U.S. patent application number 09/942133 was filed with the patent office on 2002-09-05 for abrasion and/or puncture resistant fabrics, airbag cushions, and methods.
Invention is credited to Bowen, Derek L., Hildreth, David D., Keshavaraj, Ramesh, Li, Shulong, Willbanks, Charles E..
Application Number | 20020122908 09/942133 |
Document ID | / |
Family ID | 26922950 |
Filed Date | 2002-09-05 |
United States Patent
Application |
20020122908 |
Kind Code |
A1 |
Li, Shulong ; et
al. |
September 5, 2002 |
Abrasion and/or puncture resistant fabrics, airbag cushions, and
methods
Abstract
Typical road surfaces are concrete, and gravel filled asphalt.
They are very abrasive to fabrics that slide on those surfaces. For
the new side impact curtain-type airbag, in a rollover situation,
the airbag needs to protect the occupant from directly contacting
the road hazard and should not deflate quickly or break when
sliding on such road surfaces. We have found that a layer of
elastomer can provide much better abrasion resistance than a layer
of heavy industrial fabric. A Jacquard bag coated with 1.2
oz/yd.sup.2 polyurethane showed significant increase in air leakage
rate after 5 cycles of concrete sliding abrasion. A 3 mil thick
polyurethane film was laminated to the coated Jacquard woven
airbag. After 110 cycles of sliding abrasion using the same
concrete, no visual damage or change in bag leakage was observed.
This finding indicates surprisingly better abrasion resistance of a
thin elastomer film than a heavy industrial fabric.
Inventors: |
Li, Shulong; (Spartanburg,
SC) ; Bowen, Derek L.; (LaGrange, GA) ;
Willbanks, Charles E.; (Spartanburg, SC) ;
Keshavaraj, Ramesh; (Peachtree City, GA) ; Hildreth,
David D.; (LaGrange, GA) |
Correspondence
Address: |
Milliken & Company
P.O. Box 1927
Spartanburg
SC
29304
US
|
Family ID: |
26922950 |
Appl. No.: |
09/942133 |
Filed: |
August 29, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60229112 |
Aug 30, 2000 |
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Current U.S.
Class: |
428/36.2 |
Current CPC
Class: |
B32B 2255/02 20130101;
Y10T 442/2861 20150401; B32B 5/026 20130101; B32B 2571/00 20130101;
B32B 2305/186 20130101; D06N 3/14 20130101; B32B 27/32 20130101;
B32B 2367/00 20130101; Y10T 428/31504 20150401; B32B 2262/0269
20130101; B32B 2255/26 20130101; D03D 1/02 20130101; B32B 2323/00
20130101; B60R 2021/23547 20130101; B32B 2377/00 20130101; D06N
3/125 20130101; B32B 27/36 20130101; B60R 2021/23514 20130101; B32B
27/40 20130101; B32B 7/12 20130101; B60R 21/232 20130101; B32B
27/12 20130101; B32B 27/34 20130101; B60R 2021/0018 20130101; B60R
21/235 20130101; D06N 3/128 20130101; B32B 2307/584 20130101; D06N
3/0002 20130101; Y10T 428/1366 20150115; B32B 5/024 20130101; B32B
2305/188 20130101 |
Class at
Publication: |
428/36.2 |
International
Class: |
B32B 001/02 |
Claims
What we claim is:
1. A fabric adapted for use in airbag cushions, especially side
curtain airbags providing rollover protection, comprising: an
airbag fabric having at least one coating, film, fabric or layer on
the exterior surface thereof, having at least one of abrasion
resistance, puncture resistance, and combinations thereof, and
having an ASTM D 4833 index puncture resistance greater than about
210 lbs. and ASTM F 1342 puncture resistance greater than about 10
lbs.
2. A fabric adapted for use in airbag cushions, especially side
curtain airbags providing rollover protection, comprising: an
airbag fabric covered with a film layer, wherein said fabric is
adapted for use in an airbag having a characteristic leak-down time
after inflation of at least 5 seconds.
3. A fabric adapted for use in airbag cushions, especially side
curtain airbags providing rollover or impact protection,
comprising: an airbag fabric having at least one of a woven and
knit fabric laminated to the exterior surface thereof.
4. An airbag fabric having an ASTM D 4833 index puncture resistance
greater than about 210 lbs. and ASTM F 1342 puncture resistance
greater than about 10 lbs.
5. A puncture resistant airbag fabric comprising at least two
layers of fabric, with at least one layer being coated airbag
fabric and the other being a woven or knitted fabric.
6. A puncture resistant airbag fabric comprising at least two
laminated layers of fabric adapted for use on the side of an airbag
facing the outside of a vehicle when inflated.
7. The fabric as recited in at least one of claims 1 and 5, wherein
said coating is at least one polymer elastomer, or the like such as
silicone or polyurethane.
8. The fabric as recited in claim 1, wherein the coating, film or
layer further includes a polyurethane film laminated or placed over
the coated fabric.
9. The fabric as recited in claim 1, wherein the coating, film or
layer further includes an outer layer of fabric laminated over the
coated fabric.
10. The fabric as recited in claim 9, wherein the fabric is
laminated using an elastomeric coating, film, adhesive, or
combination thereof.
11. The fabric as recited in at least one of claims 3, 5, 6, and 9,
wherein said outer layer of fabric is constructed of at least one
of polyester, polyamide, polyolefin, polyurethane, or combinations
thereof.
12. An airbag cushion comprising the fabric of at least one of
claims 1, 2, 3, 4, 5, and 6 on at least the exterior surface
thereof.
13. The airbag cushion of claim 12, wherein said fabric is coated
with a laminate film, and wherein said airbag cushion exhibits a
characteristic leak-down time after inflation of at least 5
seconds.
14. The airbag cushion of claim 13, wherein said film is silicone
free.
15. The airbag cushion of claim 13, wherein said film comprises
polyurethane, polyamide, or copolymer elastomers.
16. The airbag cushion of claim 13, wherein said coated fabric is
woven from polyamide yarns.
17. The airbag cushion of claim 16, wherein said polyamide yarns
are formed from nylon 6,6 fiber.
18. The airbag cushion of claim 16, wherein said polyamide yarns
are multifilament yarns characterized by a linear density of about
210-630 denier.
19. The airbag cushion of claim 18, wherein said multifilament
yarns are characterized by a filament linear density of about 7
denier per filament or less.
20. The airbag cushion of claim 13, wherein said film is present on
said airbag fabric surface in an amount of about 0.5 to 10.0 mils
thick or ounces per square yard.
21. The airbag cushion of claim 20, wherein said film is present on
said airbag fabric in a thickness of at most 5 mils or in an amount
of at most 5 ounces per square yard.
22. The airbag cushion of claim 12, wherein said fabric is coated
with a film layer; wherein said film possesses a tensile strength
of at least 2,000 psi and an elongation at break of at least 180%;
and wherein said airbag cushion exhibits a characteristic leak-down
time after inflation of at least 5 seconds.
23. The airbag cushion of claim 22, wherein said film comprises
polyurethane.
24. The airbag cushion of claim 22, wherein said coated fabric is
woven from polyamide yarns.
25. The airbag cushion of claim 24 wherein said polyamide yarns are
formed from nylon 6,6 fiber.
26. The airbag cushion of claim 24, wherein said polyamide yarns
are multifilament yarns characterized by a linear density of about
210-630 denier.
27. The airbag cushion of claim 26, wherein said multifilament
yarns are characterized by a filament linear density of about 7
denier per filament or less.
28. The airbag cushion of claim 22, wherein said film is present on
said airbag fabric surface in a thickness of about 0.5-10.0 mils or
an amount of about 0.5-10.0 ounces per square yard.
29. The airbag cushion of claim 22, wherein said film is present
coated on said airbag fabric surface in a thickness of about 3 mils
or an amount of about 3 ounces per square yard.
30. An inflatable fabric comprising the fabric of at least one of
claims 1, 2, 3, 4, 5, and 6.
31. The fabric as recited in claim 30 wherein there are at least
two layers of fabric in certain discrete areas of the fabric and at
least one single fabric layer at a discrete area within said
fabric.
32. The fabric of claim 31 wherein said at least two layers of
fabric within said inflatable fabric are formed from one type of
weave pattern.
33. The fabric of claim 32 wherein the weave pattern of said at
least two layers of fabric within said inflatable fabric is a plain
weave pattern.
34. The fabric of claim 31 wherein at least two discrete areas of
single fabric layers are present within said inflatable fabric, and
wherein said at least two single fabric layers are separated by an
area of double layer fabric.
35. The fabric of claim 34 wherein said at least two single fabric
layer areas are seams through the inflatable fabric which run
parallel to each other.
36. The fabric of claim 34 wherein said at least two single fabric
layer areas are constructed from basket weave patterns containing
an even number of yarns.
37. The fabric of claim 34 wherein said separator double fabric
layer between said two single layers of fabric comprises an even
number of weft yarns.
38. The fabric of claim 37 wherein said separator double fabric
layer comprises at most 12 weft yarns and at least 2 weft
yarns.
39. The fabric of claim 38 wherein said at least two single fabric
layers are constructed solely from two-by-two basket weave patterns
and said separator double fabric layer comprises four weft
yarns.
40. The fabric as recited in claim 30, wherein said fabric has at
least two layers of fabric in certain discrete areas of the fabric
and at least one single fabric layer at a discrete area within said
fabric, wherein the weave diagram for such a fabric does not
exhibit more than three consecutive filled or unfilled blocks in
any row or column.
41. The fabric as recited in claim 30, wherein said fabric has at
least two layers of fabric in certain discrete areas of the fabric
and at least one single fabric layer at a discrete area within said
fabric, wherein only two separate weave densities are present
within the fabric structure in the area of the junction of the two
layers and single fabric layer.
42. An airbag structure that does not exhibit significant change in
pressure characteristic when collided with a broken glass surface
at its peak pressure.
43. A puncture resistant airbag comprising different constructions
or coatings on the side facing the occupant and on the side facing
outside, where the side facing the occupant has an ASTM F 1342
puncture resistance of less than about 12 lbs. and the side facing
the outside of the vehicle has an ASTM F 1342 puncture resistance
of greater than about 10 lbs.
44. In an airbag cushion, the improvement comprising: at least one
exterior surface having an inner fabric layer, an intermediate
coating, primer or adhesive layer, and an outer film or fabric
layer, and having an ASTM D 4833 index puncture resistance greater
than about 210 lbs. and ASTM F 1342 puncture resistance greater
than about 10 lbs.
45. The airbag of claim 44, wherein said outer film or fabric layer
is a polyurethane film, and said coating, primer or adhesive layer
is a polyurethane coating.
46. The airbag of claim 45, wherein said film is about 3 mils thick
and said coating is about 1.2 ounces per square yard.
47. The airbag of claim 44, wherein said airbag is at least one of
puncture resistant and abrasion resistant.
48. The airbag of claim 44, wherein said at least one surface
having an ASTM F 1342 puncture force of at least about 10 lbs.
49. The airbag of claim 45, having a puncture force of at least
about 25 lbs.
50. The airbag of claim 41, wherein said at least one surface
having an ASTM D 4833 index of at least about 250 lbs.
51. The airbag of claim 47, having an index of at least about 300
lbs.
52. An airbag cushion adapted for use between an occupant and a
window comprising: an inner or inside surface, wall, construction,
or coating adjacent the occupant, and an outer or outside surface,
wall, construction, or coating adjacent the window, wherein said
inner or inside surface, wall, construction, or coating adjacent
the occupant is at least one of lighter, softer, more flexible, and
less abrasive than said outer or outside surface, wall,
construction, or coating adjacent the window of said vehicle.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of and priority to U.S.
provisional Patent Application Serial No. 60/229,112, filed on Aug.
30, 2000, hereby incorporated by reference herein.
