Substrate with stretch and heat sealing properties to make a multidirectional restraint module design

• US 20020187696A1
• Filed: 09/19/2001
• Published: 12/12/2002
• Est. Priority Date: 06/07/1999
• Status: Active Grant

• Current Assignee: Bradford Coatings, Llc
• Original Assignee: Manuel J. Veiga, Richard J. Satin
• Inventors: Veiga, Manuel J., Satin, Richard J.
• Granted Patent: US 6,740,607 B2
• Time in Patent Office: Days
• US Class Current: 442/76
• CPC Class Codes: B32B 2262/0261 Polyamide fibres
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 25/10 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2553/02 Shock absorbing
• CPC Class Codes: B32B 2605/08 Cars
• 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: B32B 5/026 Knitted fabric
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B60R 2021/0018 Roll-over
• CPC Class Codes: B60R 2021/23514 coated fabric
• CPC Class Codes: B60R 21/235 characterised by their material
• 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: 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: 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 442/2738 : Coating or impregnation intended to function as an adhesive to solid surfaces subsequently associated therewith
• 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

The invention is directed to coating a plurality of polyurethane films onto a stretchable knit fabric substrate and heat sealing such substrates together to yield an air curtain or air bag having improved air-holding properties.

Claims

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

a) a textile substrate of a stretchable knit fabric having opposed surfaces;

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

c) a second coating layer of an elastomeric polyurethane on said first coating layer.

2. The coated textile substrate of claim 1 wherein said textile substrate is a fabric constructed from synthetic fibers.

3. The coated textile substrate of claim 2 wherein the synthetic fibers are selected from the group consisting of polyamides and polyesters.

4. The coated textile substrate of claim 1 wherein the adhesive polyurethane layer is selected from the group consisting of aliphatic or aromatic polyester or polyether polyurethanes.

5. The coated textile substrate of claim 1 wherein the adhesive polyurethane layer is a film having a thickness of from about 0.5 mils to about 2.5 mils.

6. The coated textile substrate of claim 5 wherein the thickness of the adhesive polyurethane film is about 1.5 mils.

7. The coated textile substrate of claim 1 wherein the elastomeric polyurethane layer is an aliphatic or aromatic polyether or polyester polyurethane having from about 30% to about 100% solids, by weight.

8. The coated textile substrate of claim 1 wherein the elastomeric polyurethane layer is a film having a thickness of from about 0.5 mils to about 8.0 mils.

9. The coated textile substrate of claim 8 wherein the elastomeric polyurethane film has a thickness of about 2 mils.

10. The coated textile substrate of claim 1 wherein the other surface is coated with an adhesive polyurethane forming a first coating layer and a second coating layer of an elastomeric polyurethane on said first coating layer.

11. The coated textile substrate of claim 1 wherein the other surface of said knitted textile substrate is coated with a polysiloxane.

13. The method of claim 12 wherein the textile substrate is selected from the group consisting of polyesters, polyamides or other synthetic fibers.

14. The method of claim 12 wherein the elastomeric polyurethane film is selected from the group consisting of aliphatic or aromatic polyether or polyester polyurethanes having a solids content of from about 30% to about 100%, by weight.

15. The method of claim 12 wherein the elastomeric polyurethane film has a thickness of from about 0.5 mils to about 8.0 mils.

16. The method of claim 15 wherein the elastomeric polyurethane film has a thickness of about 2 mils.

17. The method of claim 12 wherein the adhesive polyurethane is selected from the group consisting of aliphatic or aromatic polyether and polyester polyurethanes.

18. The method of claim 12 wherein the adhesive polyurethane film has a thickness of from about 0.5 mils to about 2.5 mils.

19. The method of claim 18 wherein the adhesive polyurethane film has a thickness of about 1.5 mils.

20. The method of coating the other surface of said knitted textile substrate in accordance with claim 12.

21. The method of claim 12 and including coating an elastomeric polysiloxane film to the other surface of said knitted textile substrate.

