阅读说明：本技术 整体编织式车辆乘员保护装置及其制造方法 (Integrally woven vehicle occupant restraint device and method of making same ) 是由 B·R·希尔 于 2019-02-27 设计创作，主要内容包括：一种用于制造整体编织式(OPW)安全气囊的方法,该方法包括提供具有纺丝油剂的纱线、以及将纱线整经到织机的至少一个梁上。将纱线同时编织成织物安全气囊结构,该织物安全气囊结构具有限定可充气体积的两层部分和形成界定可充气体积的接缝的单层部分。对安全气囊结构进行涂覆,以覆盖纺丝油剂。切割经涂覆的安全气囊结构,以限定整体编织式安全气囊。(A method for manufacturing an integrally woven (OPW) airbag includes providing a yarn having a spin finish, and warping the yarn onto at least one beam of a loom. The yarns are simultaneously woven into a fabric airbag structure having two layer portions defining an inflatable volume and a single layer portion forming a seam bounding the inflatable volume. The airbag structure is coated to cover the spin finish. The coated airbag structure is cut to define a unitary woven airbag.)

1. A method for manufacturing an integrally woven (OPW) airbag, the method comprising:

providing a yarn having a spin finish thereon;

warping the yarn onto at least one beam of a loom;

simultaneously knitting yarns into a fabric airbag structure having two layer portions defining an inflatable volume and a single layer portion forming a seam bounding the inflatable volume;

coating the airbag structure to cover the spin finish; and

cutting the coated airbag structure to define the OPW airbag.

2. The method of claim 1, wherein the coating comprises silicone.

3. The method of claim 1, wherein the coating comprises a polyvinyl chloride (PVC) primer.

4. The method of claim 1, wherein the coating layer comprises a phosphate-based flame retardant material.

5. The method of claim 1, wherein the airbag structure is coated without scouring the yarn.

6. The method of claim 1, wherein the airbag structure is coated without washing the yarn.

7. The method of claim 1, wherein the airbag structure is coated without drying the yarn.

8. The method of claim 1, wherein the step of warping the yarn to a loom comprises warping the yarn to at least one beam of an air jet loom or rapier loom.

9. The method of claim 1, wherein the coating has a T-peel adhesion to the airbag structure of from about 0.78 to about 1.13.

10. The method of claim 1, wherein the spin finish comprises about 1.0% -3.0% of the OPW airbag weight.

11. The method of claim 1, wherein the airbag structure forms a side curtain.

12. An OPW airbag comprising:

a fabric structure having two layer portions defining an inflatable volume and a single layer portion forming a seam bounding the inflatable volume, the fabric structure comprising: knitting yarns, wherein spinning oil is arranged on the knitting yarns; and

a coating covering the spin finish.

13. The airbag of claim 12, wherein said coating comprises silicone.

14. The airbag of claim 12, wherein said coating comprises a PVC primer.

15. The airbag of claim 12, wherein said coating layer comprises a phosphate-based flame retardant material.

16. The airbag of claim 12, wherein said coating has a T-peel adhesion to said fabric structure of from about 0.78 to about 1.13.

17. The airbag of claim 12, wherein said spin finish comprises about 1.0% to 3.0% of the weight of said OPW airbag.

18. The airbag of claim 12, wherein said fabric structure forms a side curtain.

Technical Field

The present invention generally relates to an apparatus for assisting in protecting an occupant of a vehicle. More particularly, the present invention relates to an integrally woven (OPW) inflatable airbag and a method of manufacturing the same.

Background

It is known to inflate inflatable vehicle occupant protection devices in the event of a vehicle collision to help protect a vehicle occupant. Examples of inflatable vehicle occupant protection devices include driver and passenger frontal airbags, side airbags, curtain airbags, inflatable safety belts, inflatable knee bolsters, and inflatable headliner panels.

The inflatable vehicle occupant protection device may have various configurations. For example, inflatable vehicle occupant protection devices may be constructed of stacked woven panels (panels) that are interconnected by means such as stitching or ultrasonic welding to form a connection or seam that helps define the inflatable volume of the protection device. As another example, an inflatable vehicle occupant protection device may have an integral knit (OPW) construction in which overlapping panels are simultaneously knit. The panels are woven together to form a connection or seam that helps define the inflatable volume of the OPW protection device.

