CN101151339A - 液体聚合物涂料组合物和用其涂布的气囊 - Google Patents

液体聚合物涂料组合物和用其涂布的气囊 Download PDF

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CN101151339A
CN101151339A CNA2006800105420A CN200680010542A CN101151339A CN 101151339 A CN101151339 A CN 101151339A CN A2006800105420 A CNA2006800105420 A CN A2006800105420A CN 200680010542 A CN200680010542 A CN 200680010542A CN 101151339 A CN101151339 A CN 101151339A
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R·H·帕克
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Abstract

本发明公开了一种用于气囊织物的涂料组合物,该组合物由与硅酮或非硅酮组分发生化学反应形成交联的聚合物网络的液体硅橡胶和液体有机聚合物形成。通过向本文所述的液体硅橡胶化合物中加入液体有机聚合物,发现了显示充气气体保留率提高的气囊涂层。其优势在于,这些涂层的产生是在不使用有机溶剂的情况下完成的。本发明还公开了用本发明的制剂涂布的气囊。

Description

液体聚合物涂料组合物和用其涂布的气囊
技术领域
本发明涉及一种含有液体硅橡胶和液体有机聚合物的交联混合物的织物涂料组合物。该涂料组合物的生产不需要有机溶剂,由此得到了更安全、更廉价和更环保的材料。该涂料组合物从相对低分子量的组分制成交联的聚合物网络,非常适用于气囊织物,尤其是非常适合在用于制造侧帘式气囊的需要低透气性的气囊织物上使用。
背景技术
在过去几十年中,气囊已经从含有两块大致对称(通常为圆形)的气囊布料的驾驶员侧气囊发展成为具有独特几何形状和构造的更复杂的乘客侧和侧帘式气囊。侧帘式气囊通常从位于沿车辆侧窗的车顶内的包装容器展开。这些设计在翻车碰撞过程中通过将充气状态保持较长时间来保护乘客的侧帘式气囊,应该不仅能提供缓冲作用,也能防护破碎的玻璃和其他碎片。因此,必要的是在与翻车事故有关的可能的长时间内侧帘式气囊保留大量的气体(在高气压下)来保持充气状态。
已经发现有效的侧帘式气囊可以生产为一片式机织(优选机织提花)制品。由于省略了通常与生产多片布料气囊相关的切割和缝纫步骤,一片式提花气囊垫体的生产更经济。这种系统的明显缺点是在生产过程中目标气囊必须在外侧涂有涂层。传统的驾驶员侧气囊包括气囊部件内部的涂层,而这些一片式机织结构必须使涂层在气囊部件的外部(即,在成品气囊内部涂布是不可能的)。
涂层一般涂布在用于汽车气囊的织物上以阻止不希望的空气透过织物,并在较小的程度上防护织物免受用于对气囊充气的热气体的损害。已经使用了多种材料来产生这些织物涂层,从早期以聚氯丁烯作为选择的材料的努力,到后来优选硅酮或含硅酮材料的结果。使用硅酮聚合物混合物作为气囊涂料的尝试描述在例如美国专利第6,348,543号、6,468,929号和6,545,092号中。
在一片式侧帘式气囊的情况下,采用高度官能化的涂料是特别重要的。与在内部具有涂层的驾驶员侧气囊不同(此时气囊的移动往往会将涂层压在织物表面上),在外部具有涂层的一片式气囊中,实际上在展开过程中涂料被推离织物表面。这种压力可能导致两个重要问题——涂层破裂和涂层与气囊布料分离——这可能导致气囊整个失灵。本发明提供了一种有效地克服这些问题的涂料组合物,其即是经济可行的又是环保的。
尽管单独使用硅酮聚合物有许多缺点(例如,相对高的透气性、相对高的成本、以及由于其润滑性而有引起纱线移位的倾向),但是已经发现可以通过形成所谓的“互穿聚合物网络”(IPN)来改变硅酮聚合物的行为。IPN是一种特殊类型的聚合物混合物,其中聚合物存在于网络中,该网络是当聚合物组分热动力学相容地达到它们相互溶解的点、或在显微程度上基本彼此分散时形成的。一般情况下,或实际上,当混合物内的所有聚合物物种形成化学交联时发生IPN。
在以前产生IPN的尝试中,各组分溶解在同一溶剂中,最后相互溶解(即,聚合物与硅酮溶解在溶剂中)。甲苯是这种溶剂的一个例子。当以这种方式开发出功能性涂料时,气囊织物的制造商已经想到用其他不太昂贵、更安全和更环保的系统来替代溶剂基制剂。本发明通过用包括液体硅橡胶和液体共聚物的聚合物混合物来替代以前尝试的溶解于溶剂的聚合物固体,从而满足了这些制造商的需要。
