Airbag Base Fabric and Method for Manufacturing Same
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Solution Overview
Problem
Airbag base fabrics face challenges in maintaining flame resistance, especially when the resin-coated side is exposed, and existing solutions do not adequately address flame resistance after exposure to outdoor environmental conditions.
Innovation Solution
A polyamide multifilament woven fabric with a silicone film layer, specific chemical properties, and thermal dimensional stability is developed, featuring a cyclopentanone content within a certain ppm range, phosphorus atoms, and a controlled molecular chain end balance, which results in self-extinguishing properties and low burning speed on both coated and non-coated sides after environmental resistance testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the resin-coated side is made as the outer surface of the airbag base fabric, then the airbag can be used with either side facing outward, but the burning speed increases and flame resistance deteriorates
Solution Approach 1:
The patent applies parameter changes by carefully controlling the cyclopentanone content within 0-250 ppm range and managing the molecular chain end balance (carboxylic acid ends greater than amine ends by 10-50 millimole equivalent/kg). These parameter adjustments modify the chemical properties of the polyamide multifilament to achieve self-extinguishing properties and reduce burning speed on the resin-coated side while maintaining versatility
Solution Approach 2:
The patent uses composite materials by combining polyamide multifilament yarn with silicone film coating. The specific composition and chemical properties of the polyamide base material work synergistically with the silicone coating to provide flame resistance on both sides of the fabric, enabling the resin-coated side to serve as outer surface with improved fire safety
2Adaptability or versatility
If the airbag is mounted outside the vehicle, then pedestrian protection is enhanced, but exposure to harsh environmental conditions reduces flame resistance
Solution Approach 1:
The patent applies preliminary action by pre-controlling the chemical composition and thermal dimensional stability of the polyamide multifilament before environmental exposure. The cyclopentanone content is controlled at 0-250 ppm and molecular chain end balance is established (carboxylic acid ends exceeding amine ends by 10-50 millimole equivalent/kg) in advance, creating inherent flame-resistant properties that maintain reliability after outdoor environmental exposure
Solution Approach 2:
The patent uses parameter changes by optimizing the silicone film amount (10-100 g/m2) and controlling the thermal dimensional stability (shrinkage rate ≤1.4%). These parameter adjustments ensure the fabric maintains its flame-resistant properties and structural integrity after exposure to UV rays, heat, rain, and other outdoor environmental conditions
3Weight of moving object
If lightweight properties are improved by reducing coating amount, then air permeability is enhanced, but flame resistance may be compromised
Solution Approach 1:
The patent applies parameter changes by optimizing the silicone film coating amount within 10-100 g/m2 range. This controlled coating thickness achieves the right balance between lightweight properties and flame resistance. Additionally, controlling the cyclopentanone content (0-250 ppm) and molecular chain end balance enhances the base fabric's inherent flame-resistant properties, allowing effective fire protection with minimal coating
Solution Approach 2:
The patent uses composite materials by combining the polyamide multifilament base fabric with a thin silicone film coating. The specific chemical composition of the polyamide (with controlled cyclopentanone content and molecular chain end balance) provides inherent flame resistance, while the silicone coating adds protective properties. This composite structure achieves flame resistance and lightweight properties simultaneously
Data Source
AI summary
Provided is an airbag base fabric in which combustibility due to both resin coating surface ignition and non-fabric surface ignition in the airbag base fabric is suppressed according to combustibility evaluation as defined in FMVSS 302 after environmental testing. The present invention pertains to a polyamide multifilament textile airbag base fabric and a method for manufacturing the same, the airbag base fabric being characterized by having a silicone film on at least one surface of the textile, the silicone film weight being 10 g/m2 to 100 g/m2 (inclusive), the cyclopentanone content being 0-250 ppm (inclusive) in relation to the textile weight, the greater shrinkage rate among the shrinkage rates in each of the warp and weft directions before and after heating for 60 minutes at 105° C. being 0-1.4% (inclusive), and the blade combing resistance after 400 hours in an environment of 85° C. and 95% relative humidity being 350 N or greater.