 9 wherein said woven textile substrate is comprised of woven nylon filaments.

13. The coated textile fabric of claim 9 wherein said first coating layers are selected from the group consisting of aromatic or aliphatic polyester polyurethanes and aromatic or aliphatic polyether polyurethanes.

14. The coated textile fabric of claim 9 wherein both said first coating layers are coated with a second coating layer of elastomeric polyurethane.

15. The coated textile fabric of claim 9 wherein one of said first coating layers is coated with a second coating layer of elastomeric polyurethane and one of said other first coating layers is coated with a second coating layer of polysiloxane.

16. The coated textile fabric of claim 14 wherein at least one of said second coating layers of elastomeric polyurethane is coated with a third coating layer of elastomeric polyurethane.

17. The coated textile fabric of claim 15 wherein at least one of said second coating layers of polysiloxane is coated with a third coating layer of polysiloxane.

18. The coated textile fabric of claim 15 wherein said second coating layer of elastomeric polyurethane is coated with a coating layer of elastomeric polyurethane.

19. The coated textile fabric of claim 15 wherein said second coating layer of polysiloxane is coated with a third coating layer of polysiloxane.

20. The coated textile fabric of claim 15 wherein said second coating layer of polyurethane is coated with a third coating layer of elastomeric polyurethane and said second coating layer of polysiloxane is coated with a third coating layer of polysiloxane.

21. The coated textile fabric of claim 9 wherein said first coating layers of adhesive polyurethane each have a coating weight of from about 0.3 ounces/sq. yd to about 1.5 ounces/sq. yd.

22. The coated textile fabric of claim 21 wherein said coating weight is about 0.5 ounces/sq. yd.

23. The coated textile fabric of claim 9 wherein said second coating layer is an elastomeric polymer selected from the group consisting of aromatic or aliphatic polyether polyurethanes and aromatic or aliphatic polyester polyurethanes having a solids content of from about 30% to about 100% by weight.

24. The coated textile fabric of claim 23 wherein said second coating layer has a coating weight of about 1 ounce/sq. yd. to about 8 ounces/sq. yd.

25. The coated textile fabric of claim 24 wherein said second coating layer has a coating weight of about 2 ounces/sq. yd.

26. The coated textile fabric of claim 9 wherein said third coating layer is an elastomeric polymer selected from the group consisting of aromatic or aliphatic polyether polyurethanes and aromatic or aliphatic polyester polyurethanes having a coating weight of from about 0.2 ounces/sq. yd. to about 2.0 ounces/sq. yd.

27. A coated textile fabric for an air-holding vehicle restraint system, which comprises:

a) a woven fabric nylon having first and second opposed outer surfaces, at least one portion thereof defined by at least two fabric layers positioned in face-to-face relation and unconnected to define at least one pre-configured air holding cavity, each said cavity having adjacent thereto, a fabric portion wherein said fabric layers are connected to each other;

b) at least a first coating layer of adhesive polyurethane coated on both said first and second opposed outer surfaces of said textile substrate; and

c) at least a second coating layer of a polymeric material coated on both of said first coating layers of adhesive polyurethane.