Current manufacturing methods for OPW airbags involve multi-step processes that are time consuming and expensive. To this end, fig. 1A shows a conventional manufacturing process for producing yarns that are woven to form current OPW protection devices. In fig. 1A, scrap of a plurality of different polymers (e.g., nylon and polyethylene terephthalate (PET)) is mixed and placed in a scrap hopper. The mixture was pumped to a single screw extruder which led to a spinneret. The spinneret further extrudes the mixture into a series of yarn filaments via melt spinning.

The spun filaments are gathered at their ends opposite the spinneret to form a strand of yarn. In the melt spinning process, air is applied to the filaments in a quenching operation. This will allow the filaments to cool and solidify. However, the filaments are not electrically conductive and therefore static electricity may be a problem during the spinning/gathering step. To overcome this problem, spin finishes are applied (e.g., sprayed) to the spun filaments by an applicator before they are fully gathered to form strands.

Spin finishes are usually produced by emulsifying alkyl chain molecules with the aid of surfactants in an aqueous medium. In some examples, the spin finish is oil-based and comprises about 0.5% -1.0% of the weight of the OPW protection device. The type of spin finish used is based on the type of post-treatment the strand will undergo. In any event, the spin finish provides surface lubrication, antistatic action, and improves contact/cohesion between filaments. The spin finish coating may also provide an interface between the filaments and any other contacting surface of the loom (e.g., guide rolls, hot plates, knitting needles, etc.) (see: 1) Review on the Manufacturing Process of Polyester-PET and Nylon-6 finishing Yarn by Sahas Bansal and Pramod Raichurkay, International journal of Textile Engineering and Process 2 edition (2Intl.J.L.on Textile Engineering and Process) pp.23-28 (2016); and 2) Manufactured Fibre Technology by Gupta, V.B. and Kothari V.K. (Manufactured Fibre Technology), page 140 (Chapman & Hall Press 1997).

The strand (the yarn filaments of which are coated with a spin finish) is passed through take-up godet and friction roller to draw the strand. Speed V of godet roller and roller₁-V₃Successively, this reduces the longitudinal section of the thread strand while lengthening the thread strand. The drawing process also aligns the yarn molecules in a more parallel arrangement and brings the molecules closer together, thereby increasing crystallization and orientation. In any case, the thread strand is wound on a winder.

Referring to fig. 1B, the yarn (in the form of a thread strand) is removed from the winder and placed on at least one beam of the loom (also known as a warp). The yarns are then woven simultaneously, in certain locations as separate superposed layers of material and in other locations as a single layer of material, to produce an OPW fabric panel. In one example, the stacked layers form the inflatable chamber and the single layer forms the seam.

During weaving, the warp and weft yarns wear as they pass over each other. On weaving looms, the warp yarns are subjected to several types of stress-related effects, such as cyclic strain, deflection and wear on the various loom parts, and friction between the yarns. In other words, both the loom and other yarns may have an effect on the level of stress applied to the warp yarns. This may vary depending on, for example, the weave pattern, weave density, etc.

Prior to knitting, a film is applied to the yarns as a precaution/precaution in anticipation of these induced stresses, which helps to promote yarn integrity and protect the yarns during the knitting process. This film application process is known as sizing and may be accomplished, for example, by dipping the yarn into the film or spraying the yarn. Different types of water soluble polymers known as textile sizing/chemicals can be used. Exemplary sizing agents include modified oils, starch slurries, gelatin, polyvinyl alcohol (PVA), carboxymethyl cellulose (CMC), and acrylates. Waxes may be added to the sizing to reduce the fraying of the warp yarns. In any event, the sizing typically comprises about 1.0% to 3.0% by weight of the OPW fabric roll.

The film applied in the sizing step protects the yarn from abrasion and increases the breaking strength, elasticity and smoothness of the yarn while reducing the static and hairiness of the yarn. The sizing thus provides structural integrity to the yarn during the knitting process. The degree of strength enhancement depends on the adhesion between the fiber and the sizing, the amount of sizing penetration, and the degree of sizing encapsulation of the yarn.

In the current process, OPW fabric panels are rolled up and washed to remove the sizing film from the yarn. This removal process is known as scouring and can be time consuming and expensive. To this end, the scouring process may comprise repeatedly washing the OPW fabric in the sink with soap and water at elevated temperature. Once this is done, it is desirable to apply an outer coating and/or laminate to the washed OPW fabric to improve permeability, flame retardancy, etc. of the airbag ultimately formed from the OPW fabric.