12. A method of coating a textile substrate for an air-holding vehicle restraint system, which comprises:

a) coating an elastomeric polyurethane onto a release paper and drying at elevated temperature to form an elastomeric polyurethane film on the release paper;

b) coating an adhesive polyurethane onto the elastomeric film;

c) applying a knitted textile substrate onto the adhesive polyurethane and then drying at elevated temperature to laminate the knitted textile substrate to the adhesive polyurethane; and

d) stripping the release paper whereby a polyurethane knit composite is formed.

22. A method of making an air-holding restraint system for a vehicle, which comprises:

a) coating an adhesive polyurethane to a surface of a first knitted textile substrate to form a first coating layer;

b) coating an elastomeric polyurethane to the first coating layer to form a second coating layer;

c) repeating the coating steps (a) and (b) on a surface of a second substrate selected from the group consisting of woven and non-woven textile substrates;

d) sealing the first and second coated textile substrates together by radio frequency sealing, hot air sealing or ultrasonic sealing.

23. The method of claim 22 wherein the air-holding restraint system is an air bag.

24. The method of claim 22 wherein the air-holding restraint system is an air curtain.

25. The method of claim 22 wherein the knitted textile substrate is selected from the group consisting of polyesters, polyamides or other synthetic fibers.

26. The method of claim 22 wherein the second textile substrate is a woven nylon.

27. The method of claim 22 wherein the adhesive polyurethane coating layer is selected from the group consisting of aliphatic or aromatic polyester or polyether polyurethanes.

28. The method of claim 22 wherein the adhesive polyurethane film on the knitted substrate has a thickness of from about 0.5 mils to about 2.5 mils.

29. The method of claim 28 wherein the film thickness is about 1.5 mils.

30. The method of claim 22 wherein the second coating layer is an elastomeric aliphatic polyether or polyester polyurethane having a solids content of about 30% to about 100%, by weight.

31. The method of claim 22 wherein the elastomeric polyurethane layer on the knitted substrate has a film thickness of from about 0.5 mils to about 8.0 mils.

32. The method of claim 31 wherein the elastomeric polyurethane layer on the knitted substrate has a film thickness of about 2.0 mils.

33. The method of claim 22 wherein the second textile substrate has an adhesive polyurethane film coating of from about 0.5 mils to about 2.5 mils thickness.

34. The method of claim 22 wherein the second textile substrate has an elastomeric polyurethane film coating of from about 0.5 to about 8.0 mils thickness.

35. The method of claim 22 wherein the sealing is effected at a radio frequency of from about 10 to about 80 megahertz.

37. The method of claim 36 wherein the knitted textile substrate is selected from the group consisting of polyesters and polyamides.

38. The method of claim 36 wherein the knitted fabric substrate is selected from the group consisting of polyesters and polyamides.

39. The method of claim 36 wherein the first coating layer is selected from the group consisting of aliphatic or aromatic polyester or polyether polyurethanes.

40. The method of claim 36 wherein the adhesive coating layer has a film thickness of from about 0.5 mils to about 2.5 mils.

41. The method of claim 40 wherein the film thickness is about 1.5 mils.

42. The method of claim 36 wherein the second coating layer is an elastomeric aliphatic or aromatic polyether or polyester polyurethane having a solids content of from about 30% to about 100%, by weight.

43. The method of claim 36 wherein the polyurethane elastomeric coating layer has a film thickness of from about 0.5 mils to about 8.0 mils.

44. The method of claim 43 wherein the film thickness is about 2 mils.

45. The method of claim 36 including repeating the coating steps (a) and (b) on the other surface of said knitted textile substrate and drying at elevated temperature to form a polyurethane coating on the other surface of said textile substrate.

46. The method of claim 36 and including coating an elastomeric polysiloxane to the other surface of said textile substrate and drying at elevated temperature to form a polysiloxane coating on the other surface of said textile substrate.

