Laminated multi-layered woven textile fabrics for use in air holding vehicle restraint systems

• US 6,753,275 B2
• Filed: 08/03/2001
• Issued: 06/22/2004
• 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.
• Primary Examiner(s): SINGH-PANDEY, ARTI R
• Application Number:
  US09/921,979
• Publication Number:
  US 20020175510A1
• Time in Patent Office: 1,054 Days
• Field of Search: 280/728.1, 280/729, 280/733, 280/748.1, 106/287.13, 106/287.14, 106/287.16, 428/34.1, 428/34.3, 428/34.6, 428/35.2, 428/35.7, 428/35.9, 428/36.1, 428/36.6, 428/36.91, 428/101, 428/166, 442/76, 442/164, 442/168, 442/169, 442/182, 442/203, 442/286
• US Class Current: 442/164
• 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: D10B 2505/124 Air bags
• 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 428/1317 Multilayer [continuous layer]
• CPC Class Codes: Y10T 428/1334 Nonself-supporting tubular film or bag [e.g., pouch, envelope, packet, etc.]
• CPC Class Codes: Y10T 428/1352 Polymer or resin containing [i.e., natural or synthetic]
• CPC Class Codes: Y10T 428/1359 Three or more layers [continuous layer]
• 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 428/1379 Contains vapor or gas barrier, polymer derived from vinyl chloride or vinylidene chloride, or polymer containing a vinyl alcohol unit
• CPC Class Codes: Y10T 428/1393 Multilayer [continuous layer]
• CPC Class Codes: Y10T 428/24025 Superposed movable attached layers or components
• CPC Class Codes: Y10T 428/24562 Interlaminar spaces
• 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 442/2861 Coated or impregnated synthetic organic fiber fabric
• CPC Class Codes: Y10T 442/2893 Coated or impregnated polyamide fiber fabric
• CPC Class Codes: Y10T 442/2902 Aromatic polyamide fiber fabric
• CPC Class Codes: Y10T 442/3008 Woven fabric has an elastic quality
• 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 442/3854 : Woven fabric with a preformed polymeric film or sheet

Abstract

A multi-layered woven side air curtain has pre-configured air holding cavities and a polymeric film laminated thereto. An adhesive polyether polyurethane or polyester polyurethane prime coat layer is first coated onto a textile substrate, and then a polymeric film, such as polyamide, polyolefin, or polyurethane is laminated thereto. The textile substrate may be woven of nylon, polyester, or other synthetic fibers. According to an alternative embodiment, a multi-layered composite film product can be used as a film laminate without the need for a prime coat adhesive layer being first applied to the textile substrate. In such a case, the adhesive prime coat is applied to the textile substrate in a single step via the film laminate itself. The side air curtain can be pre-configured or prefabricated to numerous varied designs and shapes prior to coating.

Claims

1. An automotive protective device comprising a woven textile substrate having two outer surfaces and pre-configured air holding cavities woven therein, each of said outer surfaces having an adhesive polyurethane layer coated thereon and a polymeric film laminated thereto.

2. The automotive protective device of claim 1 wherein said woven textile substrate is a nylon, polyester or other synthetic fiber.

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

4. The automotive protective device of claim 2 wherein said woven textile substrate is nylon.

5. The automotive protective device of claim 2 wherein said adhesive polyurethane layer comprises an aliphatic or aromatic polyester polyurethane or polyether polyurethane.

6. The automotive protective device of claim 5 wherein said adhesive polyurethane layer has a coating weight of from about 0.25 ounces per square yard to about 2.5 ounces per square yard.

7. The automotive protective device of claim 5 wherein said adhesive polyurethane layer has a coating weight of about 1.2 ounces per square yard.

8. The automotive protective device of claim 5 wherein said adhesive polyurethane layer has a solids content of from about 25% to about 45%.

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

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

11. A method of manufacturing an automotive protective device which comprises:

a) taking a woven textile substrate having two outer surfaces and pre-configured air holding cavities woven therein;

b) coating each of said outer surfaces of said woven textile substrate with an adhesive polyurethane coating composition; and

c) laminating a polymeric film to each of said outer surfaces of said woven textile substrate.

12. The method of claim 11 wherein said woven textile substrate is a nylon, polyester or other synthetic fiber.

13. The method of claim 12 wherein said adhesive polyurethane coating composition comprises an aliphatic or aromatic polyether polyurethane or polyester polyurethane, and an isocyanate material having a temperature at which it becomes activated and adhesively binding.

14. The method of claim 12 wherein said polymeric film laminate is a polyamide, polyester, polyolefin or polyurethane film.

15. The method of claim 13 wherein said adhesive polyurethane coating step takes place at a temperature below the activation temperature of the isocyanate material.

16. The method of claim 12 wherein said woven textile substrate is nylon.

17. The method of claim 11 wherein said woven textile substrate is first coated on each of said outer surfaces with an adhesive polyurethane coating composition comprising an aromatic or aliphatic polyester polyurethane or polyether polyurethane and an isocyanate material, to which coated outer surfaces a polymeric film comprising a polyamide, polyester or polyurethane film is thereafter laminated under heat and pressure sufficient to adhesively activate said isocyanate material.

