Airbag fabric processing very low cover factor

• US 6,294,487 B1
• Filed: 09/24/1999
• Issued: 09/25/2001
• Est. Priority Date: 09/24/1999
• Status: Expired

• Current Assignee: Milliken & Company
• Original Assignee: Milliken & Company
• Inventors: Keshavaraj, Ramesh
• Primary Examiner(s): Cole, Elizabeth M.
• Assistant Examiner(s): SINGH-PANDEY, ARTI R
• Application Number:
  US09/405,999
• Time in Patent Office: 732 Days
• Field of Search: 280/728.1, 428/34.3, 428/34.5, 428/34.6, 428/34.7, 428/36.1, 442/76, 442/152, 442/158, 442/164, 442/168, 442/181, 442/203, 442/218
• US Class Current: 442/218
• 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 2021/23514 coated fabric
• CPC Class Codes: B60R 21/235 characterised by their material
• CPC Class Codes: D03D 1/02 Inflatable articles
• CPC Class Codes: D06N 3/0002 characterised by the substrate
• CPC Class Codes: D06N 3/14 with polyurethanes
• 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 428/1362 Textile, fabric, cloth, or pile containing [e.g., web, net, woven, knitted, mesh, nonwoven, matted, etc.]
• 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 442/2762 Coated or impregnated natural fiber fabric [e.g., cotton, wool, silk, linen, etc.]
• CPC Class Codes: Y10T 442/2811 Coating or impregnation contains polyimide or polyamide
• 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 442/3179 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 442/3301 Coated, impregnated, or autogenous bonded

Abstract

The present invention relates to an airbag fabric which is woven in such a manner as to possess a cover factor of less than about 1900 but which simultaneously, through the presence of a film (laminate) or coating, possesses an extremely low air permeability. The utilization of such a loosely constructed fabric within airbag cushions has heretofore not been possible, even with the application of standard airbag coatings (such as silicones) over the fabric surface since such coatings with not easily remain in contact over the loosely constructed fabric surface (i.e., the coating would leak through the fabric). The coupling of a low cover factor fabric with a laminate film (or with a coating wherein the cover factor is at least 1600), however, solves such a problem and permits the utilization of inexpensively produced woven fabrics within airbag applications.

Claims

1. An airbag fabric for incorporation within an airbag cushion comprising a woven fabric substrate, at least a portion of which is coated or laminated, wherein said woven fabric substrate has a cover factor below about 1900, and wherein the air permeability of said airbag fabric is less than about 0.5 cfm under 124 Pa pressure at about 25°

C.

2. The airbag fabric of claim 1 wherein said woven fabric substrate is coated or laminated with a coating or film selected from the group consisting of polyurethane, polyacrylate, polyamide, polyester, and copolymers thereof.

3. The airbag fabric of claim 1 wherein said cover factor below about 1800.

4. The airbag fabric of claim 3 wherein said cover factor below about 1775.

5. The airbag fabric of claim 4 wherein said cover factor below about 1750.

6. The airbag fabric of claim 5 wherein said coating or laminate comprises polyurethane.

7. The airbag fabric of claim 6 wherein the thickness of said coating or laminate is from 0.1 to about 3.5 mils.

8. An airbag cushion comprising the airbag fabric of claim 6.

9. An airbag cushion comprising the airbag fabric of claim 7.

10. The airbag fabric of claim 4 wherein said coating or laminate comprises polyurethane.

11. The airbag fabric of claim 10 wherein the thickness of said coating or laminate is from 0.1 to about 3.5 mils.

12. An airbag cushion comprising the airbag fabric of claim 11.

13. An airbag cushion comprising the airbag fabric of claim 10.

14. The airbag fabric of claim 3 wherein said coating or laminate comprises polyurethane.

15. The airbag fabric of claim 14 wherein the thickness of said coating or laminate is from 0.1 to about 3.5 mils.

16. An airbag cushion comprising the airbag fabric of claim 15.

17. An airbag cushion comprising the airbag fabric of claim 14.

18. The airbag fabric of claim 1 wherein the thickness of said coating or laminate is from 0.1 to about 3.5 mils.

19. An airbag cushion comprising the airbag fabric of claim 18.

20. An airbag cushion comprising the airbag fabric of claim 1.