FIELD OF THE INVENTION
[0002] This invention relates generally to abrasion resistant
and/or puncture resistant fabrics, coated, layered and/or laminated
inflatable fabrics, and methods. More particularly, it concerns
airbag cushions to which films, fabrics, layers, and/or coatings
have been applied and which exhibit enhanced abrasion resistance
and/or puncture resistance. The inventive inflatable fabrics are
especially suited for use in automotive restraint cushions that
require abrasion resistance and/or puncture resistance (such as
side curtain airbags).
BACKGROUND OF THE INVENTION
[0003] Side curtain airbags differ from driver side and passenger
side airbags in that side curtain airbags preferably retain at
least half of their inflated pressure for a period of 5 seconds or
longer. Side curtain airbags must retain their fill for a longer
period since a rollover event would occur over some duration rather
than, for example, an instantaneous front or rear impact.
[0004] Further, side curtain airbags which provide for rollover
protection not only must keep their fill for a certain duration,
but also should provide some abrasion and/or puncture resistance so
that they do not lose their inflation as the vehicle rolls and the
exterior of the bag contacts a broken window, asphalt, concrete,
debris, and/or the like.
[0005] Although it has been known to provide low permeability
driver and passenger side airbag fabrics and airbag cushions,
attempts at constructing side curtain airbags and in particular
side curtain airbags with rollover protection has been
problematic.
[0006] Airbags for motor vehicles are known and have been used for
a substantial period of time. A typical construction material for
airbags has been a polyester or nylon fabric, coated with an
elastomer such as neoprene, or silicone. The fabric used in such
bags is typically a woven fabric formed from synthetic yarn by
weaving practices that are well known in the art.
[0007] The coated material has found acceptance because it acts as
an impermeable barrier to the inflation medium. This inflation
medium is generally a nitrogen, argon, or similar gas or gas blend
generated from a gas generator or inflator. Such gas is conveyed
into the cushion at a relatively warm temperature. The coating
obstructs the permeation of the fabric by such hot gas, thereby
permitting the cushion to rapidly inflate without undue
decompression during a collision event.
[0008] Airbags may also be formed from uncoated fabric which has
been woven in a manner that creates a product possessing low
permeability or from fabric that has undergone treatment such as
calendering to reduce permeability. Fabrics which reduce air
permeability by calendering or other mechanical treatments after
weaving are disclosed in U.S. Pat. No. 4,921,735; U.S. Pat. No.
4,977,016; and U.S. Pat. No. 5,073,418 (all incorporated herein by
reference).
[0009] Silicone coatings typically utilize either solvent based or
complex two component reaction systems. Dry coating weights for
silicone have been in the range of about 3 to 4 ounces per square
yard or greater for both the front and back panels of side curtain
airbags. As will be appreciated by one of ordinary skill in this
art, high add on weights substantially increase the cost of the
base fabric for the airbag and make packing within small airbag
modules very difficult. Furthermore, silicone exhibits very low
tensile strength and elongation at break characteristics which do
not withstand high pressure inflation easily without the
utilization of very thick coatings.
[0010] The use of certain polyurethanes as coatings as disclosed in
U.S. Pat. No. 5,110,666 to Menzel et al. (herein incorporated by
reference) permits low add on weights reported to be in the range
of 0.1 to 1 ounces per square yard but the material itself is
relatively expensive and is believed to require relatively complex
compounding and application procedures due to the nature of the
coating materials. The 5,110,666 patent, however, fails to disclose
any pertinent elasticity and/or tensile strength characteristics of
their particular polyurethane coating materials. Furthermore, there
is no discussion pertaining to the importance of the coating
ability (and thus correlated low air permeability) at low add-on
weights of such polyurethane materials on side curtain airbags
(only for fabrics which are utilized within driver or passenger
side cushions).
[0011] All airbags must be inflatable extremely quickly; upon
sensing a collision, in fact, airbags usually reach peak pressures
within 10 to 20 milliseconds. Regular driver side and passenger
side air bags are designed to withstand this enormous inflation
pressure; however, they also deflate very quickly in order to
effectively absorb the energy from the vehicle occupant hitting the
bag. Such driver and passenger side cushions (airbags) are thus
made from low permeability fabric, but they also deflate quickly at
connecting seams (which are not coated to prevent air leakage) or
through vent holes. Furthermore, the low add-on coatings taught
within Menzel, and within U.S. Pat. No. 5,945,186 to Li et al.,
would not provide long-term gas retention; they would actually not
withstand the prolonged and continuous pressures supplied by
activated inflators for more than about 2 seconds, at the most. The
low permeability of these airbag fabrics thus aid in providing a
small degree of sustained gas retention within driver and passenger
airbag cushions to provide the deflating cushioning effects
necessary for sufficient collision protection. Such airbag fabrics
would not function well with side curtain airbags, since, at the
very least, the connecting seams which create the pillowed,
cushioned structures within such airbags, as discussed in greater
detail below, would not be coated. As these areas provide the
greatest degree of leakage during and after inflation, the
aforementioned patented low coating low permeability airbag fabrics
would not be properly utilized within side curtain airbags.
[0012] As alluded to above, there are three primary types of
different airbags, each for different end uses. For example,
driver-side airbags are generally mounted within steering columns
and exhibit relatively high air permeabilities in order to act more
as a cushion for the driver upon impact. Passenger-side airbags
also comprise relatively high air permeability fabrics which permit
release of gas either therethrough or through vents integrated
therein. Both of these types of airbags are designed to protect
persons in sudden collisions and generally burst out of packing
modules from either a steering column or dashboard (and thus have
multiple "sides").
[0013] Side curtain airbags, however, have been designed primarily
to protect passengers during rollover crashes by retaining their
inflation state for a long duration and generally unroll from
packing containers stored within the roofline along the side
windows of an automobile (and thus have a back and front side
only). Side curtain airbags therefore not only provide cushioning
effects but also should provide protection from broken glass and
other debris. As such, it is imperative that side curtain airbags,
as noted above, retain large amounts of gas, as well as high gas
pressures, to remain inflated throughout the longer time periods of
the entire potential rollover situation.
[0014] To accomplish this, these side curtains are generally coated
with very large amounts of sealing materials on both the front and
back sides. Since most side curtain airbag fabrics comprise woven
blanks that are either sewn, sealed, or integrally woven together,
discrete areas of potentially high leakage of gas are prevalent,
particularly at and around the seams. It has been accepted as a
requirement that heavy coatings were necessary to provide the low
permeability (and thus high leak-down time) necessary for side
curtain airbags. Without such heavy coatings, such airbags would
most likely deflate too quickly and thus would not function
properly during a rollover collision. As will be well understood by
one of ordinary skill in this art, such heavy coatings add great
cost to the overall manufacture of the target side curtain airbags.
There is thus a great need to manufacture low permeability side
curtain airbags with less expensive (preferably lower coating
add-on weight) coatings without losing the aging, humidity, and
permeability characteristics necessary for proper functioning upon
deployment.
[0015] Furthermore, there is a current drive to store such low
permeability side curtain airbags within cylindrically shaped
modules. Since these airbags are generally stored within the
rooflines of automobiles, and the area available is quite limited,
there is always a great need to restrict the packing volume of such
restraint cushions to their absolute minimum. However, the
previously practiced low permeability side curtain airbags have
proven to be very cumbersome to store in such cylindrically shaped
containers at the target automobile's roofline. The actual time and
energy required to roll such heavily coated low permeability
articles as well as the packing volume itself, has been very
difficult to reduce. Furthermore, with such heavy coatings
utilized, the problems of blocking (i.e., adhering together of the
different coated portions of the cushion) are amplified when such
articles are so closely packed together. The chances of delayed
unrolling during inflation are raised when the potential for
blocking is present. Thus, a very closely packed, low packing
volume, low blocking, low permeability side curtain airbag is
highly desirable.
SUMMARY OF THE INVENTION
[0016] In light of the background above, it is an object of the
present invention to provide an abrasion resistant and/or puncture
resistant fabric, airbag cushion, and/or method.
[0017] In accordance with a more particular object of the present
invention, there is provided an improved side curtain airbag which
affords rollover protection.
[0018] It is still another object to provide an airbag fabric or
cushion which has both abrasion and puncture resistance.
[0019] It is yet still another object of the present invention to
provide an airbag which has an inner or inside surface, wall,
construction, or coating adjacent the occupant which is at least
one of lighter, softer, more flexible, less abrasive, and the like
than an outer or outside surface, wall, construction, or coating
adjacent the window of a vehicle.
[0020] It is still another object of the present invention to
provide an airbag having differing inner and outer surfaces,
constructions, walls, coatings, or the like, with the outer
surface, wall, construction, coating, or the like having better
puncture resistance and/or abrasion resistance than the inner
surface, wall, construction, coating, or the like.
[0021] Also, it can be readily seen that there exists a need for a
low permeability, side curtain airbag that provides a necessarily
high leak-down time upon inflation and after long-term storage.
[0022] It is therefore an object of this invention to provide a
coated and/or laminated airbag possessing extremely high leak-down
time characteristics after inflation and thus complementary low
permeability characteristics. Another object of the invention is to
provide an inexpensive side curtain airbag cushion. A further
object of this invention is to provide a highly effective airbag
coating or adhesive formulation or laminate construction providing
extremely low permeability airbag structures after inflation. An
additional object of this invention is to provide an airbag which
not only provides beneficial and long-term low permeability, but
also exhibits excellent long-term storage stability (through heat
aging and humidity aging testing). Yet another object of the
invention is to provide a low permeability side curtain airbag
possessing a low rolled packing volume and non-blocking
characteristics for effective long-term storage within the roofline
of an automobile.
[0023] Accordingly, one embodiment this invention is directed to an
airbag cushion comprising a coated fabric, wherein said fabric is
laminated with a film, wherein said film is of about 0.5-10.0 mils
thick, preferably 2-4 mils, and/or wherein said airbag cushion,
after long-term storage, exhibits a characteristic leak-down time
of at least 5 seconds. Also, this invention concerns an airbag
cushion comprising a coated fabric, wherein said fabric is coated
with a laminate film; wherein said laminate film possesses a
tensile strength of at least 2,000 psi and an elongation of at
least 180%; and wherein said airbag cushion, after long-term
storage, exhibits a characteristic leak-down time of at least 5
seconds.
[0024] A mil is a unit of thickness equal to one thousandth of an
inch (0.0254 millimeter). A mil of coating is approximately equal
to about one ounce per square yard of coating.
[0025] The term "characteristic leak-down time" is intended to
encompass the measurement of time required for the entire amount of
inflation gas introduced within an already-inflated (to a peak
initial pressure which "opens" up the areas of weak sealing) and
deflated airbag cushion to leak out upon subsequent re-inflation at
a constant pressure of 10 psi. It is well known and well understood
within the airbag art, and particularly concerning side curtain
(low permeability) airbag cushions, that retention of inflation gas
for long periods of time is of utmost importance during a
collision. Side curtain airbags are designed to inflate as quickly
as driver- and passenger-side bags, but they must deflate very
slowly to protect the occupants during roll over and side impact.
Thus, it is imperative that the bag exhibit a very low leakage rate
after the bag experiences peak pressure during the instantaneous,
quick inflation. Hence, the coating on the bag must be strong
enough to withstand the shock and stresses when the bag is inflated
so quickly. Thus, a high characteristic leak-down time measurement
is paramount in order to retain the maximum amount of beneficial
cushioning gas within the inflated airbag. Airbag leakage after
inflation (and after peak pressure is reached) is therefore closely
related to actual pressure retention characteristics. The pressure
retention characteristics (hereinafter referred to as "leak-down
time") of already-inflated and deflated side curtain airbags can be
described by a characteristic leak-down time t, wherein: 1 t (
second ) = Bag volume ( ft 3 ) Volumetric leakage rate ( SCFH * )
at 1 - psi .times. 3600 * SCFH : standard cubic feet per hour .
