One-piece woven, side impact airbag having two layer coating
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Solution Overview
Problem
Current airbag coating compositions and textiles face challenges in reducing gas permeability while maintaining cost-effectiveness and fabric stability, especially with reduced yarn construction, leading to increased air leakage and compromised performance.
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 without penetrating to the inner side of the fabric.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-layer coating is applied to reduce gas permeability, then gas barrier performance is improved, but coating uniformity and adhesion are compromised due to surface roughness and holes
Solution Approach 1:
The coating system is divided into two distinct layers: a primer layer that provides foundational adhesion and a gas barrier layer that delivers uniform gas permeability control. This segmentation allows each layer to optimize its specific function without compromising the other, resolving the contradiction between gas barrier performance and coating uniformity.
Solution Approach 2:
The primer layer is applied first to create a stable, adherent base that fills surface irregularities and prepares the textile substrate. This preliminary action ensures that the subsequent gas barrier layer can be applied uniformly, achieving both good adhesion and consistent gas barrier performance.
2Ease of manufacture
If reduced yarn construction is used to lower cost, then manufacturing cost is reduced, but air leakage increases and gas holding capability deteriorates
Solution Approach 1:
The invention uses a composite coating system combining a primer layer and a gas barrier layer with different functional properties. This composite structure allows reduced yarn construction to be used while the coating composite compensates for the increased permeability, maintaining gas holding capability at lower costs.
3Reliability
If a thick coating layer is applied to seal all holes and roughness, then gas barrier performance is improved, but coating material consumption and manufacturing cost increase
Solution Approach 1:
By dividing the coating into two specialized layers, the system achieves effective gas barrier performance with optimized material usage. The primer layer handles adhesion and surface preparation, while the gas barrier layer focuses on gas permeability control, preventing excessive material consumption that would occur with a single thick layer.
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 cost-effectiveness and fabric stability, even with reduced yarn construction, thereby enhancing the gas holding capabilities of airbags.
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.