However, as noted above, yarn spin finishes are typically oil-based, which is not conducive to receiving or adhering the type of exterior coating/laminate desired for airbag fabrics. That is, if only the size is removed during scouring, no external coating/lamination can be applied to the spin finish coated yarn. In other words, the spin finish disadvantageously prevents the airbag from receiving its outer coating/laminate. Accordingly, the scouring process is configured to also remove the spin finish from the yarn, thereby allowing the yarn to receive the outer coating/laminate.

Once the sizing and spin finish is removed from the yarn, the washed OPW fabric is dried and/or heat-set. In one example, this includes vacuum removing excess water from the fabric and then drying the fabric with heat. The outer coating and/or laminate may then be applied directly to the spin finish-free yarn of the dried roll. The coated roll is then cut using a marker yarn to separate the roll into individual OPW airbags.

Disclosure of Invention

According to one aspect, a method for manufacturing an integrally woven (OPW) airbag includes providing a yarn having a spin finish, and warping the yarn onto at least one beam of a loom. The yarns are simultaneously woven into a fabric airbag structure having two layer portions defining an inflatable volume and a single layer portion forming a seam bounding the inflatable volume. Coating the airbag structure to cover the spin finish. Cutting the coated airbag structure to define the unitary woven airbag.

According to another aspect, an OPW airbag includes a fabric structure having a two-layer portion defining an inflatable volume and a single-layer portion forming a seam bounding the inflatable volume, the fabric structure including a woven yarn having a spin finish disposed thereon. And the coating covers the spinning oil agent.

According to another aspect, alone or in combination with any other aspect, the coating comprises silicone.

According to another aspect, alone or in combination with any other aspect, the coating comprises a polyvinyl chloride (PVC) primer.

According to another aspect, alone or in combination with any other aspect, the coating layer comprises a phosphate-based flame retardant material.

According to another aspect, alone or in combination with any other aspect, the airbag structure is coated without scouring the yarns.

According to another aspect, alone or in combination with any other aspect, the airbag structure is coated without washing the yarn.

According to another aspect, alone or in combination with any other aspect, the airbag structure is coated without drying the yarn.

According to another aspect, alone or in combination with any other aspect, the step of warping the yarn to a loom comprises warping the yarn to at least one beam of an air jet loom or rapier loom.

According to another aspect, alone or in combination with any other aspect, the coating has a T-peel adhesion to the airbag structure of from about 0.78 to about 1.13.

According to another aspect, alone or in combination with any other aspect, the spin finish comprises about 1.0% -3.0% of the weight of the OPW airbag.

According to another aspect, alone or in combination with any other aspect, the airbag structure forms a side curtain.

Drawings

Fig. 1A is a schematic illustration of a current yarn manufacturing process.

Fig. 1B is a flow chart illustrating a current method of forming a protective device from the yarn made by the process of fig. 1A.

FIG. 2 is a schematic diagram according to an exemplary apparatus for assisting in protecting an occupant of a vehicle.

Fig. 3 is a side view of a curtain airbag of the device of fig. 2.

FIG. 4 is a cross-sectional view taken generally along line 4-4 in FIG. 3, illustrating the weaving of a portion of the curtain airbag.

Fig. 5 is a side view of a roll of fabric material used to form the curtain airbag of fig. 3.

Fig. 6 shows the roll of fig. 5 in an unrolled state.

Fig. 7 is a flow chart illustrating a method of forming the apparatus of fig. 2.

Fig. 8 is a graph illustrating the deployment characteristics of a curtain airbag formed in accordance with the present invention.

Detailed Description

The present invention generally relates to an apparatus for assisting in protecting an occupant of a vehicle. More particularly, the present invention relates to an OPW inflatable airbag and a method of manufacturing the same. The method comprises weaving OPW airbags on an air jet or rapier loom and then coating and/or laminating the airbags to improve their impermeability. Advantageously, the method allows for the application of coatings and/or laminates to OPW airbags under weaving conditions without the need to scour, heat, wash or dry the fabric.