[0026] It is understood that the 10 psi constant is not a
limitation to the invention; but merely the constant pressure at
which the characteristic leak-down time measurements are made.
Thus, even if the pressure is above or below this amount during
actual inflation or after initial pressurizing of the airbag, the
only limitation is that if one of ordinary skill in the art were to
measure the bag volume and divide that by the volumetric leakage
rate time (measured by the amount leaking out of the target airbag
during steady state inflation at 10 psi), the resultant measurement
in time would be at least 5 seconds. Preferably, this time is
greater than about 9 seconds; more preferably, greater than about
15 seconds; and most preferably, greater than about 20 seconds.
[0027] Alternatively, and in a manner of measurement with
uninflated side curtain airbags, the term "leak-down time" may be
measured as the amount of time required for at least half of the
introduced inflation gas to escape from the target airbag after
initial peak pressure is reached. Thus, this measurement begins the
instant after peak initial pressure is reached upon inflation (such
as, traditionally, about 30 psi) with a standard inflation module
which continues to pump gas into the target airbag during and after
peak initial pressure is reached. It is well understood that the
pressure of gas forced into the airbag after peak initial pressure
is reached will not remain stable (it decreases during the
subsequent introduction of inflation gas), and that the target
airbag will inevitably permit escape of a certain amount of
inflation gas during that time. The primary focus of such side
curtain airbags (as noted above) is to remain inflated for as long
as possible in order to provide sufficient cushioning protection to
vehicle occupants during rollover accidents. The greater amount of
gas retained, the better cushioning effects are provided the
passengers. Thus, the longer the airbag retains a large amount of
inflation gas, and consequently the greater the characteristic
leak-down time, the better cushioning results are achieved. At the
very least, the inventive airbag should retain at least half of its
inflated gas volume 5 seconds subsequent to reaching peak initial
pressure. Preferably, this time is 9 seconds, more preferably 15
seconds, and most preferably 20 seconds or more.
[0028] Likewise, the term, "after long-term storage" encompasses
either the actual storage of an inventive airbag cushion within an
inflator assembly (module) within an automobile, and/or in a
storage facility awaiting installation. Such a measurement is
generally accepted, and is well understood and appreciated by the
ordinarily skilled artisan, to be made through comparable analysis
after representative heat and humidity aging tests. These tests
generally involve 107.degree. C. oven aging for 16 days, followed
by 83.degree. C. and 95% relative humidity aging for 16 days and
are universally accepted as proper estimations of the conditions of
long-term storage for airbag cushions. Thus, this term encompasses
such measurement tests. The inventive airbag fabrics should exhibit
proper characteristic leak-down times after undergoing such
rigorous pseudo-storage testing.
[0029] Typical road surfaces are concrete, and gravel filled
asphalt. They are very abrasive to fabrics that slide on those
surfaces. For the new side impact curtain-type airbag (side curtain
airbag), in a rollover situation, the airbag needs to protect the
occupant from directly contacting the road hazard and should not
deflate quickly or break when sliding on such road surfaces.
[0030] We have found that fabric usually provides excellent
abrasion resistance in most cases, and that fabrics laminated to or
coated with a tough rubber material provide abrasion resistance. In
the case of abrasion over typical road surfaces, we have
surprisingly found that a layer of elastomer can provide much
better abrasion resistance than a layer of heavy industrial
fabric.
[0031] We have tested Jacquard woven airbags coated and laminated
with different materials. The airbag is first inflated to and
maintained at 10 psi air pressure, then a 13 lb., 1.5 ft. long
concrete block was laid on one area of the bag and allowed to slide
back and forth. A Jacquard bag coated with 1.2 oz/yd.sup.2
polyurethane showed significant increase in air leakage rate after
5 cycles of concrete sliding abrasion. To see if an extra layer of
heavy fabric would protect the airbag from such abrasion, a 420
denier, 49.times.49 plain weave airbag fabric was laminated on a
coated Jacquard woven bag. The 420 denier fabric had many broken
filaments in a few cycles. In about 25 cycles, the yarns
perpendicular to the concrete sliding direction were all broken and
removed by the sliding abrasion. After 25 cycles, the remaining
laminated 420 denier fabric provided very little protection for the
Jacquard woven bag against the sliding abrasion. A 3 mil thick
Duraflex PT 9400 polyurethane film was laminated to a coated
Jacquard woven airbag. After 110 cycles of sliding abrasion using
the same concrete, no visual damage or change in bag leakage was
observed. This finding indicates surprisingly better abrasion
resistance of a thin elastomer film than a heavy industrial
fabric.
[0032] We have studied airbags laminated with different films and
films with different thicknesses. We have noted that the toughness
of the elastomer needs to be above a certain value in order to
provide the necessary abrasion resistance.
[0033] One layer of fabric may be used on top of this elastomeric
layer for puncture resistance. Preferred elastomeric materials are
polyurethane, Neoprene and other rubbers with high toughness. The
combination of an elastomeric layer and a layer of extra fabric can
provide both abrasion and puncture resistance. The elastomer layer
can act as an abrasion resistant layer, gas barrier and adhesive
layer between the base airbag fabric and the extra fabric top
layer.
[0034] At least one embodiment of the present invention provides
airbags with excellent abrasion resistance against typical road
surfaces by having a tough elastomeric layer with a thickness
greater than about 0.5 mil, preferably about 1.5 mil or more.
Compared to a similar structure laminated with a layer of heavy
fabric, the inventive structure has better abrasion resistance,
better flexibility, is thinner, and costs less.
[0035] This layer of elastomer can be applied by film lamination,
transfer coating, extrusion coating, and other coating methods.
This layer of elastomer does not have to have uniform thickness.
Instead of an elastomer layer, one can print elastomer dots on the
fabric with small spacing between the dots.
[0036] Traditionally, driver and passenger airbags are energy
absorbing safety barriers between an occupant and the interior of a
vehicle, such as dashboard, windshield and steering wheel. New side
impact curtain airbags (side curtain airbags) are now providing a
safety barrier between an occupant and exterior hazards in an
auto-accident. Due to the possible presence of various sharp
objects such as broken window glass, nails, and jagged sheet metal
in a collision, side curtain airbags with puncture resistance are
needed but not currently provided to the market. The current driver
side airbag or passenger airbag construction does not provide good
puncture resistance at its working inflated state to hazards such
as broken window glass.
[0037] The present invention encompasses the following
constructions that provide superior resistance to puncture:
[0038] 1. Triple layer sandwich--On at least the side facing the
exterior of a vehicle, the airbag has a fabric/elastomer/fabric
three layer structure (FIG. 12C). The outer fabric layer provides
some abrasion resistance and combines with the strength of the
inner fabric layer to provide puncture resistance. The middle
elastomeric layer provides abrasion resistance and the low gas
permeability to allow the airbag to stay inflated for a desired
length of time at a desired pressure. The elastomeric layer can
also function as an adhesive layer to bond the outer and inner
fabric layers together. The choice of fabric constructions is
crucial in obtaining the desired puncture resistance. To obtain the
desired puncture resistance, it is preferred that the fabric be
constructed from high strength yarn such as high tenacity Nylon,
polyester, polyethylene (such Spectra.TM.), and aramids (such as
Kevlar.TM.). The fabric should have high yarn density to prevent
sharp objects from going through the yarn interstices. It is also
desirable for the sandwich to be thin so that the whole airbag can
be packed into a small volume. Therefore, fabrics from small denier
yarn at high pick and end counts are preferred.
[0039] 2. Airbag with an elastomeric inner bladder that is loosely
attached to the outer fabric layer. The inner bladder has the
ability to stretch substantially without breaking or bursting when
a sharp object penetrates through the outer layer of airbag fabric.
Thus, the inner bladder functions much like a puncture resistant
inner tube for a vehicle tire (FIG. 12K).
[0040] 3. A puncture resistant barrier interposed between the
airbag and exterior of the vehicle when the airbag is deployed. The
barrier may or may not be attached firmly to the airbag itself
(FIG. 12L).
[0041] 4. A system of small gas filled cells interposed between the
airbag and exterior of vehicle when the airbag is deployed. The
system of cells is designed to support the airbag and keep sharp
objects from penetrating the airbag even when some of the cells
themselves are punctured (FIG. 12M).
[0042] To prevent puncture and premature deflation of an airbag
during a collision, various combinations of fabric, coating and
films are used in accordance with selected embodiments of the
present invention to achieve the desired result.
[0043] It is common practice to coat a fabric or woven structure
with the same coating and the same weight coating on both sides.
The nature of at least -one embodiment of the present invention is
to provide a product that has a coating on both sides of the fabric
or woven structure that can provide different characteristics or
performance for each side (side 102, 104 of airbag 126 of FIGS. 3
and 6). The method of accomplishing this can be through utilizing a
different weight coating on one side versus another or using a
different chemical on each side. The coating can be tailored to the
performance that is required e.g. the outside (104) OPW can be
coated with a tough polymer to resist puncture or abrasion while
the side toward the occupant (102) can be coated with a non
abrasive coating. The primary use of this would be for jacquard
woven inflatable restraints, but could be used for any inflatable
fabric, cushion, airbag, etc.
[0044] Selected objects of at least one embodiment of the present
invention include:
[0045] On a jacquard woven fabric provide a different weight
coating on each side based on end use performance requirements.
[0046] On a jacquard woven fabric provide a different coating on
either side based on end use performance requirements.
[0047] On a flat fabric provide a different weight coating on
either side.
[0048] Allows the design of coated fabrics tailored to specific end
use performance requirements.
[0049] A sewn bag made of coated fabric with different coatings on
each side.
[0050] Curtain airbags used for rollover protection are typically
designed as one gas holding system. In rollover accidents, these
airbags have a high probability of coming in contact with road and
broken glass debris. Any puncture or abrasion to the fabric
structure of the bag away from the occupant side because of the
debris from the broken glass or from the road can make this entire
system ineffective. Also, the portion of the curtain bag closer to
the occupant should be less abrasive to the occupant during
deployment or the pressurization phase.
[0051] In order to accomplish this, quite different properties are
given to either side of the side curtain. For example, different
size yarns can be used on each side of the curtain, yarns of bigger
diameter and higher tenacity can be used on the side away from the
occupant, and the like. Bigger yarns provide higher surface area
and hence provide better resistance to puncture. On the side of the
side curtain where the occupant comes in contact, finer yarns can
be used in order to be gentler on the occupant.
[0052] Curtain bags produced with many different technologies like
sewn, jacquard or dobby woven, welded or sealed seams can use this
approach.
[0053] Additional objects and advantages of the invention will be
set forth in part in the description which follows, and in part
will be obvious from the description, or may be learned by practice
for the invention. It is to be understood that both the foregoing
general description and the following detailed description of
preferred embodiments are exemplary and explanatory only, and are
not to be viewed as in any way restricting the scope of the
invention as set forth in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0054] FIG. 1 depicts the side, inside view of a vehicle prior to
deployment of the inventive side curtain airbag.
[0055] FIG. 2 depicts the side, inside view of the vehicle after
deployment of the inventive side curtain airbag.
[0056] FIG. 3 depicts an inside side view of the side curtain
airbag.
[0057] FIG. 4 provides a side view of a side curtain airbag
container.
[0058] FIG. 5A provides a schematic cross-sectional view of a
stored airbag within the container of FIG. 4.
[0059] FIG. 5B provides a schematic cross-sectional view of an
alternatively stored airbag.
[0060] FIG. 6 depicts an outside side view of the airbag of FIG.
3.
[0061] FIG. 7 is a graphical representation of resistance to
abrasion by gravel.
[0062] FIG. 8 is a graphical illustration of resistance to abrasion
by concrete.
