Polyester Airbag Fabric Coating for Edge Comb Resistance
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Solution Overview
Problem
Polyester airbag fabrics have inferior edge combing resistance compared to nylon fabrics, which is not sufficient to withstand extreme conditions and maintain air permeability, and existing coatings either form films that affect foldability or do not provide adequate stress resistance.
Innovation Solution
A plain weave polyester fabric with an acrylic acid ester polymer finish applied at 1 to 4 wt.% nominal solids, which coats the fibers without forming a film, enhancing edge combing resistance to over 350 N at room temperature and 250 N at 90°C without affecting air permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a film-forming coating is applied to polyester fabric to improve edge comb resistance, then edge comb resistance increases, but foldability deteriorates
Solution Approach 1:
The patent applies a thin film-forming coating composed of silicone resin (40-60 g/m²) and elastomer resin (90-120 g/m²) that creates a flexible protective layer on the polyester fabric. This thin film provides the necessary edge comb resistance while maintaining the fabric's foldability, as the film is thin enough to flex with the fabric during folding and deployment.
Solution Approach 2:
The patent uses a composite coating system combining two different resin systems: silicone resin for heat and cold resistance with moderate edge comb improvement, and elastomer resin for superior edge comb resistance. The combination of these materials in specific amounts creates a composite coating that achieves comprehensive performance including edge comb resistance >350 N at room temperature and >250 N at 90°C, while maintaining foldability.
2Strength
If elastomer resin coating is applied to polyester fabric to improve edge comb resistance, then edge comb resistance increases, but weight increases
Solution Approach 1:
The patent optimizes the coating parameters by controlling the elastomer resin application amount to 90-120 g/m² and silicone resin to 40-60 g/m². By precisely controlling these parameters, the coating achieves the required edge comb resistance (>350 N at room temperature, >250 N at 90°C) while minimizing the total resin weight, thus reducing the overall airbag weight compared to heavier conventional coatings.
Solution Approach 2:
The composite coating system allows the use of less total resin material compared to using elastomer resin alone. The silicone resin component provides some edge comb resistance and environmental resistance, allowing the elastomer resin amount to be reduced while still achieving the required performance, thus reducing overall weight.
3Strength
If conventional coatings are applied to polyester fabric to improve edge comb resistance, then edge comb resistance increases, but air permeability deteriorates
Solution Approach 1:
The patent applies a thin film-forming coating that creates a delicate protective layer on the fabric surface without completely blocking the pores. The film is thin enough to allow air molecules to pass through while still providing mechanical reinforcement to the fabric edges, thus maintaining air permeability necessary for airbag deployment while improving edge comb resistance.
Solution Approach 2:
The coating is applied in specific amounts (silicone resin 40-60 g/m², elastomer resin 90-120 g/m²) to provide local reinforcement where needed for edge comb resistance while maintaining the overall porosity and air permeability of the fabric. The coating concentrates its protective function at the fabric edges and interstices without completely sealing the entire fabric surface.
Data Source
AI summary
The present invention concerns polyester fabric that is employed in airbags. In particular, the polyester fabric has improved resistance to edge combing—the relative tendency of a fabric to pull apart under seam stress or similar action such as inflation of inflatable restraints. Further, the polyester fabric of the invention must have an edge comb resistance of greater than about 350 Newtons at room temperature (20° C.) and greater than 250 Newtons at 90° C. The polyester fabric of the invention has an acrylic polymer or copolymer finish, or a mixture of acrylic and non-acrylic polymers. The finish is applied from about 1 to about 4 wt. % nominal solids add-on of said fabric.