Coated airbag, method for making the same, and airbag module comprising the coated airbag

Abstract

An airbag comprises a textile substrate and a coating on at least a portion of the surface of the textile substrate. The coating comprises a polyurethane polymer and a phosphorous compound. The phosphorous compound can be selected from the group consisting of esters of phosphoric acid, esters of phosphonic acid, esters of phosphinic acid, and mixtures thereof. An airbag module comprises the above-described airbag, a gas generator, and a cover at least partially enclosing the airbag and gas generator.

What is claimed is: 
     
         1 . An airbag comprising:
 (a) a textile substrate, the textile substrate having at least one surface; and   (b) a coating on at least a portion of the surface of the textile substrate, the coating comprising:
 (i) a polyurethane polymer; and 
 (ii) a phosphorous compound selected from the group consisting of esters of phosphoric acid, esters of phosphonic acid, esters of phosphinic acid, and mixtures thereof. 
   
     
     
         2 . The airbag of  claim 1 , wherein the textile substrate is a woven fabric comprising a plurality of synthetic yarns. 
     
     
         3 . The airbag of  claim 2 , wherein the synthetic yarns comprise fibers selected from the group consisting of polyamide fibers, polyester fibers, polyolefin fibers, and mixtures thereof. 
     
     
         4 . The airbag of  claim 1 , wherein the phosphorous compound conforms to the structure of Formula (I) below: 
       
         
           
           
               
               
           
         
         wherein R 1  is selected from the group consisting of alkyl groups, haloalkyl groups, aminoalkyl groups, aryl groups, haloaryl groups, aralkyl groups, and groups conforming to the structure —O—R 4 ; 
         wherein R 2  is selected from the group consisting of alkyl groups, haloalkyl groups, aminoalkyl groups, aryl groups, haloaryl groups, aralkyl groups, and groups conforming to the structure —O—R 5 ; 
         wherein R 3  is selected from the group consisting of alkyl groups, haloalkyl groups, aryl groups, haloaryl groups, aralkyl groups and groups conforming to the structure of Formula (II) below: 
       
       
         
           
           
               
               
           
         
         wherein R 4  and R 5  are independently selected from the group consisting of alkyl groups, haloalkyl groups, aryl groups, haloaryl groups, and aralkyl groups; and 
         wherein R 6  is selected from the group consisting of arylene groups, aralkylene groups, and poly(oxyalkylene) groups. 
       
     
     
         5 . The airbag of  claim 1 , wherein the phosphorous compound is present in the coating in an amount of about 1 part to about 80 parts per 100 parts of the polyurethane polymer. 
     
     
         6 . The airbag of  claim 5 , wherein the phosphorous compound is present in the coating in an amount of about 10 to about 60 parts per 100 parts of the polyurethane polymer. 
     
     
         7 . A method for producing an airbag, the method comprising the step of:
 (a) providing a textile substrate, the textile substrate having at least one surface;   (b) providing a coating composition, the coating composition comprising:
 (i) a liquid medium; 
 (ii) a polyurethane polymer; and 
 (iii) a phosphorous compound selected from the group consisting of esters of phosphoric acid, esters of phosphonic acid, esters of phosphinic acid, and mixtures thereof; 
   (c) applying the coating composition to at least a portion of the surface of the textile substrate; and   (d) drying the textile substrate to produce a coating on at least a portion of the surface of the textile substrate.   
     
     
         8 . The method of  claim 7 , wherein the textile substrate is a woven fabric comprising a plurality of synthetic yarns. 
     
     
         9 . The method of  claim 8 , wherein the synthetic yarns comprise fibers selected from the group consisting of polyamide fibers, polyester fibers, polyolefin fibers, and mixtures thereof. 
     