[0063] FIG. 9 is a graphical representation of resistance to
puncture by glass (time to lose half of initial pressure).
[0064] FIG. 10 is a cross-sectional view of an inventive all-woven
inflatable fabric showing double and single layer areas including
two separate single layer areas.
[0065] FIG. 11 is a weave diagram illustrating a potentially
preferred repeating pick pattern formed using repeating plain weave
and basket weave four-pick arrangements.
[0066] FIGS. 12A-12M are schematic cross-sectional layer diagrams
of selected embodiments of the side wall of the airbag toward the
window.
DETAILED DESCRIPTION OF THE INVENTION
[0067] In accordance with at least one embodiment, the inventive
coating and/or film preferably possess a tensile strength of at
least 2,000 psi and an elongation to break of greater than about
180%. Preferably, the tensile strength is at least 3,000 psi, more
preferably, 6,000 psi, and most preferably at least about 8,000 psi
(the high end is basically the highest one can produce which can
still adhere to a fabric surface). The preferred elongation to
break is more than about 200%, more preferably more than about
300%, and most preferably more than about 600%. These
characteristics of the film and/or coating translate to a material
that is both very strong (and thus will withstand enormous
pressures both at inflation and during the time after inflation and
will not easily break) and can stretch to compensate for such large
inflation, etc., pressures. The film itself is produced prior to
actual contact with the target airbag cushion, or fabric, surface.
In order to apply such a film, a lamination procedure is performed
through the simultaneous exposure of heat and pressure over the
film while in contact with the target surface. The laminate may be
applied over any portion of the target structure, although
preferably it coats the entire exterior surface of the cushion or
fabric. Also, more than one laminated film may be present on the
target cushion as one type of film (possessing certain tensile
strength and elongation characteristics) may be preferably applied
to certain discrete areas of the target cushion while a different
film with different characteristics may be selected at other
locations (such as at the seams). The only requirement is that the
final product exhibit the aforementioned high leak-down properties.
The film and/or coating appears to act by "cementing" the contacted
individual yarns in place and possibly preventing leakage through
open areas between woven yarns and/or stitches. During inflation,
then, the film and/or coating prevents leakage through the
interstitial spaces between the yarns and aids in preventing yarn
shifting (which may create larger spaces for possible gas
escape).
[0068] The utilization of such high tensile strength and high
elongation at break components permits the consequent utilization,
surprisingly, of low add-on weight amounts of such films or
coatings. Normally, the required coatings (which are not films, but
actual coating formulations applied to the surface which then may
form non-laminated films) on side curtain airbags are at least 3.5
ounces per square yard (with the standard actually higher than
that, at about 4.0). The inventive airbag cushions require merely
about 0.5 or more mils thick or about 0.5 ounces per square yard of
the desired film and/or coating to effectuate the desired high
characteristic leak-down time (low permeability). Furthermore, the
past coatings were required to exhibit excellent heat and humidity
aging stability. Unexpectedly, even at such low add-on amounts, and
particularly with historically questionable coating materials
(polyurethanes, for example), the inventive coatings, and
consequently, the inventive coated airbag cushions, exhibit
excellent heat aging and humidity aging characteristics. Thus, the
coating compositions and coated airbags are clearly improvements
within this specific airbag art.
[0069] Of particular interest as the desired films are
polyurethanes, although any film which possesses the same desired
tensile strength and elongation characteristics noted above may
function within this inventive low permeability airbag cushion.
Copolymers of polyurethanes, polyamides, and the like, may be
utilized, as merely one type of example. Also, such films may or
may not be cross-linked on the airbag surface. Preferably, the film
is a polyurethane and most preferably is a polycarbonate
polyurethane or a polyurethane film based on polytetramethylene
glycol diol (available from Deerfield Urethane, Inc., Ivyland, Pa.,
under the tradename Dureflex.TM. PT9400). This specific film
exhibits a tensile strength of 8,000 psi and an elongation at break
of about 600%. Such a film may be added in an amount of as low as
about 0.5 mils or ounces per square yard on the desired cushion and
still provide the requisite high characteristic leak-down time. Of
course, any other film meeting the characteristics as noted above
is encompassed within this invention; however, the add-on weights
of other available films may be greater than this preferred one,
depending on the actual tensile strength and elongation properties
available. However, an upper limit of about 10.0 mils or ounces per
square yard should not be exceeded to meet this invention. The
desired films may be added in multiple layers if desired as long
the required thickness for the overall coating is not exceeded.
Alternatively, the multiple layer film/coating system may also be
utilized as long as at least one film possessing the desired
tensile strength and elongation at break is utilized and the
requisite low permeability is exhibited.
[0070] Other possible components present within or on these films
are thickeners, antioxidants, flame retardants, coalescent agents,
adhesion promoters, and colorants. In accordance with the
potentially preferred practices of the present invention, a primer
or adhesive coating is first applied to the target cushion surface.
Upon drying of this first layer, the desired film is then laminated
through heat and pressure to the selected areas of the target
surface for a sufficient time to effectuate lamination. Preferably,
the preferred film (or films) will not include any silicone, due to
the extremely low tensile strength (typically below about 1,500
psi) characteristics exhibited by such materials. However, in order
to provide effective aging and non-blocking benefits, such
components may be applied to the film as a topcoat as long as the
add-on weight of the entire film and topcoat does not exceed about
10.0 ounces per square yard. Additionally, elastomers comprising
polyester or polyether segments or other similar components, are
undesirable, particularly at very low add-on weights (i.e., 0.8-1.2
oz/yd.sup.2) due to stability problems in heat and humidity aging
(polyesters easily hydrolyze in humidity and polyethers easily
oxidize in heat); however, such elastomers may be utilized in
topcoat formulations as long, again, as the 10.0 ounces per square
yard is not exceeded. For puncture resistance, silicone can be used
but should be added in greater quantities than other
elastomers.
[0071] Among the other additives particularly preferred within or
on the film (or films) are heat stabilizers, flame retardants,
primer adhesives, and materials for protective topcoats. A
potentially preferred thickener is marketed under the trade
designation NATROSOL.RTM. 250 HHXR by the Aqualon division of
Hercules Corporation which is believed to have a place of business
at Wilmington, Del. In order to meet Federal Motor Vehicle Safety
Standard 302 flame retardant requirements for the automotive
industry, a flame retardant is also preferably added to the
compounded mix. One potentially preferred flame retardant is
AMSPERSE F/R 51 marketed by Amspec Chemical Corporation which is
believed to have a place of business at Gloucester City, N.J. As
noted above, primer adhesives may be utilized to facilitate
adhesion between the surface of the target fabric and the film
itself. Thus, although it is preferable for the film to be the sole
component of the entire coating in contact with the fabric surface,
it is possible to utilize adhesion promoters, such as isocyanates,
epoxies, functional silanes, and other such resins with adhesive
properties, without deleteriously effecting the ability of the film
to provide the desired low permeability for the target airbag
cushion. A topcoat component, as with potential silicones, as noted
above, may also be utilized to effectuate proper non-blocking
characteristics to the target airbag cushion. Such a topcoat may
perform various functions, including, but not limited to, improving
aging of the film (such as with silicone) or providing blocking
resistance due to the adhesive nature of the coating materials
(most noticeably with the preferred polyurethane
polycarbonates).
[0072] Airbag fabrics must pass certain tests in order to be
utilized within restraint systems. One such test is called a
blocking test which indicates the force required to separate two
portions of coated fabric from one another after prolonged storage
in contact with each other (such as an airbag is stored).
Laboratory analysis for blocking entails pressing together coated
sides of two 2 inch by 2 inch swatches of airbag fabric at 5 psi at
100.degree. C. for 7 days. If the force required to pull the two
swatches apart after this time is greater than 50 grams, or the
time required to separate the fabrics utilizing a 50 gram weight
suspended from the bottom fabric layer is greater than 10 seconds,
the coating fails the blocking test. Clearly, the lower the
required separating force, the more favorable the coating. For
improved blocking resistance (and thus the reduced chance of
improper adhesion between the packed fabric portions), topcoat
components may be utilized, such as talc, silica, silicate clays,
and starch powders, as long as the add-on weight of the entire
elastomer composition (including the topcoat) does not exceed about
10.0 ounces per square yard (and preferably exists at a much lower
level, about 1.5, for instance).
[0073] Two other tests which the specific coated airbag cushion
must pass are the oven (heat) aging and humidity aging tests. Such
tests also simulate the storage of an airbag fabric over a long
period of time upon exposure at high temperatures and at relatively
high humidities. These tests are actually used to analyze
alterations of various different fabric properties after such a
prolonged storage in a hot ventilated oven (>100.degree. C.)
(with or without humid conditions) for 2 or more weeks. For the
purposes of this invention, this test was used basically to analyze
the air permeability of the coated side curtain airbag by measuring
the characteristic leak-down time (as discussed above, in detail).
The initially produced and stored inventive airbag cushion should
exhibit a characteristic leak-down time of greater than about 5
seconds (upon re-inflation at 10 psi gas pressure after the bag had
previously been inflated to a peak pressure above about 15 psi and
allowed to fully deflate) under such harsh storage conditions.
Since polyurethanes, the preferred elastomers in this invention,
may be deleteriously affected by high heat and humidity (though not
as deleteriously as certain polyester and polyether-containing
elastomers), it may be prudent to add certain components within a
topcoat layer and/or within the elastomer itself. Antioxidants,
antidegradants, and metal deactivators may be utilized for this
purpose. Examples include, and are not intended to be limited to,
Irganox.RTM. 1010 and Irganox.RTM. 565, both available from CIBA
Specialty Chemicals. This topcoat may also provide additional
protection against aging and thus may include topcoat aging
improvement materials, such as, and not limited to, polyamides, NBR
rubbers, EPDM rubbers, and the like, as long as the elastomer
composition (including the topcoat) does not exceed the about 10.0
ounces per square yard (preferably much less than that, about 2-4)
of the add-on weight to the target fabric.
[0074] The substrate to which the thin film coatings are applied to
form the airbag base fabric in accordance with at least one
embodiment of the present invention is preferably a woven fabric
formed from yarns comprising synthetic fibers, such as polyamides
or polyesters. Such yarn preferably has a linear density of about
105 denier to about 840 denier, more preferably from about 210 to
about 630 denier. Such yarns are preferably formed from multiple
filaments wherein the filaments have linear densities of about 7
denier per filaments or less, more preferably about 6 dpf or less,
and most preferably about 4 dpf or less. In the more preferred
embodiment such substrate fabric will be formed from fibers of
nylon, and most preferred is nylon 6,6. It has been found that such
polyamide materials exhibit particularly good adhesion and
maintenance of resistance to hydrolysis when used in combination
with the coating according to the present invention. Such substrate
fabrics are preferably woven using fluid jet weaving machines as
disclosed in U.S. Pat. Nos. 5,503,197 and 5,421,378 to Bower et al.
(incorporated herein by reference). Such woven fabric will be
hereinafter referred to as an airbag base fabric. As noted above,
when the inventive airbag is a side curtain airbag, it must exhibit
extremely low permeability. As noted previously and extensively,
such side curtain airbags (a.k.a., cushions) must retain a large
amount of inflation gas during a collision in order to accord
proper long-duration cushioning protection to passengers during
rollover accidents. Any standard side curtain airbag may be
utilized in combination with the inventive coatings, films,
fabrics, layers, and/or the like to provide a product which
exhibits the desired characteristic leak-down times as noted above.
Most side curtain airbags are produced through labor-intensive
sewing or stitching (or other manner) together two separate woven
fabric blanks to form an inflatable structure. Furthermore, as is
well understood by the ordinarily skilled artisan, such sewing,
etc., is performed in strategic locations to form seams (connection
points between fabric layers) which in turn produce discrete open
areas into which inflation gasses may flow during inflation. Such
open areas thus produce pillowed structures within the final
inflated airbag cushion to provide more surface area during a
collision, as well as provide strength to the bag itself in order
to withstand the very high initial inflation pressures (and thus
not explode during such an inflation event).