发明内容
本发明公开了一种用于气囊织物的涂料组合物,该组合物由用硅酮和非硅酮组分化学交联而形成一系列聚合物网络的液体硅橡胶和液体有机聚合物组成。通过向本文所述的液体硅橡胶化合物中加入液体有机聚合物,该组合物的机械性质使其与单独使用液体硅橡胶时相比其性能改变得更适合用作气囊涂料,而且不需要溶剂。本发明还公开了用本发明的制剂涂布的气囊。
附图说明
图1是通过向液体硅橡胶中加入液体有机聚合物而产生的互穿聚合物网络的形成机制的图解示意图;并且
图2是显示用本发明的各种涂料组合物涂布的气囊的气体保留率的线图。
具体实施方式
这里所定义的术语“液体硅橡胶”是指特征均在于在常温下是液体的多种硅酮化合物中的一种。这些化合物的例子已经在文献中有所描述,使用的术语诸如聚硅氧烷、聚二甲基硅氧烷、带有多烷基官能基的聚硅氧烷和带有乙烯基官能基的聚硅氧烷。预期在这里使用的液体硅橡胶的一个例子(许多例子之一)是得自Shin-Etsu Chemical Co.的聚二甲基硅氧烷产品。
优选,液体硅橡胶是包括含“乙烯基”的聚硅氧烷、铂催化剂和液体有机氢聚硅氧烷交联剂的混合硅酮聚合物。术语“乙烯基”是指硅-乙烯基(Si-CH=CH2)。交联剂含有“氢化物”,即末端为氢化硅烷(Si-H)基的聚合物链。产生聚合物网络的反应在(a)乙烯基和硅酮聚合物的氢化物基团、以及(b)硅酮聚合物的氢化物基团和有机聚合物的碳-碳双键之间发生。
这里所定义的术语“液体有机聚合物”是指特征均在于至少一个不饱和碳碳双键(-C=C-)以及在室温下是液体的多种有机化合物之一。这些化合物可以通过参与硅酮上的不饱和位点与“氢化物”(SiH)交联剂之间的反应而与液体硅橡胶发生反应,该反应优选被混合硅酮聚合物中存在的贵金属如铂所催化。
液体有机聚合物化合物的分子量分布容易影响其与液体硅橡胶结合形成聚合物网络的行为。由具有高分子量分布的聚合物组成的有机材料往往更粘稠,最终可以是固体。在没有溶剂帮助的情况下,这就使它们越来越难以在其他材料中分散。这种高粘度的特性对于使用传统方法如刮刀涂布法来涂布混合材料的能力有负面影响。相反,如果有机材料由低分子量分布的聚合物组成,则得到的固化涂层的机械性能(抗张强度、撕裂强度等)可能因此受到负面影响,从而使该材料不适合用于气囊涂层的预期用途。
满足这里所使用的所需标准的液体有机聚合物的例子包括液体形式的聚异戊二烯(包括顺1-4-聚异戊二烯)、丁基橡胶和三元乙丙橡胶(EPDM)。在一个优选实施方案中,液体有机聚合物是聚异戊二烯。
液体有机聚合物与液体硅橡胶的比例决定了聚合物网络是否如希望的那样进行工作,即为涂料提供足够的附着力、强度和挠性以防止其破裂或剥离。
已经发现液体有机聚合物在涂料中的最佳水平应该是存在量为总聚合物网络(与包括其他组分的液体硅橡胶化合物)的2%-20%。更优选,液体有机聚合物的存在量为总聚合物网络的5%-12%,最优选存在量为总聚合物网络的大约5%。
液体有机聚合物可以被机械地混合为液体硅酮聚合物而不需要加热。可以使用单或双行星混合机或本领域公知的其他混合装置来进行有效地混合。优选,尽量减少加入至涂料分散体中的空气是理想的。混合各组分所需的时间长度取决于要混合的各种组分的用量、以及混合装置的类型和效率。对于Kitchen Aid-商标的行星混合机,混合大约2,000克的投料量一般所需的时间为大约5分钟。很显然,较大的投料量要使用较大的混合装置和容器来进行更有效地混合,可能需要较长的混合时间。
当混合时,有机聚合物被分散至硅酮聚合物中。一旦硅酮聚合物和有机聚合物已经被有效地进行了分散,则下一步涉及交联反应,其中硅酮聚合物与其自身和有机聚合物发生交联。该反应在加热条件下(即,“固化”工艺)通过催化剂如铂引发。
图1显示了分散体形式和固化工艺后的液体硅酮聚合物(斜线表示)和液体有机聚合物(交叉影线表示)。固化后,交联网络形成,其中经氢化物交联剂,硅酮聚合物相互交联并与有机聚合物交联。得到的交联的聚合物网络显示在图1的下部。
相信在氢化物和硅酮聚合物的乙烯基官能团之间、以及硅酮聚合物的氢化物基团和有机聚合物的碳-碳双键位点之间发生了交联作用。当交联反应完成时,有机聚合物变成了硅酮聚合物网络的一部分,因此将有机聚合物包含的附加特性(但不是硅酮的固有特性)赋予所生成的聚合物网络。
总之,形成交联的聚合物网络的方法包括以下的步骤:(a)提供如这里所述的混合硅酮聚合物,其包括含“乙烯基”的聚硅氧烷、铂催化剂和液体有机氢聚硅氧烷交联剂;(b)将该混合硅酮聚合物与具有至少一个不饱和碳-碳双键的液体有机聚合物混合,产生聚合物分散体;(c)将聚合物分散体涂布在气囊或气囊织物上;和(d)在催化剂的存在下,将聚合物分散体加热反应形成交联的聚合物网络。