     
         10 . The method of  claim 7 , wherein the phosphorous compound conforms to the structure of Formula (I) below: 
       
         
           
           
               
               
           
         
         wherein R 1  is selected from the group consisting of alkyl groups, haloalkyl groups, aminoalkyl groups, aryl groups, haloaryl groups, aralkyl groups, and groups conforming to the structure —O—R 4 ; 
         wherein R 2  is selected from the group consisting of alkyl groups, haloalkyl groups, aminoalkyl groups, aryl groups, haloaryl groups, aralkyl groups, and groups conforming to the structure —O—R 5 ; 
         wherein R 3  is selected from the group consisting of alkyl groups, haloalkyl groups, aryl groups, haloaryl groups, aralkyl groups and groups conforming to the structure of Formula (II) below: 
       
       
         
           
           
               
               
           
         
         wherein R 4  and R 5  are independently selected from the group consisting of alkyl groups, haloalkyl groups, aryl groups, haloaryl groups, and aralkyl groups; and 
         wherein R 6  is selected from the group consisting of arylene groups, aralkylene groups, and poly(oxyalkylene) groups. 
       
     
     
         11 . The method of  claim 7 , wherein the phosphorous compound is present in the coating composition in an amount of about 1 part to about 80 parts per 100 parts of the polyurethane polymer. 
     
     
         12 . The method of  claim 11 , wherein the phosphorous compound is present in the coating composition in an amount of about 10 to about 60 parts per 100 parts of the polyurethane polymer. 
     
     
         13 . An airbag module comprising:
 (a) an airbag, the airbag enclosing an interior volume and comprising:
 (i) a textile substrate, the textile substrate having at least one surface; and 
 (ii) a coating on at least a portion of the surface of the textile substrate, the coating comprising:
 (A) a polyurethane polymer; and 
 (B) a phosphorous compound selected from the group consisting of esters of phosphoric acid, esters of phosphonic acid, esters of phosphinic acid, and mixtures thereof; 
 
   (b) a gas generator, the gas generator being connected to the airbag so that at least a portion of gases produced by the gas generator are directed into the interior volume enclosed by the airbag; and   (c) a cover at least partially enclosing the airbag and the gas generator.   
     
     
         14 . The airbag module of  claim 13 , wherein the textile substrate is a woven fabric comprising a plurality of synthetic yarns. 
     
     
         15 . The airbag module of  claim 14 , wherein the synthetic yarns comprise fibers selected from the group consisting of polyamide fibers, polyester fibers, polyolefin fibers, and mixtures thereof. 
     
     
         16 . The airbag module of  claim 13 , wherein the phosphorous compound conforms to the structure of Formula (I) below: 
       
         
           
           
               
               
           
         
         wherein R 1  is selected from the group consisting of alkyl groups, haloalkyl groups, aminoalkyl groups, aryl groups, haloaryl groups, aralkyl groups, and groups conforming to the structure —O—R 4 ; 
         wherein R 2  is selected from the group consisting of alkyl groups, haloalkyl groups, aminoalkyl groups, aryl groups, haloaryl groups, aralkyl groups, and groups conforming to the structure —O—R 5 ; 
         wherein R 3  is selected from the group consisting of alkyl groups, haloalkyl groups, aryl groups, haloaryl groups, aralkyl groups and groups conforming to the structure of Formula (II) below: 
       
       
         
           
           
               
               
           
         
         wherein R 4  and R 5  are independently selected from the group consisting of alkyl groups, haloalkyl groups, aryl groups, haloaryl groups, and aralkyl groups; and 
         wherein R 6  is selected from the group consisting of arylene groups, aralkylene groups, and poly(oxyalkylene) groups. 
       
     
     
         17 . The airbag module of  claim 13 , wherein the phosphorous compound is present in the coating in an amount of about 1 part to about 80 parts per 100 parts of the polyurethane polymer. 
     
     
         18 . The airbag module of  claim 17 , wherein the phosphorous compound is present in the coating in an amount of about 10 to about 60 parts per 100 parts of the polyurethane polymer.