[0075] Other side curtain airbag cushions exist which are of the
one-piece woven variety. Basically, some inflatable airbags are
produced through the simultaneous weaving of two separate layers of
fabric which are joined together at certain strategic locations
(again, to form the desired pillowed structures). Such cushions
thus present seams of connection between the two layers. It is the
presence of so many seams (in both multiple-piece and one-piece
woven bags) which create the aforementioned problems of gas loss
during and after inflation. The possibility of yarn shifting,
particularly where the yarns shift in and at many different ways
and amounts, thus creates the quick deflation of the bag through
quick escaping of inflation gasses. Thus, the base airbag fabrics
do not provide much help in reducing permeability (and correlated
characteristic leak-down times, particularly at relatively high
pressures). It is this seam problem which has primarily created the
need for the utilization of very thick, and thus expensive,
coatings to provide necessarily low permeability in the past.
[0076] Recently, a move has been made away from both the
multiple-piece side curtain airbags (which require great amounts of
labor-intensive sewing to attached woven fabric blanks) and the
traditionally produced one-piece woven cushions, to more specific
one-piece woven fabrics which exhibit substantially reduced floats
between woven yarns to substantially reduce the unbalanced shifting
of yarns upon inflation, such as described in U.S. Pat. No.
6,220,309, hereby completely incorporated by reference herein.
These one-piece woven bags are generally produced on dobby or
jacquard fluid-jet looms, preferably the utilized one-piece airbag
is made from a jacquard weaving process. With such an improvement,
the possibility of high leakage at seams is substantially reduced.
These airbags provide balanced weave constructions at and around
attachment points between two layers of fabrics such that the
ability of the yarns to become displaced upon inflation at high
pressures is reduced as compared with the standard one-piece woven
airbags. Such inventive one-piece woven bags may still be
problematic in that the weave intersections may be displaced upon
high pressure inflation such that leakage may occur at too high a
rate for proper functioning. As a result, there is usually still a
need to coat such one-piece woven structures with materials which
reduce and/or eliminate such an effect. However, such one-piece
woven structures permit extremely low add-on amounts of elastomeric
coatings for low permeability effects. In fact, these inventive
airbags function extremely well with low add-on coatings below
about 1.5 and as low as about 0.8 ounces per square yard.
[0077] As described in U.S. Pat. No. 6,220,309, inflatable
protective cushions used in passenger vehicles are a component of
relatively complex passive restraint systems. The main elements of
these systems are: an impact sensing system, an ignition system, a
propellant material, an attachment device, a system enclosure, and
an inflatable protective cushion. Upon sensing an impact, the
propellant is ignited causing an explosive release of gases filing
the cushion to a deployed state which can absorb the impact of the
forward movement of a body and dissipate its energy by means of
rapid venting of the gas. The entire sequence of events usually
occurs within about 100 milliseconds. In the undeployed state, the
cushion is stored in or near the steering column, the dashboard, in
a door, or in the back of a front seat placing the cushion in close
proximity to the person or object it is to protect.
[0078] Inflatable cushion systems commonly referred to as air bag
systems have been used in the past to protect both the operator of
the vehicle and passengers. Systems for the protection of the
vehicle operator have typically been mounted in the steering column
of the vehicle and have utilized cushion constructions directly
deployable towards the driver. These driver-side cushions are
typically of a relatively simple configuration in that they
function over a fairly small well-defined area between the driver
and the steering column. One such configuration is disclosed in
U.S. Pat. No. 5,533,755 to Nelsen et al., issued Jul. 9, 1996, the
teachings of which are incorporated herein by reference.
[0079] Inflatable cushions for use in the protection of passengers
against frontal or side impacts must generally have a more complex
configuration since the position of a vehicle passenger may not be
well defined and greater distance may exist between the passenger
and the surface of the vehicle against which that passenger might
be thrown in the event of a collision. Prior cushions for use in
such environments are disclosed in U.S. Pat. No. 5,520,416 to
Bishop; U.S. Pat. No. 5,454,594 to Krickl; U.S. Pat. No. 5,423,273
to Hawthorn et al.; U.S. Pat. No. 5,316,337 to Yamaji, et al.; U.S.
Pat. No. 5,310,216 to Wehner et al.; U.S. Pat. No. 5,090,729 to
Watanabe; U.S. Pat. No. 5,087,071 to Wallner et al.; U.S. Pat. No.
4,944,529 to Backhaus; and U.S. Pat. No. 3,792,873 to Buchner et
al.
[0080] The majority of commercially used restraint cushions are
formed of woven fabric materials utilizing multifilament synthetic
yarns of materials such as polyester, nylon 6 or nylon 6,6
polymers. Representative fabrics for such use are disclosed in U.S.
Pat. No. 4,921,735 to Bloch; U.S. Pat. No. 5,093,163 to Krummheuer
et al.; U.S. Pat. No. 5,110,666 to Menzel et al.; U.S. Pat. No.
5,236,775 to Swoboda et al.; U.S. Pat. No. 5,277,230 to Sollars,
Jr.; U.S. Pat. No. 5,356,680 to Krummheuer et al.; U.S. Pat. No.
5,477,890 to Krummheuer et al.; U.S. Pat. No. 5,508,073 to
Krummheuer et al.; U.S. Pat. No. 5,503,197 to Bower et al.; and
U.S. Pat. No. 5,704,402 to Bowen et al. A two-weave construction
airbag cushion is exemplified in U.S. Pat. No. 5,651,395 to Graham
et al. but does not discuss the importance of narrow basket-weave
single fabric layers.
[0081] As will be appreciated, the permeability of an airbag
cushion structure is an important factor in determining the rate of
inflation and subsequent rapid deflation following the impact
event. Different airbag cushions are utilized for different
purposes. For instance, some airbag cushions are installed within
inflation modules for driver protection within the steering column
of an automobile. Others are utilized as protection for front seat
passengers and are installed in and around the glove compartment
and/or on the dashboard in front of such a passenger seat. Still
others have been developed in an effort to protect all passengers
during a long-duration impact event, such as, for example, a
rollover collision. In those types of crashes, the target airbag
cushion must inflate quickly under high pressure (such as between
about 10 and 40 psi) and remain inflated at a relatively high
pressures in order to provide the greatest degree of protection to
such passengers.
[0082] Furthermore, such long-duration airbag cushions preferably
comprise "pillow" formations created through the attachment of at
least two different fabrics or fabric ends together and sealed,
sewn, or the like, together. Upon inflation the free space between
the attachment points inflate as well, thereby producing the
desired cushioned "pillow" structures. Such long-duration,
"pillowed" structures have been disclosed in the prior art as
airbag cushions within U.S. Pat. No. 5,788,270 to Halano. However,
in order to provide a suitable, effective airbag fabric and cushion
comprising two or more points of attachment between fabrics or
fabric ends, there has been a need to improve upon the structural
integrity of the seams at such attachment points to prevent
unwanted and potentially harmful leakage of gas or air from within
the target airbag cushion. The prior art has discussed the
development of coatings to place over the sewn seams at such
attachment points in order to seal the potentially loose portions
of such seams and/or to keep the individual yarns of the airbag
fabrics at the attachment points stationary in order to prevent
yarn shifting and thus possible openings for air or gas leakage.
However, such coatings are actually supplemental to the seam
structures in providing the necessary barrier to air or gas. A
strong, effective, efficient weave construction is the primary
method of initially producing an effective airbag fabric for
incorporation within an airbag cushion.
[0083] Previous attempts have been made at producing inflatable
fabrics comprising "pillowed" chambers (such as for side curtains,
and the like) which have been produced solely through a weaving
procedure and which exhibit reduced air permeability within their
weave constructions (in other words, fabrics which are not sewn
together to form an inflatable structure). For instance, U.S. Pat.
No. 5,011,183 to Thornton et al. discloses an inflatable fabric
structure comprising at least two different areas of differing
fabric layers. Patentees discuss two layers of fabric produced by a
plain weave and single layer constructions of a plurality of
different weave patterns. The interface between the two different
fabric layer areas must exhibit at least three different fabric
densities (which are dictated by weave constructions), wherein the
two looser constructions (double layer plain weave and single layer
basket weave) are separated by a tighter construction (single layer
plain weave). Such an overall inflatable fabric structure may
possess the necessary air permeability characteristics required for
proper functioning within a side curtain airbag cushion
(particularly upon coating with a standard airbag coating
composition); however, the numerous differences in fabric densities
also place varying pressures upon discrete areas of the fabric
(particularly at or near the interface between the differing fabric
layer areas) such that yarn shifting will most likely occur during
an inflation event which may produce discontinuities in the
integrity of the coating which may in turn compromise the long-term
air permeability required for certain airbag applications.
[0084] Attempts have been made at improving on such a fabric;
however these have led to an increase in the number of different
fabric density areas on the fabric, rather than reducing such
differing densities. For example, a plain weave construction has
been utilized within the double layer area, adjacent to a
transition weave pattern, which connects with an Oxford weave
pattern, and then either a basket-weave or plain weave construction
for the remainder of the single layer area on the fabric. Such a
complicated scheme is difficult to produce on a weaving apparatus,
as an initial problem. Secondly, the utilization of an Oxford weave
zone has been utilized in an attempt to prevent the possibility of
weaving in a plain pattern (which is highly undesirable due to the
difficulty in manufacturing such high density single-layers fabrics
from double-layer amounts of yarn). However, if the area of single
layer of fabric is not substantially a straight line, and thus must
follow a curved structure, the Oxford weave will eventually become
a plain weave for at least that area around such a curved seam. In
such an instance, the interface between the two differing layers of
fabric will be irregular and invariably produce an undesirable
and/or irregular number of floats (i.e., yarns which pass either
over or under a certain number of perpendicularly oriented yarns;
greater than three such oriented yarns would produce difficulties
in preventing yarn shifting, as merely one example). As such, the
resultant fabric is itself highly undesirable as a barrier to air
permeability, even though coatings may be applied to increase such
performance. Thirdly, the individual yarns at the seam between the
double and single layer areas, will be placed upon tremendous
strain during an inflation event and, as in the Thornton et al.
teaching, will most likely result in yarn shifting. With such
shifting yarns, the permeability benefits, if any, would, again,
most likely be compromised and the produced airbag fabric would not
function as required.
[0085] In view of the foregoing, it is preferred to provide an
inflatable all-woven fabric having all-basket-woven seams at the
single/double layer interfaces within the fabric. It is even more
preferred to provide an all-woven inflatable fabric with double
layer zones of fabric and single layer zones of fabric (to form
"pillowed" chambers) which comprises at most two different fabric
densities throughout the entire fabric structure. Also, an object
of this invention is for the utilization of such inflatable fabrics
as airbag cushions within a vehicle restraint system. The term
"vehicle restraint system" is intended to mean both inflatable
occupant restraining cushion and the mechanical and chemical
components (such as the inflation means, ignition means,
propellant, and the like).
[0086] To achieve these and other objects and in accordance with
the purpose of the invention, as embodied and broadly described
herein, at least one embodiment of the invention provides an
inflatable fabric comprising at least two layers of fabric in
certain discrete areas of the fabric and at least one single fabric
layer at a discrete area within said fabric, wherein said at least
one single fabric layer is formed, for example, from a basket weave
pattern of an even number of yarns; preferably, the weave structure
for said single layer fabrics is a 2.times.2 basket weave pattern,
for example, from 4 to 8 yarns in length. Also, this invention
encompasses an inflatable fabric comprising at least two layers of
fabric in certain discrete areas of the fabric and at least one
single fabric layer at a discrete area within said fabric, wherein
the weave diagram for such a fabric does not exhibit more than
three consecutive filled or unfilled blocks in any row or column.