Fig. 2 and 3 illustrate an exemplary configuration of the apparatus 10 for assisting in protecting one or more occupants 104 of the vehicle 12. The apparatus 10 having this exemplary configuration is an inflatable vehicle occupant protection device 14 that is inflatable/deployable between the side structure 82 of the vehicle 12 and the vehicle occupant(s) 104. In this configuration, the inflatable vehicle occupant protection device 14 may also be referred to as a curtain airbag 80 that may cover at least two of the a-pillar, B-pillar, and C-pillar of the vehicle 12. However, the inflatable vehicle occupant protection device 14 may have alternative configurations.

For example, the inflatable vehicle occupant protection device 14 may be configured for deployment at any known location of the vehicle (e.g., steering wheel, door, front seat, etc.). Other vehicle occupant protection devices (not shown) that may be constructed in accordance with the present invention may include, for example, side impact airbags, inflatable seat belts, inflatable knee bolsters, and inflatable headliners. Thus, the apparatus 10 may be used to protect a driver and/or any number of passengers in the vehicle 12. In the exemplary configuration of fig. 2, the inflatable vehicle occupant protection device 14 is a curtain airbag 80 for the passenger side 20 of the vehicle 12. A similar or identical curtain airbag (not shown) may be provided on the driver's side of the vehicle 12.

The curtain airbag 80 is mounted adjacent to side structures 82 and a roof 84 of the vehicle 12. The inflator 86 is fluidly connected to the curtain airbag 80 via a fill tube 88. Inflator 86 may have a known configuration suitable for inflating curtain airbag 80. For example, inflator 86 may contain a quantity of pressurized inflation fluid (not shown) stored in gaseous form for inflating curtain airbag 80. Alternatively, the inflator 86 may contain a combination of pressurized inflation fluid and a combustible material for heating the inflation fluid, or may be a pyrotechnic inflator that uses the combustion of a gas generant material to produce the inflation fluid. As a further alternative, inflator 86 may be of any suitable type or configuration for supplying a medium for inflating curtain airbag 80.

The fill tube 88 includes openings (not shown) through which inflation fluid is directed into the curtain airbag 80. The fill tube 88 may be constructed of any suitable material, such as plastic, metal, or fabric. Alternatively, the fill tube 88 may be omitted, in which case the inflator 86 may be connected directly to the curtain airbag 80 (not shown).

Referring to fig. 3, in this exemplary configuration, curtain airbag 80 includes integrally formed panels 90 that cooperate to define an inflatable volume 94. The seam 92 extending along the panel 90 helps to define an inflatable chamber 96 within the inflatable volume 94 and a non-inflatable portion 98 of the curtain airbag 80. Curtain airbag 80 has an OPW configuration in which the airbag is a single unitary woven article having portions woven as separate single layers of material (i.e., panel 90) and portions woven as a single layer (i.e., seam 92) at the same time. The OPW configuration may be particularly beneficial in curtain airbag configurations because it may provide long duration inflation and high pressurization capabilities, which may be desirable for this and other types of airbags.

The vehicle 12 includes one or more sensors (shown schematically at 100 in fig. 2) for sensing the occurrence of an event in which inflation of the curtain airbag 80 is desired. Examples of such events include a vehicle collision, such as a front collision, a rear collision, a side collision, an offset collision, or an angled collision, a vehicle rollover, or both. Upon sensing this event, the sensor 100 provides an electrical signal(s) to the inflator 86 (or a controller connected thereto) via a lead 102, which causes the inflator to actuate and discharge fluid under pressure into the inflatable volume 94 of the curtain airbag 80 in a known manner.

The particular OPW configuration of curtain airbag 80 is by way of example only. The present invention is suitable for implementation in OPW airbag structures having any configuration (e.g., multiple inflatable sections, a single inflatable section, no inflatable sections, and any number (including zero) of seams).

Curtain airbag 80 is inflatable from a deflated storage state shown in phantom at 80' in fig. 2 to an inflated deployed state shown in solid at 80 in fig. 2. More specifically, curtain airbag 80 inflates away from roof 84 under pressure of inflation fluid from inflator 86 to a position between side structure 82 of vehicle 12 and any occupant 104 of the vehicle. Curtain airbag 80, when inflated, helps protect vehicle occupant(s) 104 in the event of a collision with vehicle 12, a vehicle rollover, or both. Curtain airbag 80, when inflated, also helps to absorb impact energy through the curtain airbag and to distribute the impact energy over a large area of the curtain airbag.

