Multi-layer coating system for jacquard woven airbags

Abstract

Novel airbag coating compositions comprising at least two separate and distinct layers are provided. The first layer (base coat), being in contact with the airbag surface, comprises a composition of at least one coating material which may comprise up to 30% by parts of the total amount of material in the first layer of a silicone resin which provides excellent adhesion, excellent tensile strength, and overall lower cost than standard silicone airbag coating materials. The second layer, being a coating for the first layer, provides excellent reinforcement and blocking characteristics to permit effective potential long-term storage and optimum use upon the occurrence of a collision. Such a second layer (topcoat) is preferably a silicone material but may also be selected from the group consisting of homopolymer and coplymer resins based on ethylene, propylene, acrylates, methacrylates, vinyl esters, acrylic acid, methacrylic acid, polyurethanes, polyamides, and inorganic materials such as talc, silica, silicate, calcium carbonate, alumina, and the like. This two-layer system permits excellent strength and blocking properties to prevent undesired adhesion between portions of the target airbag when stored as well as to prevent seam combing at relatively low cost due to the materials and the relatively low amount required for the topcoat. An airbag fabric coated with this inventive two-layer system is also contemplated within this invention.

What I claim is:  
     
         1 . A Jacquard woven side impact curtain-type airbag to which a coating system has been applied, wherein said coating system comprises at least two layers, and wherein at least one of said layers comprises at least one polyurethane.  
     
     
         2 . A Jacquard woven side impact curtain-type airbag which exhibits, upon inflation to a peak initial pressure of 30 psi using a 6.7 liter compressed nitrogen gas tank to 12 volumes of gas, a gas retention of at least 1 psi at a point in time at least 10 seconds subsequent to inflation at said peak initial pressure; wherein said airbag is coated with a coating present at an add-on weight of at most 3.0 ounces per square yard.  
     
     
         3 . The airbag of  claim 2  wherein said airbag retains at least 6 psi of retained inflation gas at least 10 seconds subsequent to inflation at said peak initial pressure.  
     
     
         4 . A Jacquard woven side impact curtain-type airbag to which a coating system has been applied, wherein said coating system comprises at least two layers; 
 wherein at least one of said layers comprises polyurethane; and    wherein said airbag exhibits, upon inflation to a peak initial pressure of 30 psi, a gas retention of a least 1 psi at a point in time at least 10 seconds subsequent to inflation at said peak initial pressure.    
     
     
         5 . The airbag of  claim 4  wherein said airbag retains at least 6 psi of retained inflation gas at least 10 seconds subsequent to inflation at said peak initial pressure.  
     
     
         6 . The airbag of  claim 1  wherein said at least one layer of coating comprising polyurethane is applied to said airbag in an add-on weight of from about 0.3 to about 2.5 ounces/square yard.  
     
     
         7 . The airbag of  claim 1  wherein said at least one layer of coating comprising polyurethane is applied to said airbag in an add-on weight of from about 0.6 to about 1.5 ounces/square yard.  
     
     
         8 . The airbag of  claim 7  wherein the aggregate add-on weight of said coating system applied to said airbag is from about 0.6 to about 3.0 ounces/square yard.  
     
     
         9 . The side impact curtain-type airbag of  claim 8  wherein the aggregate add-on weight of said coating system applied to said airbag is from about 0.6 to about 1.8 ounces/square yard.