Furthermore, this invention also concerns an inflatable fabric
comprising at least two layers of fabric in certain discrete areas
of the fabric and at least one single fabric layer at a discrete
area within said fabric, wherein only two separate weave densities
are present within the entire fabric structure.
[0087] The term "inflatable fabric" is intended to encompass any
fabric which is constructed of at least two layers of fabric which
can be sealed to form a bag article. The inventive inflatable
fabric thus must include double layers of fabric to permit such
inflation, as well as single layers of fabric either to act as a
seal at the ends of such fabric panels, or to provide "pillowed"
chambers within the target fabric upon inflation. The term
"all-woven" as it pertains to the inventive fabric thus requires
that the inflatable fabric having double and single layers of
fabric be produced solely upon a loom. Any type of loom may be
utilized for this purpose, such as water-jet, air-jet, rapier,
dobby, and the like. Jacquard weaving and dobby weaving, however,
are most preferred.
[0088] The constructed fabric may exhibit balanced or unbalanced
pick/end counts; the main requirement in the woven construction is
that the single layer areas of the inflatable fabric exhibit solely
basket-weave patterns. These patterns are made through the
arrangement of at least one warp yarn (or weft yarn) configured
around the same side of two adjacent weft yarns (or warp yarns)
within the weave pattern. The resultant pattern appears as a
"basket" upon the arrangement of the same warp (or weft) yarn to
the opposite side of the next adjacent weft (or warp) yarn. Such
basket weave patterns may include the arrangement of a warp (or
weft) yarn around the same side of any even number of weft (or
warp) yarns, preferably up to about six at any one time.
[0089] The utilization of such basket weave patterns in the single
layer zones provides a number of heretofore unexplored benefits
within inflatable fabric structures. For example, such basket weave
patterns permit a constant "seam" width and weave construction over
an entire single layer area, even where the area is curved. As
noted above, the standard Oxford weaves currently utilized cannot
remain as the same weave pattern around curved seams; they become
plain weave patterns. Also, such basket weave seam patterns permit
the construction of an inflatable fabric having only plain woven
double layer fabric areas and single layer "seams" with no "floats"
of greater than three picks within the entire fabric structure.
Such a fabric would thus not possess discrete locations where the
air permeability is substantially greater than the remaining
portions of the fabric. Generally, the prior art (such as Thornton
et al., supra) produce floats of sometimes as much as six or seven
picks at a time. Although available software to the weaving
industry permits "filling in" of such floats within weave diagrams,
such a procedure takes time and still does not continuously provide
a fabric exhibiting substantially balanced air permeability
characteristics over the entire structure. The basket-weave
formations within the single fabric layers thus must be positioned
in the fabric so as to prevent irregularities (large numbers of
floats, for example) in the weave construction at the interface
between the single and double fabric layers (as described in FIG.
10, below). Another benefit such basket weave patterns accord the
user is the ability to produce more than one area of single layer
fabric (i.e., another "seam" within the fabric) adjacent to the
first "seam." Such a second seam provides a manner of dissipating
the pressure from or transferring the load upon each individual
yarn within both seams. Such a benefit thus reduces the chances of
deleterious yarn shifting during an inflation event through the
utilization of strictly a woven fabric construction (i.e., not
necessarily relying upon the utilization of a coating as well). The
previously disclosed or utilized inflatable fabrics having both
double and single fabric layer areas have not explored such a
possibility in utilizing two basket-weave pattern seams.
Furthermore, such a two-seam construction eliminates the need for
weaving a large single fabric layer area within the target
inflatable fabric. The prior art fabrics which produce "pillowed"
chambers for airbag cushions (such as side curtains), have been
formed through the weaving of entire areas of single fabric layers
(which are not actually seams themselves). Such a procedure is
time-consuming and rather difficult to perform. The inventive
inflatable fabric merely requires, this alternative embodiment, at
least two very narrow single fabric layer areas (seams) woven into
the fabric structure (another preferred embodiment utilizes merely
one seam of single layer fabric); the remainder of the fabric
located within these two areas may be double layer if desired.
Thus, the inventive fabric permits an improved, cost-effective,
method of making a "pillowed" inflatable fabric.
[0090] The inflatable fabric itself is preferably produced from
all-synthetic fibers, such as polyesters and polyamides, although
natural fibers may also be utilized in certain circumstances.
Preferably, the fabric is constructed of nylon-6,6. The individual
yarns utilized within the fabric substrate must generally possess
deniers within the range of from about 40 to about 840; preferably
from about 100 to about 630.
[0091] As noted above, coatings should be applied to the surface as
a necessary supplement to the air permeability, abrasion resistance
and/or puncture resistance of the inventive fabric. Since one
preferred ultimate use of this inventive fabric is as a side
curtain airbag which must maintain a very low degree of air
permeability throughout a collision event (such as a rollover where
the curtain must protect passengers for an appreciable amount of
time), a decrease in permitted air permeability is highly
desirable. Any standard coating, such as a silicone, polyurethane,
polyamide, polyester, rubber (such as neoprene, for example), and
the like, may be utilized for this purpose and may be applied in
any standard method and in any standard amount on the fabric
surface.
[0092] Furthermore, although it is not preferred, it has been found
that the inventive coating composition provides similar low
permeability benefits to standard one-piece woven airbags,
particularly with the inventive add-on amounts of high tensile
strength, high elongation, non-silicone coatings; however, the
amount of coating required to permit high characteristic leak-down
times is much higher than for the aforementioned Sollars, Jr.
inventive one-piece woven structure. Thus, add-on amounts of as
much as 1.5 or more ounces per square yard may be necessary to
effectuate the proper low level of air permeability for these other
one-piece woven airbags. Even with such higher add-on coatings, the
inventive coatings themselves clearly provide a marked improvement
over the standard, commercial, less preferred silicone, etc.,
coatings (which must be present in amounts of at least 3.0 ounces
per square yard).
[0093] Additionally, it has also been found that the inventive film
coating compositions, at the inventive add-on amounts, etc.,
provide the same types of benefits with the aforementioned sewn,
stitched, etc., side curtain airbags. Although such structures are
highly undesirable due to the high potential for leakage at these
attachment seams, it has been found that the inventive coating
provides a substantial reduction in permeability (to acceptable
characteristic leak-down time levels, in fact) with correlative
lower add-on amounts than with standard silicone and neoprene
rubber coating formulations. Such add-on amounts may approach about
2.7 ounces per square yard or more, but lower amounts have proven
effective (2.2 ounces per square yard, for example) depending on
the utilization of a sufficiently high tensile strength and
sufficiently stretchable elastomeric component within the film
coating composition directly in contact with the target fabric
surface. Again, with the ability to reduce the amount of coating
materials (which are generally always quite expensive), while
simultaneously providing a substantial reduction in permeability to
the target airbag structure, as well as high resistance to humidity
and extremely effective aging stability, the inventive coating
composition, and the inventive coated airbag itself is clearly a
vast improvement over the prior airbag coating art.
[0094] Another aspect of this invention, is the ability to pack the
coated airbag cushions within cylindrical storage containers at the
roof line of a target automobile in as small a volume as possible.
In a rolled configuration (in order to best fit within the
cylindrical container itself, and thus in order to best inflate
upon a collision event downward to accord the passengers sufficient
protection), the inventive airbag may be constricted to a
cylindrical shape having a diameter of about 24 millimeters or
more. In such an instance, with a 2 meter long cylindrical roofline
storage container, the necessary volume of such a container would
equal about 855 cm.sup.3 or more (with the volume calculated as
2[Pi]radius.sup.2). Standard rolled packing diameters are at least
25 millimeters for commercially available side curtain airbag
cushions (due to the thickness of the required coating to provide
low permeability characteristics). Thus, the required cylindrical
container volume would be at least 980 cm.sup.3. Preferably, the
rolled diameter of the inventive airbag cushion during storage is
about 21 millimeters or more (giving a packed volume of about 647
cm.sup.3 or more). In relation, then, to the depth of the airbag
cushion upon inflation (i.e., the length the airbag extends from
the roofline down to its lowest point along the side of the target
automobile, such as at the windows), the quotient of the inventive
airbag cushion's depth (which is standard at approximately 17
inches or 431.8 millimeters) to its rolled packed diameter should
be at least about 18.0 or less. Of course, this range of quotients
does not require the depth to be at a standard of 17 inches, and is
primarily a function of coating thickness, and thus add-on
weight.
[0095] Also, it has been discovered that any film and/or coating
with a tensile strength of at least 2,000 psi and an elongation at
break of at least 180% coated onto and over both sides of a side
curtain airbag fabric surface at a weight of at most about 10.0
ounces per square yard, and preferably below about 7.0, more
preferably below about 6.0, and most preferably less than about 5.0
ounces per square yard, provides a coated airbag cushion which
exhibits extremely low and extended permeability upon and after
inflation. This unexpectedly beneficial type and amount of film
coating thus provides an airbag cushion which will easily inflate
after prolonged storage and will remain inflated for a sufficient
amount of time to ensure an optimum level of safety within a
restraint system. Furthermore, it goes without saying that the less
film coating composition required, the less expensive the final
product. Additionally, a lower required amount of film coating
composition will translate into a decrease in the packing volume of
the airbag fabric within an airbag device. This benefit thus
improves the packability for the airbag fabric.
[0096] One preferred airbag cushion of this invention was produced
in accordance with the following Example:
EXAMPLE
[0097] First, an adhesive primer formulation was produced having
the composition:
1 Component Parts by weight Desmoderm .RTM. 43195 (Bayer
Corporaiton, polyurethane 25 grams resin) Dimethylformamide
(Aldrich, solvent) 75 grams Desmodur .RTM. CB-75N (Bayer,
polyisocyanate adhesion 4 grams promoter)
[0098] This primer coating was applied to both sides of a 2.5 liter
size Jacquard woven nylon airbag (of 440 denier fibers), made in
accordance with the Figures and preferred embodiments within U.S.
patent application Ser. No. 09/406,264, to Sollars, Jr., previously
incorporated by reference. The primer coating was dried at about
160.degree. C. for about 2 minutes to obtain a dry coating weight
of about 0.25 ounces per square yard on each side. Subsequently, a
2 mil thick polyurethane film (Dureflex.TM. PT9400) was then
laminated on both sides of the primer coated airbag utilizing a
hotpress providing about 80 psi press pressure at about 188.degree.
C. with a residence time of about 1 minute. The total polyurethane
film add-on weight on each side of the airbag was about 2.2 ounces
per square yard. The airbag was then rapidly inflated to 30 psi air
pressure. More than 28 seconds elapsed before the air pressure
leaked down to 8 psi. The leakage rate was thus measured at 10 psi
to be about 4 SCFH. The characteristic leak-down time was an
astounding amount, greater than 80 seconds.
[0099] As depicted in FIG. 1, an interior of a vehicle 10 prior to
inflation of a side curtain airbag is shown. The vehicle 10
includes a front seat 12 and a back seat 14, a front side window 16
and a back-side window 18, a roofline 20, within which is stored a
cylindrically shaped container 22 housing the inventive side
curtain airbag 26. Also present within the roofline 20 is an
inflator assembly 24 which ignites and forces gas into the side
curtain airbag 26 upon a collision event.
[0100] FIG. 2 shows the inflated side curtain airbag 26. As noted
above, the airbag 26 may be coated with a coating formulation
and/or film, preferably polyurethane polycarbonate. The inventive
airbag 26 will preferably remain sufficiently inflated for at least
5 seconds, and preferably as high as at least 20 seconds.