Curtain airbag 80 has an OPW construction that promotes seam integrity, makes packaging easier and more compact, and provides uniform shrinkage in the weft direction. To achieve this, the OPW configuration of curtain airbag 80 is configured such that certain portions of the airbag are woven with different weave patterns. The curtain airbag 80 is described with reference to its length measured in the warp direction (left to right as viewed in fig. 3) and its width measured perpendicular to the length and in the weft direction (top to bottom as viewed in fig. 3).

Referring to fig. 4, panels 90 each include a plurality of warp yarns or "ends" indicated at 110. The panels 90 also each include a plurality of weft yarns or "pick" indicated at 112. Warp yarns 110 and weft yarns 112 are oriented perpendicular to each other. Warp yarns 110 are interwoven with weft yarns 112 in an alternating or "over and under" manner. In the area of the curtain airbag 80 other than the seam 92, each panel 90 is woven in a one-by-one (1 × 1) weave pattern (referred to in the art as a "plain weave" pattern). As shown in FIG. 4, in this plain weave pattern, a single warp yarn 110 weaves around a single weft yarn 112. Since the curtain airbag 80 has an OPW configuration, a plain weave is referred to in the art as a double plain weave.

The weave pattern includes what is known in the art as "float". "float" refers to the number of adjacent warp yarns 110 or weft yarns 112 over or under which a weft or warp yarn extends, respectively. The number of floats in a woven fabric will vary depending on the particular weave type of fabric being woven. For example, a plain weave fabric includes a single float because the warp and weft yarns pass over and under a single weft yarn and a single warp yarn, respectively. As another example, a2 x 2 woven fabric includes two floats because the warp and weft yarns pass over and under two adjacent weft and warp yarns, respectively.

Seam 92 has a configuration that varies according to the plain weave pattern to provide the desired functionality for the particular seam. In the portion shown in FIG. 4, seam 92 has a non-plain one-by-two (1 × 2) weave pattern (hereinafter referred to as a low float weave pattern). A low float weave pattern is shown and described in U.S. patent publication No. 2006/0284403, which is incorporated herein by reference in its entirety.

In this 1 x 2 weave pattern, the warp yarn 110 indicated at 122 is a first warp yarn, and the warp yarn indicated at 124 is a second warp yarn. Yarns 122 and 124 are interwoven alternately over and under each set of two weft yarns 112. Each warp yarn 110 weaves on opposite sides of each weft yarn 112. It should be appreciated, however, that seam 92 may have an alternative non-plain weave pattern, examples of which are indicated below.

In addition to those floats that typically occur in a weave pattern, floats may also occur in areas of the fabric where different weave patterns interface with one another. This is particularly important in OPW airbag designs where the double layer plain weave interfaces with the non-plain weave pattern, for example, at the transition between the inflatable chamber 96 and the seam 92. The amount and location of these excess floats is determined by the weave pattern of the fabric at the interface. While there may inevitably be excess floats at the interface, the weave pattern may be configured to a large extent to help place the desired number of floats at the desired locations at the interface between the weave patterns.

In the exemplary configuration, the curtain airbag 80 includes a plain woven portion and a non-plain woven portion. A portion 200 (indicated as not having cross-hatching) of the curtain airbag 80 shows a portion of the woven fabric panel 90 that is woven in a plain weave as a separate layer. The portion of the curtain airbag 80 indicated by cross-hatching at 202 illustrates the portions of the woven panel 90 that are woven together with a1 x 2 low float weave pattern to help form the seams 92 of the curtain airbag 80. The portion of the curtain airbag 80 shown in phantom at 204 illustrates the portions of the woven panel 90 that are woven together with "counting tubes" (gegenschlauch) seams to help form additional seams 92 of the curtain airbag 80. The portions 202, 204 forming the seam 92 may have alternative weave patterns, one or more of: a3 x 3 panama weave pattern, a basket weave pattern, an alternative basket weave pattern, and/or a weave repeat pattern.