本发明的涂料组合物和气囊进一步在实施例1中如下进行描述。
实施例1
将已经在工业中用作原样尺寸气囊模型的实验室气囊用于这些实施例中。每个一片式机织气囊用选自下表中的制剂涂布。在涂布过程中,已涂布的气囊与150℃的温度接触2分钟,随后将已涂布的气囊在实验室烤箱中在170℃下后固化2分钟。
实施例1A(对比例):液体硅橡胶,从Shin-Etsu公司通过商业途径获得,其以商品名“X-34-1766-8”销售,通过将硅酮组合物的“A”和“B”组分合并而活化。
实施例1B:50重量份“A”组分X-34-1766-8和20重量份顺-1,4-聚异戊二烯(从Elementis Specialties公司通过商业途径获得,商品名为“ISOLENE 400”)与50重量份“B”组分X-34-1766-8混合。
气囊充气至15p.s.i.并密封。随时间变化监测内部压力,结果以线图显示在图2中。
在气囊工业中,一般气囊剩余压力报告为充气后12秒时的压力。仅用液体硅橡胶涂布的实施例1A的气囊显示剩余压力仅为大约7.75p.s.i.,或其初始充气压力的大约51%。含有与液体硅橡胶混合的液体有机聚合物的实施例1B的气囊显示剩余气囊压力为大约10.8p.s.i.,或初始充气压力的大约72%。
因此,用本发明的组合物涂布的实施例1B气囊与仅用液体硅酮涂布的气囊相比其所充入的空气的透气性较低,显示了在用于侧帘式气囊时的显著优势,在这种情况下气体保留率在维持保护性环境中是特别重要的(例如,在翻车碰撞的情况下)。
本发明的涂料也可以含有某些硅烷偶联剂以提高含硅酮涂料与织物的附着力(如三甲氧基有机硅烷类、三乙氧基有机硅烷类、其混合物和类似物)。已经发现这些添加剂能显著地增加本发明的涂料在目标一片式机织气囊垫体上的附着力以防止可能在充气过程中某些垫体可能发生的很难看的起泡现象(象动脉瘤一样)。
在本发明的涂料组合物中也可加入各种添加剂,包括颜料或染料(以增强美感或为了识别的目的)、阻燃剂、惰性成分(如碳酸钙或其他填充材料)、以及必须用于加工该组合物并使其适合用作气囊涂层的加工助剂。
在一个实施方案中,本发明的涂料与任意类型的基布或已组装的气囊一起使用。根据基布的最终用途,要合并在一起的具体的硅酮聚合物混合物和基布的具体类型可以发生变化。这些基布可由下述纤维形成:天然纤维如棉花、苎麻、马尼拉麻、羊毛和类似物;合成纤维如聚酯、聚酰胺、再生纤维素和类似物;以及无机纤维如玻璃、硼衍生物纤维和类似物。而且,目标织物可以是机织、针织、无纺和类似织物。更优选本发明的气囊基布是提花或多臂(Dobby)机织一片式气囊垫体。
任何标准的低透气性气囊织物构造可用作本发明的涂料组合物的目标气囊织物。尽管本发明的涂料组合物已经被描述用于侧帘式气囊,应该理解的是该涂料组合物同样非常适用于其他的气囊构造(例如,驾驶员侧或乘客侧气囊)。另外,尽管本发明的涂料被描述用于预先成型的气囊垫体,应该理解的是本发明的涂料同样可在随后可由其切割出气囊布料的气囊基布上使用。
但如前所述,优选目标基布是由合成纤维如聚酯类和聚酰胺类的纱线形成的提花或多臂机织垫体。优选这种纱线的线性密度为大约210丹尼尔至大约630丹尼尔。优选这些纱线由多股丝线形成,其中该丝线的线性密度为每股丝线大约6丹尼尔或更小。此后已涂布有涂层的织物基布称为“气囊基布”。
在本发明的另一个实施方案中,在分散本发明的涂料的各种组分过程中,优选在气囊基布上刮涂该制剂,然后将得到的涂层气囊基布在烤箱内在150℃到200℃的温度固化,使聚合物成分交联,最终形成薄涂层。这里所使用的刮涂法,包括但不限于刮刀涂布(如在轧辊上刮涂、在间隙刮上刮涂(knife over gap)、在台面上刮涂(knife overtable)、浮刀和在泡沫垫上刮涂(knife-over-foam pad)的方法)。因为涂料组合物显示了优异的附着性,因此通常仅需涂布一次就能在目标基布上提供有效的、稳定的、低透气性的涂层。
涂层的最终干重可根据目的用途进行变化。对于其中所充入的空气保留较长时间不太重要的织物(如某些用于非翻滚式侧帘、驾驶员侧和乘客气囊垫体),增加的重量可以是每平方码一盎司。对于其中需要将所充入的空气保留较长时间的织物,特别是要用于侧帘用途的提花或多臂机织气囊,增加的重量(优选)将在每平方码大约1.0到大约3.0盎司,这取决于气囊的设计。
如前所述,基布优选是机织聚酰胺材料如尼龙。在最优选的实施方案中,这种基布将由尼龙6,6纤维形成。已经发现这种聚酰胺材料当与根据本发明的涂料一起使用时显示了特别好的附着力。
应用本发明的涂料组合物产生的有益效果是不需要溶剂就能形成交联的聚合物网络,得到了更安全、更经济和更环保的材料。