18. The method of claim 17 wherein said polymeric film is laminated sequentially on said two outer surfaces.

19. The method of claim 17 wherein said polymeric film lamination takes place at a temperature of from about 275°

F. to about 450°

F. and at a pressure of from about 200 psi to about 1000 psi.

20. The method of claim 19 wherein said polymeric film lamination takes place at a temperature of about 400°

F. and at a pressure of from about 500 psi to about 600 psi.

21. A composite sealing and air holding laminating film for use in the manufacture of an automotive protective device with a woven textile substrate having pre-configured air holding cavities woven therein, said composite laminating film comprising a polymeric carrier film and a layer of adhesive polyurethane coated thereon.

22. The composite sealing and air holding laminating film of claim 21 wherein said polymeric carrier film is a polyamide, polyester, polyolefin or polyurethane film.

23. The composite sealing and air holding laminating film of claim 21 wherein said adhesive polyurethane coating comprises an aliphatic or aromatic polyester polyurethane or polyether polyurethane and an isocyanate material.

24. The composite sealing and air holding laminating film of claim 21 wherein said polymeric carrier film is a polyamide, polyolefin or polyurethane film and said adhesive polyurethane coating thereon is an aliphatic or aromatic polyester polyurethane or polyether polyurethane.

25. The composite sealing and air holding laminating film of claim 24 wherein said adhesive polyurethane coating layer has a thickness of from about 0.5 mils to about 5.0 mils.

26. The composite sealing and air holding laminating film of claim 24 wherein said adhesive polyurethane coating layer has a thickness of from about 1.0 mils to about 1.5 mils.

27. The composite sealing and air holding laminating film of claim 24 wherein said adhesive polyurethane coating layer has a solids content of from about 25% to about 45%.

28. The composite sealing and air holding laminating film of claim 24 wherein said polymeric carrier film has a thickness of from about 0.2 mils to about 5.0 mils.

29. The composite sealing and air holding laminating film of claim 24 wherein said polymeric carrier film has a thickness of from about 0.5 mils to about 1.0 mils.

30. A method of making a composite sealing and air holding laminating film for use in the manufacture of an automotive protective device comprising a woven textile substrate having pre-configured air holding cavities woven therein which comprises:

a) casting a solution comprising a polymeric carrier film and a solvent onto a release paper;

b) solidifying said carrier film layer by evaporating said solvent;

c) coating an adhesive polyurethane layer onto said polymeric carrier film; and

d) drying said adhesive polyurethane material.

31. The method of claim 30 wherein said polymeric carrier film layer is comprised of a polyamide, polyester or polyurethane material.

32. The method of claim 30 wherein said adhesive polyurethane layer comprises an aromatic or aliphatic polymeric polyether polyurethane or polyester polyurethane and an isocyanate material.

33. The method of claim 31 wherein said polymeric carrier film layer has a thickness of from about 0.2 mils to about 5.0 mils.

34. The method of claim 31 wherein said polymeric carrier film layer has a thickness of from about 0.5 mils to about 1.0 mils.

35. The method of claim 32 wherein said adhesive polyurethane layer has a thickness of from about 0.5 mils to about 5.0 mils.

36. The method of claim 32 wherein said adhesive polyurethane layer has a thickness of from about 1.0 mils to about 1.5 mils.

37. An automotive protective device comprising a woven textile substrate having two outer surfaces and pre-configured air holding cavities woven therein and a composite sealing and air holding laminating film comprising a polymeric carrier film and a layer of adhesive polyurethane coated thereon laminated to each of the outer surfaces of said textile substrate.

38. The automotive protective device of claim 37 wherein said polymeric carrier film is a polyamide, polyolefin or polyurethane film.

39. The automotive protective device of claim 37 wherein said adhesive polyurethane coating is an aliphatic or aromatic polyester polyurethane or polyether polyurethane.

40. The automotive protective device of claim 37 wherein said polymeric carrier film is a polyamide, polyolefin or polyurethane film and said adhesive polyurethane coating thereon is an aliphatic or aromatic polyester polyurethane or polyether polyurethane.

41. The automotive protective device of claim 37 wherein said adhesive polyurethane coating layer has a thickness of from about 0.5 mils to about 5.0 mils.

42. The automotive protective device of claim 37 wherein said adhesive polyurethane coating layer has a thickness of from about 1.0 mils to about 1.5 mils.

43. The automotive protective device of claim 37 wherein said adhesive polyurethane coating layer has a solids content of from about 25% to about 45%.

44. The automotive protective device of claim 37 wherein said polymeric carrier film has a thickness of from about 0.2 mils to about 5.0 mils.

45. The automotive protective device of claim 37 wherein said polymeric carrier film has a thickness of from about 0.5 mils to about 1.0 mils.

46. A method of making a composite sealing and air holding laminating film for use in the manufacture of an automotive protective device comprising a woven textile substrate having pre-configured air holding cavities woven therein which comprises:

a) coating an adhesive polyurethane layer onto a carrier film layer; and

b) drying said adhesive polyurethane material.

47. The method of claim 46 wherein said polymeric carrier film layer is comprised of a polyamide, polyester, polyolefin or polyurethane material.

48. The method of claim 47 wherein said adhesive polyurethane layer comprises an aromatic or aliphatic polymeric polyether polyurethane or polyester polyurethane and an isocyanate material.

49. The method of claim 47 wherein said polymeric carrier film layer has a thickness of from about 0.2 mils to about 5.0 mils.

50. The method of claim 47 wherein said polymeric carrier film layer has a thickness of from about 0.5 mils to about 1.0 mils.

51. The method of claim 48 wherein said adhesive polyurethane layer has a thickness of from about 0.5 mils to about 5.0 mils.

52. The method of claim 48 wherein said adhesive polyurethane layer has a thickness of from about 1.0 mils to about 1.5 mils.