The portion indicated by cross-hatching at 206 extends around the entire perimeter 208 of curtain airbag 80 and shows the portions of panel 90 that are woven together with the BST 99 weave pattern. The portion of curtain airbag 80 indicated by cross-hatching at 210 is disposed along the top of perimeter 208 and at the rear end of the curtain airbag. Each portion 210 includes one or more openings 207 that receive fasteners (not shown) to help secure curtain airbag 80 to vehicle 12 adjacent roof 84. Portion 210 shows the portions of panel 90 that are woven together with a ripstop weave pattern. The portions of curtain airbag 80 indicated by cross-hatching at 212 are disposed within the perimeter of some portions 210 and represent portions of panel 90 that are woven together with a BST 24 weave pattern. Portion 212 extends around opening 207 in portion 210.

The portion of curtain airbag 80 shown by cross-hatching at 214 is disposed at the front end of the curtain airbag and shows the portion of panel 90 that is woven together with a3 x 3 panama/square flat weave pattern. Portions 216 of the curtain airbag 80 are provided at the front and rear ends of the curtain airbag and represent portions of the panel 90 that are woven together with a measuring mark (measuremarker) weave pattern. It will be appreciated that any of the portions 206, 210, 212, 214, 216 may be present in alternative weave patterns known in the art.

The plain woven portion and the non-plain woven portion of the panel 90 may have different gas permeabilities. For example, the non-plain weave portion may have a higher gas permeability than the plain weave portion due to a looser weave and a higher tendency for yarn displacement in the non-plain weave. To this end, and with reference to fig. 3, an outer coating and/or laminate 190 may be applied to the panel 90 to help control and maintain the gas permeability of the panel at a desired level. The curtain airbag 80 can thus maintain the improved seam integrity and packaging provided by the plain and non-plain woven portions described above without sacrificing gas permeability.

Coating 190 may be any coating suitable for providing the desired permeability characteristics. For example, coating 190 may comprise a urethane or silicone material that is gas impermeable or substantially gas impermeable. Possible coatings that may be used in the present invention include, but are not limited to, CS2 coatings available from Bradford Industries (Lowell, MA) in luerl. The CS2 coating may be silicone coated nylon and/or polyester, and may include a PVC primer. To help prevent blocking, a urethane coating based on polyether or polyester may be applied as an additional coating, or it may be mixed with the coating 190. Liquid-based flame retardants such as phosphates (e.g., phosphoric acid), 1, 3-phenylene tetraphenyl ester (sold under the trade name fyroflex RDP (ICL-IP, usa), st-louis, MO, st-louis inc.), or aryl phosphates (also sold under the trade name Lindol CDP (also from ICL-IP usa)) may also be added to the coating 190.

The panel 90 used to construct the curtain airbag 80 is formed from a continuous roll of web material 150 (shown in fig. 5 (rolled) and 6 (unrolled)). The weave pattern for the woven panel 90 is selected to facilitate processing of the roll of woven material 150. Once the roll 150 is produced and any coating(s) 190 applied, the panel 90 is cut from the roll to define the curtain airbag 80. Such cutting may be performed by a cutter (not shown) that uses a vision system to help improve cutting accuracy.

The vision system searches for marks on the web of the roll 150 that allow the system to determine whether the cut is in place. Typically, these markings include intersecting marking yarns 213 (fig. 6) woven into the fabric of panel 90 when roll 150 is in the unwound state. The marking yarn 213 has a different color than the rest of the fabric on the roll 150 and is therefore visually prominent. The marking yarn 213 is visible on a first side 152 of the roll 150 and white on an opposite second side 151 of the roll.

To weave the intersecting marking yarns 213, warp bundles having a marking color are installed at one or more warp positions on the loom. To form the marker yarn 213 intersection, the yarn is inserted at the appropriate weft position along the length of the roll 150 and at the appropriate warp position. As a result, a grid of warp and weft marker yarns 213 is formed on the first side 152 of the roll 250. Marking yarn 213 may be, for example, 470dtex black marking yarn that can be recognized by a vision system.

In one exemplary method 300 for forming curtain airbag 80 shown in fig. 7, a yarn including a spin finish is provided at step 310. At step 320, the yarn is beamed onto at least one beam of a loom (e.g., an air jet loom or rapier loom). At step 330, the warped yarns are woven on a loom to form a roll 150 having an OPW configuration (see fig. 5).

