Barrier layer for inflatable structures

Abstract

An air-impermeable fabric is disclosed. The air-impermeable fabric has a fabric substrate, which may also be referred to as a base fabric. Disposed over the fabric substrate is a barrier layer comprising a polymer binder and at least 20 weight percent graphene nanoplatelets, based on the total weight of the barrier layer. A barrier underlayer, which may or may not also include graphene nanoplatelets, is disposed between the fabric substrate and the barrier layer. A barrier overlayer, which may or may not also include graphene nanoplatelets, is disposed on the opposite side of the barrier layer from the barrier underlayer

1 . An air-impermeable fabric, comprising
 a fabric substrate;   a barrier layer comprising a first resin binder and graphene nanoplatelets, said barrier coating comprising at least 20 wt. % of the graphene nanoplatelets, based on the total weight of the barrier layer; and   a barrier overlayer disposed on the opposite side of the barrier layer from the barrier underlayer, comprising a second resin binder.   
     
     
         2 . The air-impermeable fabric of  claim 1 , further comprising a barrier underlayer disposed between the barrier layer and the fabric, comprising a third resin binder 
     
     
         3 . The air-impermeable fabric of  claim 2 , wherein the barrier underlayer comprises from 0.5 wt. % to 5 wt. % of graphene nanoplatelets, based on the total weight of the barrier underlayer. 
     
     
         4 . The air-impermeable fabric of  claim 1 , wherein the barrier overlayer comprises from 0.5 wt. % to 5 wt. % of graphene nanoplatelets, based on the total weight of the barrier overlayer. 
     
     
         5 . The air-impermeable fabric of  claim 2 , wherein the barrier underlayer and the barrier overlayer each independently comprises from 0.5 wt. % to 5 wt. % of graphene nanoplatelets, based on the total weight of the barrier underlayer and the barrier overlayer, respectively. 
     
     
         6 . The air-impermeable fabric of  claim 1 , wherein the barrier layer comprises from 20 wt. % to 90 wt. % of the graphene nanoplatelets, based on the total weight of the barrier layer. 
     
     
         7 . The air-impermeable fabric of  claim 1 , wherein the barrier layer comprises from 20 wt. % to 60 wt. % of the graphene nanoplatelets, based on the total weight of the barrier layer. 
     
     
         8 . The air-impermeable fabric of  claim 1 , wherein the barrier layer comprises from 25 wt. % to 45 wt. % of the graphene nanoplatelets, based on the total weight of the barrier layer. 
     
     
         9 . The air-impermeable fabric of  claim 1 , wherein the barrier layer comprises from 25 wt. % to 35 wt. % of the graphene nanoplatelets, based on the total weight of the barrier layer. 
     
     
         10 . The air-impermeable fabric of  claim 1 , wherein the barrier layer comprises about 30 wt. % of the graphene nanoplatelets. 
     
     
         11 . The air-impermeable fabric of  claim 1 , wherein the barrier layer further comprises a phosphorus-based flame retardant. 
     
     
         12 . The air-impermeable fabric of  claim 1 , wherein the barrier layer has a thickness of from 0.01 μm to 5 μm. 
     
     
         13 . The air-impermeable fabric of  claim 1 , wherein the barrier layer has a thickness of from 0.1 μm to 2 μm. 
     
     
         14 . The air-impermeable fabric of  claim 2 , wherein each of the barrier underlayer and the barrier overlayer independently has a thickness of 0.5 μm to 20 μm. 
     
     
         15 . The air-impermeable fabric of  claim 1 , further comprising a heat-resistant layer disposed on the opposite side of the fabric substrate from the barrier layer. 
     
     
         16 . The air-impermeable fabric of  claim 15 , wherein the heat-resistant layer comprises ceramic microspheres and/or aluminum in a resin binder. 
     
     
         17 . The air-impermeable fabric of  claim 1 , wherein the fabric substrate is subjected to calendaring compression prior to disposition thereon of the barrier layer, barrier underlayer, and barrier overlayer. 
     
     
         18 . The air-impermeable fabric of  claim 1 , having an areal weight of less than or equal to 6 oz/yd 2  (170 g/m 2 ). 
     
     
         19 . An inflatable structure comprising the air-impermeable fabric of  claim 1 . 
     
     
         20 . The inflatable structure of  claim 19  that is an aircraft evacuation slide.