Process for forming an airbag
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Solution Overview
Problem
Current airbag coating compositions and textiles face challenges in achieving optimal gas permeability and adhesion, particularly with reduced yarn constructions, leading to increased permeability and potential coating strikethrough.
Innovation Solution
A coating composition featuring a primer layer with a first thermoplastic polymer and a gas barrier layer with a second thermoplastic polymer, applied to a woven textile substrate, where the primer layer has surface roughness and holes that the gas barrier layer fills, reducing air permeability and preventing coating penetration to the inner side.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If reduced yarn construction is used to lower cost and weight, then manufacturing cost and weight are reduced, but gas permeability increases and coating adhesion deteriorates
Solution Approach 1:
The coating system is divided into two distinct layers: a primer layer containing first thermoplastic polymer particles that penetrates and adheres to the textile substrate, and a gas barrier layer containing second thermoplastic polymer particles that provides the gas blocking function. This segmentation allows each layer to be optimized for its specific function while working together to solve the contradiction between reduced construction and gas holding ability.
Solution Approach 2:
The invention uses a composite coating structure with two different thermoplastic polymer systems. The primer layer uses polymers with specific glass transition temperatures and particle sizes optimized for substrate penetration and adhesion, while the gas barrier layer uses polymers optimized for gas blocking. This composite approach allows the coating system to achieve both good adhesion on reduced construction fabrics and effective gas holding.
2Ease of manufacture
If reduced yarn construction is used, then cost and weight are reduced, but coating adhesion and gas barrier performance worsen
Solution Approach 1:
The primer layer is applied first to prepare the substrate surface by penetrating into the textile structure and forming anchoring points. This preliminary action creates an optimized surface for the subsequent gas barrier layer, ensuring both adhesion and uniformity. The primer layer's roughness and holes are intentionally designed to be filled by the gas barrier layer, preventing strikethrough and ensuring consistent performance.
Solution Approach 2:
Different regions of the coating system have different properties optimized for their specific functions. The primer layer has higher penetration capability and roughness, while the gas barrier layer has smoother, more uniform properties optimized for gas blocking. This local quality differentiation allows the overall system to achieve both cost-effectiveness through reduced construction and high manufacturing precision in gas barrier integrity.
3Strength
If primer layer with holes is used for adhesion, then coating adhesion improves, but gas permeability increases
Solution Approach 1:
The coating is segmented into two layers with distinct functions: the primer layer contains controlled holes and roughness that provide adhesion pathways to the substrate, while the gas barrier layer is positioned to fill and seal these pathways. This segmentation allows the system to maintain both adhesion (through primer holes) and gas barrier integrity (through gas barrier layer sealing).
Solution Approach 2:
The gas barrier layer acts as an intermediary that seals the pathways created by the primer layer. The primer layer first establishes adhesion by penetrating and anchoring to the substrate, creating a rough surface with holes. The gas barrier layer then fills these holes and provides the gas blocking function, mediating between the adhesive requirements of the primer and the gas barrier requirements of the overall system.
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 solution effectively reduces air permeability to levels comparable to traditional high construction fabrics, while maintaining the benefits of reduced yarn construction, such as lower cost and weight, and providing improved gas holding properties.
Implementation Method 1
The gas barrier layer contains a second thermoplastic polymer and at least partially fills in the surface roughness and holes of the primer layer
Data Source
AI summary
An airbag textile containing a woven textile having an inner side and an outer side, a primer layer on the outer side of the textile and a gas barrier layer on the primer layer. The primer layer contains a first thermoplastic polymer and has a surface roughness and a plurality of holes extending at least partially through the thickness of the primer layer. The gas barrier layer contains a second thermoplastic polymer and at least partially fills in the surface roughness and holes of the primer layer.