48. The restraint system of claim 47 wherein the heat sealed substrates form an air-tight connection.

49. The restraint system of claim 47 wherein the knitted textile substrates are heat-sealed about their peripheries.

50. The restraint system of claim 47 wherein the textile substrates are sealed by radio frequency sealing, hot air sealing or ultrasonic sealing.

51. The restraint system of claim 50 wherein the substrates are sealed by radio frequency sealing at from about 10 to about 80 megahertz.

52. The restraint system of claim 47 wherein the air-holding restraint system is an air bag.

53. The restraint system of claim 47 wherein the air-holding restraint system is an air curtain.

54. The restraint system of claim 47 wherein the knitted textile substrates are selected from the group consisting of polyesters, polyamides or other synthetic fibers.

55. The restraint system of claim 47 wherein the adhesive polyurethane coating layer is selected from the group consisting of aliphatic or aromatic polyester or polyether polyurethanes.

56. The restraint system of claim 47 wherein the adhesive polyurethane film has a thickness of from about 0.5 mils to about 2.5 mils.

57. The restraint system of claim 56 wherein the film thickness is about 1.5 mils.

58. The restraint system of claim 47 wherein the elastomeric polyurethane film is an aliphatic or aromatic polyether or polyester polyurethane having a solids content of from about 30% to about 100%, by weight.

59. The restraint system of claim 47 wherein the elastomeric polyurethane film has a thickness of from about 0.5 mils to about 8.0 mils.

60. The restraint system of claim 59 wherein the elastomeric polyurethane film has a thickness of about 2.0 mils.

36. A method of coating a textile substrate for an air-holding vehicle restraint system, which comprises:

a) coating an adhesive polyurethane to a surface of a knitted textile substrate and drying at elevated temperature to form a first coating layer;

b) coating an elastomeric polyurethane to the polyurethane coating layer and drying at elevated temperature to form a second coating layer.

47. An air-holding vehicle restraint system, comprising:

a pair of heat-sealed polyurethane coated knitted textile substrates;

the outer surface of each substrate having an adhesive polyurethane film and an overlying elastomeric polyurethane film.

61. An air-holding vehicle restraint system, comprising:

a polyurethane coated knitted textile substrate heat-sealed to a polyurethane coated woven textile substrate;

the outer surface of each substrate having an adhesive polyurethane film and an overlying elastomeric polyurethane film.

62. The restraint system of claim 61 wherein the heat sealed substrates form an air-tight connection.

63. The air-holding vehicle restraint system of claim 61 wherein the textile substrates are heat-sealed about their peripheries.

64. The restraint system of claim 61 wherein the textile substrates are sealed by radio frequency sealing, hot air sealing or ultrasonic sealing.

65. The restraint system of claim 64 wherein the substrates are sealed by radio frequency sealing at from about 10 to about 80 megahertz.

66. The restraint system of claim 61 wherein the air-holding restraint system is an air bag.

67. The restraint system of claim 61 wherein the air-holding restraint system is an air curtain.

68. The restraint system of claim 61 wherein the knitted textile substrate is selected from the group consisting of polyesters, polyamides or other synthetic fibers.

69. The restraint system of claim 61 wherein the woven textile substrate is nylon.

70. The restraint system of claim 61 wherein the adhesive polyurethane coating layer is selected from the group consisting of aliphatic or aromatic polyester or polyether polyurethanes.

71. The restraint system of claim 61 wherein the adhesive polyurethane film has a thickness of from about 0.5 mil to about 2.5 mils.

72. The restraint system of claim 71 wherein the film thickness is about 1.5 mils.

73. The restraint system of claim 61 wherein the overlying elastomeric polyurethane film is an aliphatic or aromatic polyether or polyester polyurethane having a solids content of from about 30% to about 100%, by weight.

74. The restraint system of claim 73 wherein the overlying elastomeric polyurethane film has a thickness of from about 0.5 mils to about 8.0 mils.

75. The restraint system of claim 74 wherein the elastomeric polyurethane film has a thickness of about 2.0 mils.