Coated cloth and method for producing same
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Solution Overview
Problem
Current air-bag technologies face challenges in providing adequate heat resistance for the periphery of the inflator connection opening, as existing heat-resistant resins cannot withstand the increasingly high temperatures of the inflator gas, leading to potential damage to the air-bag base fabric.
Innovation Solution
A coated fabric with a three-dimensional construction woven from synthetic fibers, coated with an elastomer resin layer, featuring a void content of 15-60% and a thickness of 0.5-2.5 mm, which is suitable for attachment to the inflator connection opening, enhancing heat resistance and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a thick resin coating is applied to increase heat resistance, then heat resistance is improved, but coating cost increases due to multiple coating processes
Solution Approach 1:
The patent employs a three-dimensional construction woven fabric with controlled void content (15-60%) as the base structure. This porous fabric architecture provides inherent heat insulation capability, allowing the use of thinner resin coatings (50-500 g/m²) while maintaining adequate heat resistance. The void spaces within the three-dimensional weave trap air and reduce heat transfer, thereby lowering the required resin thickness and reducing coating process complexity and costs.
Solution Approach 2:
The patent creates a composite structure combining a three-dimensional construction woven fabric (providing structural integrity and heat insulation) with an elastomer resin coating (providing additional heat resistance and protection). This composite approach allows each material to contribute its strengths, achieving superior heat resistance with reduced resin用量 compared to coating flat fabrics, thus reducing manufacturing costs.
2Ease of manufacture
If usual heat-resistant resins are used, then coating process is simple, but they cannot withstand inflator gas temperatures of 2000°C or higher
Solution Approach 1:
The three-dimensional construction woven fabric with 15-60% void content acts as a thermal barrier, reducing the temperature reaching the resin coating. This porous structure traps air and impedes heat transfer, allowing conventional elastomer resins to withstand the extreme inflator gas temperatures (2000°C or higher) that they normally could not tolerate, while maintaining coating process simplicity.
Solution Approach 2:
The patent combines a three-dimensional construction woven fabric (providing thermal insulation) with elastomer resin coating (providing heat resistance). This composite structure enables the use of simple elastomer resin coatings that can be applied in single or few layers, while the underlying three-dimensional fabric protects the resin from degradation by reducing the effective temperature exposure, allowing the system to withstand 2000°C or higher inflator gas temperatures.
3Strength
If reinforcing fabrics are stacked to protect the base fabric, then mechanical strength is improved, but heat resistance remains insufficient against high temperature gases
Solution Approach 1:
The patent replaces the conventional approach of stacking reinforcing fabrics with a three-dimensional construction woven fabric that has inherent heat insulation properties due to its void content (15-60%). This porous structure provides both mechanical strength and thermal protection, eliminating the need for additional reinforcing layers while achieving adequate heat resistance against high temperature inflator gases.
Solution Approach 2:
The patent creates a composite structure where a three-dimensional construction woven fabric (providing both mechanical strength and thermal insulation) is combined with an elastomer resin coating (providing enhanced heat resistance). This composite approach simultaneously addresses both mechanical strength requirements and heat resistance needs, outperforming simple fabric stacking while protecting the base fabric from high temperature gases.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The coated fabric effectively withstands hot gases, providing excellent heat resistance and flexibility, reducing damage to the air-bag main body fabric during inflator gas expansion, while maintaining cost-effectiveness and mechanical properties.
Implementation Method 1
an amount of the elastomer resin layer being 50 to 500 g/m 2
Implementation Method 2
a three dimensional construction woven fabric which is selected from a three-layer woven fabric and a four-layer woven fabric
Data Source
Figure 1
Figure 2(a)~2(b)
AI summary
The present invention addresses the problem of providing a cloth which, when used as an air bag main body cloth, does not undergo the damage caused by a high-temperature gas generated from an inflater, and therefore has high heat resistance and is suitable for an air bag. The means for solving the problem is a coated cloth for an air bag, which is produced by applying an elastomer resin layer on at least one surface of a three-dimensional woven fabric in an amount of 50 to 500 g/m2 per one surface, said coated cloth being characterized by having void spaces formed therein, wherein the void content in the coated cloth is 15 to 60%. Preferably, the coated cloth is used in applications in which the coated cloth is attached onto the periphery of an inflater connection opening in an air bag.