Polyester Sewing Thread for Airbag Seams
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Solution Overview
Problem
Existing polyester sewing threads for airbags lack sufficient strength, heat resistance, and stability under high temperature and pressure conditions, leading to issues like melting and gas leakage when the airbag is unfolded.
Innovation Solution
A polyester sewing thread is developed by doubling and twisting polyester yarns with specific properties, such as high tensile strength, elongation, and heat resistance, and bonding them using methods like in-bonding, out-bonding, or in-and-out bonding to enhance durability and heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If existing polyester sewing thread is used for airbag, then cost is reduced compared to nylon or aramid threads, but the thread lacks sufficient strength, heat resistance, and stability under high temperature and pressure conditions
Solution Approach 1:
The patent applies composite materials by combining polyester yarn with bonding agents (such as polyester resin or polyurethane) to create a sewing thread that maintains the cost advantages of polyester while achieving the strength and heat resistance properties of composite structures. The bonding agent forms a matrix that binds polyester filaments together, creating a composite thread with enhanced mechanical properties and thermal stability.
Solution Approach 2:
The patent employs parameter changes by modifying the physical and chemical parameters of polyester yarn through specific processing conditions. This includes controlling yarn twist levels, bonding agent concentration, heat treatment temperatures, and moisture content to transform ordinary polyester yarn into high-performance sewing thread capable of withstanding airbag deployment conditions while maintaining cost effectiveness.
2Strength
If polyester yarn with high tensile strength is used, then strength is improved, but heat resistance and stability under high temperature conditions deteriorate
Solution Approach 1:
The patent uses composite materials by integrating polyester yarn with heat-resistant bonding agents that form a protective matrix. This composite structure allows the thread to simultaneously achieve high tensile strength from the polyester filaments and heat resistance from the bonding agent matrix, resolving the contradiction between strength and heat resistance.
Solution Approach 2:
The patent applies beforehand cushioning by incorporating heat-resistant bonding agents and performing pre-deployment heat treatment to prepare the thread structure for high-temperature conditions. The bonding agent creates a protective structure in advance that prevents thermal degradation during airbag deployment, cushioning against the harmful effects of high temperature before they occur.
3Reliability
If bonding methods like in-bonding or out-bonding are applied, then durability and heat resistance are enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent applies merging by combining the bonding agent application step with existing yarn processing operations. Instead of adding separate complex bonding equipment, the bonding agent is incorporated during standard yarn manufacturing or winding processes, merging multiple functions into existing production lines and minimizing manufacturing complexity while achieving enhanced durability and heat resistance.
Solution Approach 2:
The patent employs self-service by using bonding agents that automatically bond polyester filaments together through their inherent properties, such as self-curing resins or thermoplastic materials that bond upon contact with heat or moisture. This eliminates the need for complex external bonding equipment or multi-step processes, as the bonding agent performs the bonding function autonomously.
4Ease of manufacture
If polyester thread is used instead of nylon, then cost is reduced, but the thread melts and deteriorates under high temperature and pressure gas from the inflator
Solution Approach 1:
The patent applies composite materials by creating a layered structure where polyester yarn is embedded in a heat-resistant bonding agent matrix. This composite structure protects the polyester filaments from direct exposure to high-temperature inflator gas, preventing melting and deterioration while maintaining the cost advantages of polyester over nylon.
Solution Approach 2:
The patent uses beforehand cushioning by applying heat-resistant bonding agents and performing pre-deployment thermal treatment to prepare the thread structure for high-temperature exposure. The bonding agent creates a protective barrier in advance that cushions the polyester filaments against thermal damage during inflator operation, preventing melting and deterioration.
Data Source
AI summary
A polyester sewing thread usable for a fabric for an airbag and a cushion for an airbag is provided. The polyester sewing thread is obtained by doubling and twisting a specific polyester yarn including a plurality of polyester filaments, and bonding the polyester yarn in the manner of in-bonding, out-bonding, or in-and-out bonding. A method for producing the thread is also disclosed.