Coated airbag, process for making the same, airbag module comprising the coated airbag, and system for producing a filled, cross-linked silicone polymer

Abstract

An airbag comprises a textile substrate and a coating on at least a portion of the surface of the substrate. An airbag module comprises an airbag, a gas generator connected to the airbag, and a cover at least partially enclosing the airbag and the gas generator. A process for producing an airbag comprises the steps of providing a textile substrate, providing a coating composition, applying the coating composition to the substrate, and heating the textile substrate. A system for producing a filled, cross-linked silicone polymer comprises a first part and a second part. Each part comprises a polysiloxane compound and a plurality of filler particles.

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 cross-linked silicone polymer; and 
 (ii) a plurality of filler particles, at least a portion of the filler particles being bound to the cross-linked silicone polymer through a silicon compound covalently bonded to a surface of the filler particle. 
   
     
     
         2 . The airbag of  claim 1 , wherein the filler particles are metal hydroxide particles. 
     
     
         3 . The airbag of  claim 2 , wherein the metal hydroxide particles comprise a metal hydroxide compound selected from the group consisting of magnesium hydroxide, aluminum hydroxide, and mixtures thereof. 
     
     
         4 . The airbag of  claim 1 , wherein the silicon compound is covalently bonded to the cross-linked silicone polymer through a functional group selected from the group consisting of amine groups, siloxane groups, and alkyl groups. 
     
     
         5 . The airbag of  claim 1 , wherein the filler particles are present in the coating in an amount of about 20 parts by weight or more per 100 parts of the cross-linked silicone polymer. 
     
     
         6 . The airbag of  claim 1 , wherein the filler particles are present in the coating in an amount of about 50 parts by weight or more per 100 parts of the cross-linked silicone polymer. 
     
     
         7 . A process for producing an airbag, the process comprising the steps 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 first polysiloxane compound; 
 (ii) a second polysiloxane compound, the second polysiloxane compound comprising one or functional groups that reacts with a functional group present on the first polysiloxane compound to produce a covalent bond between the second polysiloxane compound and the first polysiloxane compound; and 
 (iii) a plurality of filler particles, the filler particles having a silicon compound covalently bonded to a surface of the filler particle, the silicon compound comprising one or more functional groups that reacts with a functional group present on the first polysiloxane compound to produce a covalent bond between the silicon compound and the first polysiloxane compound; 
   (c) applying the coating composition to at least a portion of the surface of the textile substrate; and   (d) heating the textile substrate to a temperature sufficient for the first polysiloxane compound and the second polysiloxane compound to react and form a cross-linked silicone polymer on the surface of the textile substrate.   
     
     
         8 . The process of  claim 7 , wherein the first polysiloxane compound comprises a plurality of silicon hydride groups. 
     
     
         9 . The process of  claim 9 , wherein the second polysiloxane compound comprises a plurality of vinyl groups. 
     
     
         10 . The process of  claim 9 , wherein the silicon compound comprises at least one vinyl group. 
     
     
         11 . The process of  claim 7 , wherein the filler particles are metal hydroxide particles. 
     
     
         12 . The process of  claim 7 , wherein the filler particles are present in the coating composition in an amount of about 50 parts by weight or more per 100 parts of the first polysiloxane compound. 
     
     
         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 cross-linked silicone polymer; and 
 (B) a plurality of filler particles, at least a portion of the filler particles being bound to the cross-linked silicone polymer through a silicon compound attached to a surface of the filler particle; 
 
   (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 13 , wherein the metal hydroxide particles comprise a metal hydroxide compound selected from the group consisting of magnesium hydroxide, aluminum hydroxide, and mixtures thereof. 
     
     
         16 . The airbag module of  claim 13 , wherein the metal hydroxide particles comprise aluminum hydroxide. 
     
     
         17 . The airbag module of  claim 13 , wherein the silicon compound is covalently bonded to the surface of the filler particle through an oxygen atom. 
     
     
         18 . The airbag module of  claim 13 , wherein the silicon compound is covalently bonded to the cross-linked silicone polymer through a functional group selected from the group consisting of amine groups, ether groups, and alkyl groups. 
     
     
         19 . The airbag module of  claim 13 , wherein the filler particles are present in the coating in an amount of about 20 parts by weight or more per 100 parts of the cross-linked silicone polymer. 
     
     
         20 . The airbag module of  claim 13 , wherein the metal hydroxide particles are present in the coating in an amount of about 50 parts by weight or more per 100 parts of the cross-linked silicone polymer.