[0101] FIG. 3 shows the side curtain airbag 26 prior to or after
storage in its uninflated state within the roofline cylindrically
shaped container 22. The thickness of the airbag 26, measured as
the rolled packing diameter (as in FIG. 5, below) as compared with
the depth of the airbag measured from the roofline cylindrically
shaped container 22 to the bottom most point 28 of the airbag 26
either in its uninflated or inflated state should preferably be at
least 17 and at most 29, as noted above.
[0102] FIGS. 4 and 5A aid in understanding this concept through the
viewing of the rolled airbag 26 as stored within the container 22
along line 5-5. The diameter measurement of the airbag 26 of the
example above, is roughly 24 millimeters 9 or more. The standard
depth of side curtain airbags is roughly 17 inches, or about 431.8
millimeters.
[0103] FIGS. 3 and 6 show the respective interior and exterior
surfaces 102, 104 of the airbag 26.
[0104] FIGS. 5A shows the airbag 26 being rolled. Alternatively,
FIG. 5B shows the airbag 26 being folded. The airbag 26 may be
rolled or folded and packed into a cylindrical woven or molded
tube, or the airbag 26 may be folded and held in position by straps
such as breakaway molded plastic straps.
[0105] With reference to FIGS. 7-9 of the drawings, and in
accordance with selected embodiments of the present invention
providing abrasion resistant fabrics and/or airbag cushions,
resistance to abrasion by gravel (FIG. 7) was tested by using road
side gravel placed on a test board, inflating a test bag to 10 psi,
placing the test board on the inflated bag with the gravel toward
the bag and loading the test board with a 13 lbs. concrete block,
scrubbing the gravel board across the bag at one cycle per second,
and measuring the gas flow rate required to maintain bag pressure
at 10 psi. As shown in FIG. 7 of the drawings, a bag in accordance
with the present invention (test bag) had an extremely high
resistance to abrasion by gravel in that the pressure required to
maintain bag pressure at 10 psi increased only slightly during the
initial phase of the testing and then remained relatively constant
from about 20 to 100 cycles. In contrast to the test bag of the
present invention, the base line bag showed a steady increase from
0 to 20 cycles and then a drastic increase in pressure to maintain
bag pressure at 10 psi from 20 to about 25 cycles.
[0106] The test bag was a jacquard woven airbag made of 420 denier
high tenacity nylon, coated with 1.2 oz/yd.sup.2 polyurethane on
each side, and a 3 mil thick Duraflex PT 9400 polyurethane film was
laminated on one side of the bag (FIG. 12B).
[0107] The baseline bag was a jacquard woven airbag made from 420
denier high tenacity nylon coated with 4 oz/yd.sup.2 of silicone on
each side of the bag.
[0108] With reference to FIG. 8 the drawings and resistance to
abrasion by concrete, testing of a test bag in accordance with the
present invention entailed using a concrete block as the test
media, inflating a test bag to 10 psi, placing a concrete block on
the inflated bag (about 13 lbs.), scrubbing the concrete block and
forth across the bag at one cycle per second and measuring the flow
rate required to maintain bag pressure at 10 psi. As shown in FIG.
8 of the drawings, the test bag of the present invention showed a
high resistance to abrasion by concrete and had a very low and
constant leak rate from 0 to 100 cycles. In contrast to the test
bag of the present invention, the base line bag had a higher leak
rate which increased from 0 to about 12 cycles and drastically
increased from about 12 to 20 cycles.
[0109] The test bag was a jacquard woven airbag made of 420 denier
high tenacity nylon, coated with 1.2 oz/yd.sup.2 polyurethane on
each side, and with a 3 mil thick Duraflex PT 9400 polyurethane
film was laminated on one side of the bag (FIG. 12B).
[0110] The baseline bag was a jacquard woven airbag made from 420
denier high tenacity nylon coated with 4 oz/yd.sup.2 of silicone on
each side of the bag.
[0111] With reference to FIG. 9 of a drawing, the test bag of the
present invention showed a very high resistance to puncture as
compared to a baseline bag. Testing of the test bag of the present
invention for puncture included placing shards of vehicle side
window glass on a plate, deploying the test bag to 30 psi against
the plate covered with the broken glass, dropping a 25 pound weight
on the bag as the bag reached full inflation to force the inflated
bag to impact the broken glass, and measuring the time for the
pressure to fall from 30 psi to 15 psi (time to lose half of full
pressure). As shown in FIG. 9 of the drawings, the test bag of the
present invention took at least about 5 seconds to lose half of its
pressure to drop from (30 psi to 15 psi). In contrast, the base
line bag took less than one half of a second.
[0112] The test bag was a jacquard woven airbag made of 420 denier
high tenacity nylon, coated with 1.2 oz/yd.sup.2 polyurethane on
each side, with a 3 mil thick Duraflex PT 9400 polyurethane film
laminated on one side of the bag, and with a layer of lightweight
polyester airbag fabric over the film (FIG. 12D).
[0113] The baseline bag was a jacquard woven airbag made from 420
denier high tenacity nylon coated with 4 oz/yd.sup.2 of silicone on
each side of the bag.
[0114] Hence, the test bags of the present invention showed an
unexpectedly high resistance to abrasion by gravel, unexpectedly
high resistance to abrasion by concrete, and an unexpectedly high
resistance to puncture. Such features find special applicability in
a side curtain airbag which is to provide rollover protection.
[0115] Turning now to FIGS. 10 and 11 of the drawings, in FIG. 10
there is shown a cross-section of a preferred structure for the
double fabric layers 52, 54, 58, 60, 64, 66 and single fabric
layers 56, 62 of the inventive inflatable fabric 50. Weft yarns 68
are present in each of these fabric layer areas 52, 54, 56, 58, 60,
62, 64, 66 over and under which individual warp yarns 78, 80, 82,
84 have been woven. The double fabric layers 52, 54, 58, 60, 64, 66
are woven in plain weave patterns. The single fabric layers 56, 62
are woven in basket weave patterns. Four weft yarns each are
configured through each repeating basket weave pattern within this
preferred structure; however, two or more weft yarns may be
utilized within these single fabric layer areas (seams) 56, 62. The
intermediate double fabric layer areas 58, 60 comprise each only
four weft yarns 68 within plain weave patterns. The number of such
intermediate weft yarns 68 between the single fabric layer areas
56, 62 must be in multiples of two to provide the maximum pressure
bearing benefits within the two seams 56, 62 and thus the lowest
possibility of yarn shifting during inflation at the interfaces of
the seams 56, 62 with the double fabric layer areas 52, 54, 64,
66.
[0116] FIG. 11 shows the weave diagram 70 for an inventive fabric
which comprises two irregularly shapes concentric circles as the
seams. Such a diagram also provides a general explanation as to the
necessary selection criteria of placement of basket-weave patterns
within the fabric itself. Three different types of patterns are
noted on the diagram by different shades. The first 72 indicates
the repeated plain weave pattern throughout the double fabric
layers (52, 54, 58, 60, 64, 66 of FIG. 10, for example) which must
always initiate at a location in the warp direction of 4X+1, with X
representing the number of pick arrangement within the diagram, and
at a location in the fill direction of 4X+1 (thus, the pick
arrangement including the specific two-layer
plain-weave-signifying-block 72 begins at the block four spaces
below it in both directions). The second 74 indicates an "up-down"
basket weave pattern wherein an empty block must exist and always
initiate the basket-weave pattern at a location in the warp
direction of 4X+1, with X representing the number of repeating pick
arrangements within the diagram, and at a location in the fill
direction of 4X+1, when a seam (such as 56 and 62 in FIG. 10) is
desired (thus, the pattern including the pertinent signifying
"up-down" block 74 includes an empty block within the basket-weave
pick arrangement in both the warp and fill directions four spaces
below it). The remaining pattern, which is basically a "down-up"
basket weave pattern to a single fabric layer (such as 56 and 62 in
FIG. 10) is indicated by a specifically shaded block 76. Such a
pattern must always initiate at a location in the warp direction of
4X+1 and fill of 4X+3, or warp of 4X+3 and fill of 4X+1, when a
seam is desired. Such a specific arrangement of differing "up-down"
basket weave 74 and "down-up" basket weave 76 pattern is necessary
to effectuate the continuous and repeated weave construction
wherein no more than three floats (i.e., empty blocks) are present
simultaneously within the target fabric structure. Furthermore,
again, it is believed that there has been no such disclosure or
exploration of such a concept within the inflatable fabric art.
[0117] With reference to FIGS. 3 and 6, the side curtain airbag or
cushion 26 has an interior surface 102 (close to the occupant) and
an exterior surface 104 facing the window or windows. With
reference to FIG. 10, a thick coating, layer, film, or the like 86
represents the exterior surface (window side) of the airbag 50
while a thinner coating, film, layer, or the like 88 represents the
interior surface (occupant side) of the airbag.
[0118] A side curtain type of air bag acts as a safety barrier
between the occupant of a vehicle and hazards outside of the
vehicle in a collision. Puncture resistance is preferred to prevent
premature leak-down and possible bag rupture due to impact on sharp
objects such as broken window glass, nails, splintered wood, rocks
and gravel with sharp edges, broken plastic or torn metal generated
in a vehicle crash. Bag puncture may result in loss of bag gas
pressure necessary to provide the cushioning and energy absorbing
function of the air bag, and therefore loss of safety provided by
the air bag.
[0119] The side curtain air bag may get between the occupant and
another vehicle or other outside object such as a utility pole in a
side impact accident. The air bag may also hit the ground and other
objects on the ground in a rollover type of collision. Side impact
air bags, especially rollover protection curtain type air bags are
designed to protect the occupants in those types of accidents.
[0120] Side impact air bags are usually made of coated fabric to
provide quick inflation (20-40 ms) to operating pressure for a
relatively longer time compared to a typical driver side air bag.
For rollover protection, the air bag needs to stay inflated at
relatively high pressure for an extended period of time (several
seconds). Even a small puncture in the coating by a small sharp
object can greatly lower the gas pressure in the bag and sacrifice
the bag performance. There are also situations where part of the
bag can hit against one or more small sharp objects. Due to great
bag pressure and such a small contact area, the fabric may get cut
through, and even cause the bag to burst on impact.
[0121] We have experimented with many fabric designs and fabric
combinations and found a surprising correlation between the air bag
puncture resistance under simulated crash conditions and two
different ASTM standard puncture resistance tests. We have also
found that certain fabric structures and treatments provide
unexpectedly good puncture resistance.
[0122] We have constructed different fabric structures for the side
curtain airbag and experimented with the bag performance in
puncture resistance tests. Compared to current air bag
constructions, we have demonstrated great improvement in puncture
resistance. Additionally, we have found that a combination of two
ASTM tests can provide a good correlation to puncture under
simulated crash conditions.
[0123] A test was devised to study side impact bag performance
under simulated crash conditions. Two plates that simulate the
sharp objects typically encountered in an automotive accident were
constructed (a glass plate and a gravel plate). On the glass plate,
pieces of broken glass from a car side window were fixed on a flat
thick plywood surface using epoxy resin. On the gravel plate, road
construction gravel having stones with relatively sharp edges was
fixed onto a thick plywood surface using asphalt. In the test, a
plate is horizontally fixed on a stable platform. A side curtain
type air bag positioned a couple of inches above the plate is
inflated at a fast rate (about 30 ms to its peak pressure).
Immediately after inflation, a 25 lb. weight is dropped from a 51/2
feet height onto the top side of the air bag. The dropped weight
thus pushes the fully inflated airbag down against the plate with
the sharp objects. The gas pressure inside the air bag is monitored
and the rate of pressure decay reflects the damage to the bag. As
the rate of pressure decay is approximately exponential, the "half
life"--the time for the pressure to drop to one half its initial
pressure--is a simple measure of the degree of damage to the bag.