The fabric at this stage is in the "loom state" because the yarn does not change its state on the loom once weaving is over. In other words, the yarn still includes spin finish. At step 340, the roll of loom state yarn 150 is coated with a coating 190 that covers or encapsulates the spin finish on the yarn. It should be appreciated that coating 190 may be in direct contact with the spin finish, or separated from the spin finish by an intermediate coating (not shown) added to provide desired properties to coated roll 150. Regardless, the coating 190 covers the spin finish. In any case, at step 350, the coated roll 150 is cut into the pattern shown in fig. 6 to define curtain airbag 80.

The use of a specific coating 190 and an air jet or rapier loom to form OPW curtain airbag 80 in accordance with the present invention eliminates several of the steps described above in connection with current OPW protection manufacturing processes. In particular, the use of an air-jet loom or rapier loom and the coating 190 described and contemplated herein eliminates sizing, scouring and drying of the yarn. This is possible because the selected coating 190 is particularly suitable for bonding/adhering to loom state yarns that still include a yarn spin finish. Due to this construction, there is no need to scour or wash the braided yarns to remove spin finishes prior to applying the outer coating or laminate 190. In addition, since the air-blowing and rapier weaving are performed under dry conditions, there is no need to dry the roll 150 before applying the coating 190.

One of ordinary skill in the art would recognize that the loom state yarn is not suitable for receiving the coating due to the presence of spin finish and sizing. More specifically, one would assume that the spin finish and sizing had to be removed from the yarn before coating could be applied, since the oil-based nature of most spin finishes and the stiffness of most sizing made them unsuitable for receiving the exterior coatings/laminates typically used in airbags. Accordingly, scouring/washing, heating, and drying steps are currently performed to substantially or completely remove sizing and spin finishes. This more fully prepares the braided yarn for receiving the airbag coating.

In some cases, sizing may be omitted from the process entirely. However, there is no evidence that the spin finish may do so, as its lubricating properties are required to ensure proper/adequate weaving is achieved. That is, to date, there has been no process that allows for proper coating of loom state yarns (with spin finishes thereon) for airbag cushioning. In view of this, the present invention is advantageous in that it allows coating of a loom-state yarn without removing a spin finish first, by specifically selecting a coating layer 190 capable of sufficiently adhering to and covering the spin finish left on the woven yarn.

Example 1

An integrally woven (OPW) inflatable airbag according to the present invention is formed using a denier (Dornier) (Lindan, germany) air jet loom. The yarns used are of470dtex/96 polyethylene terephthalate (PET) from American company (Atlanta, Ga.). The coating used was a CS2 coating from the bradford industry. Two airbags were used as references ("BL 1" and "BL 2"). The three airbags were heat aged at 105 ℃ for 408 hours at low humidity ("HA 1"). The three airbags were heat aged for 408 hours at 70 ℃ and high humidity ("HA 2") at 95% relative humidity. The three airbags were aged in sequence ("HA 3") by thermal shock, thermal aging, and salt water spraying using a thermitron #4 SE-10006-6 test chamber and a Russells thermal shock chamber. The balloon size was checked sequentially. The airbag was then statically deployed at 23 ℃, 85 ℃, and-35 ℃ (1 at each temperature). In FIG. 8, the deployment temperatures of the reference airbags BL1 and BL2 at 23 ℃ are shownThe unfolding characteristic of (a). The heat aged airbags HA1-HA3 appeared to have no visible damage.

Flexural wear tests were performed according to ISO5981 on both the marked side and the white side of each airbag (BL1, BL2, HA1-HA 3). In each case, cycle counts (in strokes) were observed (up to 2000 times or coating failure). All airbags tested passed.

Example 2

An OPW inflatable airbag according to the present invention is formed using a denier air jet loom. The yarns used are of470dtex/96 PET. The coating used was a CS2 coating from the bradford industry. Flexural wear tests were performed according to ISO5981 on both the marked side and the white side of the airbag. In each case, cycle counts (in strokes) were observed (up to 300 times or coating failure). All airbags tested passed.

The T-peel adhesion data (in n/mm) for the coated airbags for airbags 1 and 4 are as follows:

the T-peel adhesion of OPW airbags of the present invention was compared to a standard product (i.e., scoured fabric) airbag (in N/mm):

what has been described above is an example of the present invention. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the present invention, but one of ordinary skill in the art may recognize that many further combinations and permutations of the present invention are possible. Accordingly, the present invention is intended to embrace all such alterations, modifications and variations.