Tested bags were also examined to determine the failure mode,
namely, number of small punctures and large holes. Small punctures
are those that result in gas leakage due to a break in the coating
with 2 or fewer yarn breaks. Large holes are those that involve
multiple yarn breaks, cuts, or localized burst or tear.
2TABLE I Test results of impact drop test of bags A-K on broken
glass plate using inflation simulator. Poly- Silicone Silicone ure-
coat- coating thane 420 d ing - with coat- 420 d lami- S/1125
S/1125 Bag 1 nonwoven ed sewn nate sewn laminate struct. A B C D E
F G Half <0.3 0.3 0.3-2 5 0.5 5 Life Sec Big 22 16 9 3 0 3 1
holes Small 4 2 5 2 2 4 2 holes 630 d 630 d 100 d 100 d sewn
laminate sewn laminate Bag struct. H I J K Half Life -- 18 0.7 10
Sec Big holes 0 0 2 0 0 Small 1 0 1 1 holes Scratches 0 Other
observ. Fabric structures: A 420 denier woven Jacquard side curtain
air bag coated with 2.5 oz/yd.sup.2 high consistency silicone
rubber on each side; B 420 denier woven Jacquard side curtain air
bag coated with about 3 oz/yd.sup.2 silicone rubber with a thin
layer of non-woven fabric laminated to the top of the coating on
each side; C 420 denier woven Jacquard side curtain air bag coated
with about 1.0 oz/yd.sup.2 polyurethane on each side; D One layer
of uncoated 420 denier 49 .times. 49 airbag fabric was loosely sewn
on the outside edges of air bag C, the uncoated 420 denier fabric
faced the broken glass plate; E One layer of uncoated 420 denier 49
.times. 49 airbag fabric was laminated to one side of air bag C
using a polyurethane elastomer, and the laminated side faced to the
broken glass plate; F One layer of uncoated 78 denier 96 .times. 96
polyester fabric was loosely sewn on the outside edges of air bag
C, the uncoated fabric faced the broken glass plate; G One layer of
uncoated 78 denier 96 .times. 96 polyester fabric laminated to one
side of air bag C using a polyurethane elastomer, the laminated
fabric faced the broken glass plate; H One layer of uncoated 630
denier 40 .times. 40 airbag fabric was loosely sewn on the outside
edges of air bag C, the uncoated 630 denier fabric faced the broken
glass plate; I One layer of uncoated 630 denier 40 .times. 40
airbag fabric was laminated to one side of air bag C using a
polyurethane elastomer, and the laminated side faced to the broken
glass plate; J One layer of uncoated 100 denier 110 .times. 110
airbag fabric was loosely sewn on the outside edges of air bag C,
the uncoated 100 denier fabric faced the broken glass plate; K One
layer of uncoated 100 denier 100 .times. 110 airbag fabric was
laminated to one side of air bag C using a polyurethane elastomer,
and the laminated side faced to the broken glass plate.
[0124] Big holes: holes that have fabric tear and/or multiple yarn
cut or bursting, contribute to rapid leak down and major
failure.
[0125] Small holes: small pin holes that do not have any fabric
tear or have only 1 or 2 broken yarns. Relatively small amount of
air leaks through the small pin holes.
[0126] Half Life: time in sec. required for pressure in bag to drop
by 1/2 of the peak pressure.
[0127] ASTM F 1342 "Standard Test Method for Protective Clothing
Material Resistance to Puncture" provides a good measure regarding
how easily a sharp object can penetrate a fabric structure. ASTM D
4833 "Standard Test Method for Index Puncture Resistance of
Geotextiles, Membranes, and Related Products" provides a good
measure of how easily a fabric would burst at high stress
concentration on a small contact area. We have found that ASTM F
1342 test method gives a good indication of fabric resistance to
initial penetration by a sharp object and that ASTM D 4833 test
method relates largely to the resistance to local bursting and
tear.
[0128] ASTM D 4833--Standard Test Method for Index Puncture
Resistance of Geotextiles, Geomembranes and Related Products.
[0129] A text specimen is clamped without tension between circular
plates of a ring clamp attachment secured in a tensile testing
machine. A force is exerted against the center of the unsupported
portion of the test specimen by a solid steel rod attached to the
load indicator until rupture of the specimen occurs. The maximum
force recorded is the value of puncture resistance of the
specimen.
[0130] ASTM F 1342--Standard Test Method for Protective Clothing
Material Resistance to Puncture.
[0131] A material specimen is placed in a stationary support
assembly that is in turn affixed to the lower arm of a tensile
testing machine. A sharp puncture probe of set dimension is moved
at a constant velocity until the material specimen is punctured.
The force required to puncture the material specimen is measured by
the compression cell and the average force is reported as the
measure of resistance to puncture.
3TABLE II Test results: A. Uncoated single layer fabric 420 630
Polyester, denier, denier, 78 denier 100 denier Spun laced 49
.times. 49 40 .times. 40 96 .times. 96 110 .times. 110 non-woven
Fabric (420 d) (630 d) (PET 78) (100 d) fabric ASTM 2-6 6.9 3.3 9.7
1.5 Puncture force (LB) ASTM 174 218 43.3 118 Index puncture, LB B.
Coated fabric, single layer 420 420 denier, denier, 49 .times. 49
420 denier, 420 denier, 630 denier 49 .times. 49 silicone, 494
.times. 49 47 .times. 48 40 .times. 40 HC LR* polyurethane
Polyamide HC silicone silicone Fabric coating coating coating
coating coating ASTM 5 8 6 3 3 Puncture force ASTM 151 198 159 153
144 Index puncture .circle-solid. LR -- liquid rubber resin, HG --
high consistency rubber resin C. 2 layers structure, uncoated
fabric over coated fabric S/1125 fabric 420 d over 420 d over 630 d
over over polyurethane silicone polyurethane polyurethane Fabric
coated 420 d coated 420 d coated 420 d coated 420 d, ASTM 15.6 12
18.0 11.8 Puncture force LB ASTM Index 348 393 253 puncture force
LB D. Laminated 2 layer structures Non- Non- woven woven 420 d
lami- lami- lami- nated 2 mil nated nated to a S/1125 poly- to 420
d sili- 100 d 210 d fabric 630 d film 420 d using cone lami- lami-
lami- lami- lami- using poly- coated nated nated nated nated nated
poly- ure- 420 d to to to to to ure- Fabric thane fabric 420 d 420
d 420 d 420 d 420 d thane ASTM 26 6.2 25 21.8 16.6 26.9 8.6 13.2
punc- ture force (LB) ASTM 350 206 325 326 240 385 229 index punc-
ture force (LB) Findings: 1. Current silicone coated airbag fabric
does not have good resistance to puncture even when there is a
layer of non-woven fabric laminated on top of the coating. High
strength and tough coatings, such as polyurethane, provide better
resistance to puncture due to polyurethane's better tensile and
toughness and silicone's poor resistance to tear and lubricating
nature. Coated fabric in general # provided better protection than
uncoated fabric because the coating links the yarns and fibers
together to effectively alleviate stress concentration and to
provide better resistance to sharp object's penetration through
yarn interstices. 2. One additional layer of fabric provides
significant improvement in puncture resistance. Fabric with tighter
construction provides better protection because a sharp object is
less likely to go through the yarn interstices. Fabric with higher
breaking strength also provides better protection against bursting
caused by localized high stress such as by impact with small
objects. 3. Laminated fabric structures provide surprisingly better
puncture resistance than similar structure without lamination. 4.
The structure should have enough fabric strength to resist local
bursting and tear. However, the structure also should be as thin as
possible to provide a small packing volume. The structure also
needs to be flexible to allow folding into a small package to fit
in a small module. 5. Bag test results had good correlation to the
ASTM F 1342 and ASTM D 4833 test results. High index puncture
resistance usually has better resistance to local bursting and
tear. An index puncture resistance above 210 lbs. seems to be
adequate for the application. Index puncture resistance above 250
lbs. is preferred. In addition, and more importantly, ASTM F 1342
puncture force should be above 10 lbs. to provide good resistance
to air bag puncture. Puncture force above 15 lbs. is preferred for
this application. Above all, we have found that a fabric structure
having an ASTM D 4833 index puncture resistance of at least about
210 lbs. and an ASTM F 1342 puncture force of at least about 10
lbs. are preferred for side impact air bags that resist puncture in
typical accidents.
[0132] With reference to FIGS. 12A-12M of the drawings, schematic
cross-sectional layer diagrams of selected embodiments of the side
wall of an airbag or airbag cushion toward the window are shown.
With particular reference, FIG. 12A shows an airbag fabric having a
coating on the exterior surface thereof.
[0133] FIG. 12B shows a coated airbag fabric having a film
laminated or otherwise adhered thereto with the coating between the
film and fabric.
[0134] FIG. 12C illustrates a coated airbag fabric having an outer
fabric layer laminated or otherwise adhered thereto with the
coating between the inner and outer fabric layers.
[0135] FIG. 12D represents a multi-layered airbag laminate or
construction (such as shown in FIG. 12B) including a coated airbag
fabric and a film laminated thereto with the addition of an outer
fabric layer laminated or otherwise adhered to the film layer of
the laminate or composite.
[0136] FIG. 12E shows an airbag fabric having a film laminated or
adhered thereto.
[0137] FIG. 12F shows an airbag fabric having a primer applied
thereto and then a coating over the primer.
[0138] FIG. 12G shows a multi-layer fabric, laminate or
construction including a first airbag fabric laminated or adhered
to a second or outer fabric by an adhesive.
[0139] FIG. 12H represents a multi-layer airbag fabric, composite
or laminate including a first airbag fabric layer, a coating, a
second or outer fabric layer, and a coating or film atop the second
fabric layer.
[0140] FIG. 12I illustrates a multi-layer airbag fabric, composite
or laminate including a first layer of airbag fabric having an
inner coating or film and an outer coating, primer or adhesive with
a coating, fabric or film adhered to the upper surface of the outer
coating, primer or adhesive.
[0141] FIG. 12J represents a multi-layer airbag fabric, composite,
laminate, or the like having an airbag fabric with a coating,
primer, or adhesive layer above and below and a film located below
the lower coating, primer, or adhesive layer and a coating, fabric
or film located above the upper coating, primer, or adhesive
layer.
[0142] FIG. 12K shows an airbag fabric having a separate film layer
located below or adjacent the inner surface of the airbag
fabric.
[0143] FIG. 12L represents an airbag fabric having a separate
barrier layer located above or adjacent to the outer surface of the
airbag fabric.
[0144] FIG. 12M illustrates an airbag fabric having a coating or
film adhered thereto in a fashion producing multiple individual
cells or pockets.
[0145] FIGS. 12I-12K are directed to, for example, bag-in-bag
constructions wherein an inner coating and/or film forms an
inflatable cavity in the airbag.
[0146] The exact construction of the airbag or side walls thereof
of the present invention is not necessarily limited, but is
intended to cover all such constructions which provide the desired
puncture resistance and/or abrasion resistance as well as other
desired properties of the airbag.
[0147] The inner or lower fabric layer of FIGS. 12A-12M is
preferably woven airbag fabric and more preferably may be jacquard
or dobby woven airbag fabric of a woven one piece airbag. The outer
or upper fabric layer of FIGS. 12C, 12D, 12G, 12H, 12I, 12J, or 12K
is preferably woven airbag fabric.
[0148] The barrier of FIG. 12L is preferably a material which is
puncture and/or abrasion resistant such as a textile material,
fabric, or the like.
[0149] There are, of course, many alternative embodiments and
modifications of the present invention which are intended to be
included within the spirit and scope of the following claims. While
the invention is described and disclosed in connection with certain
preferred embodiments and practices, it is in no way intended to
limit the invention to those specific embodiments, rather it is
intended to cover equivalent structures structural equivalents and
all alternative embodiments and modifications as may be defined by
the scope of the appended claims and equivalents thereto.
* * * * *