Claims (30)

1.一种涂料制剂,其是通过合并下列组分而制成的:
(a)与有机氢聚硅氧烷交联剂和铂催化剂混合的含乙烯基液体硅酮聚合物,和
(b)液体形式的有机聚合物,所述的有机聚合物含有不饱和C=C键,
其中所述的硅酮聚合物和所述的有机聚合物在固化过程中反应形成交联的聚合物网络。
2.根据权利要求1所述的涂料制剂,其中所述有机聚合物的存在量为所述交联的聚合物网络的大约2%到大约20%。
3.根据权利要求2所述的涂料制剂,其中所述有机聚合物的存在量为所述交联的聚合物网络的大约5%到大约12%。
4.根据权利要求3所述的涂料制剂,其中所述有机聚合物的存在量为所述交联的聚合物网络的大约5%。
5.根据权利要求1所述的涂料制剂,其中所述的硅酮聚合物是双组分硅酮聚合物。
6.根据权利要求5所述的涂料制剂,其中所述的硅酮聚合物是具有乙烯基官能团的聚二甲基硅氧烷。
7.根据权利要求1所述的涂料制剂,其中所述的有机聚合物是聚异戊二烯。
8.根据权利要求7所述的涂料制剂,其中所述的有机聚合物是顺1,4-聚异戊二烯。
9.根据权利要求1所述的涂料制剂,其中所述的有机聚合物是丁基橡胶。
10.根据权利要求1所述的涂料制剂,其中所述的有机聚合物是EPDM。
11.根据权利要求1所述的涂料制剂,其中所述的涂料制剂进一步包括硅烷。
12.根据权利要求1所述的涂料制剂,其中所述的涂料制剂进一步包括颜料。
13.一种基布,所述基布的至少一部分用包括下述物质的反应产物的涂料制剂涂布:(a)至少一种有机聚合物和(b)混合硅酮聚合物。
14.根据权利要求13所述的基布,其中所述的基布是机织的。
15.根据权利要求14所述的基布,其中所述的基布是机织提花的。
16.根据权利要求13所述的基布,其中所述的基布是针织的。
17.根据权利要求13所述的基布,其中所述的基布是无纺的。
18.根据权利要求13所述的基布,其中所述的基布包括选自天然纤维、合成纤维和无机纤维的纤维。
19.根据权利要求13所述的基布,其中所述的基布用作汽车气囊。
20.一种汽车气囊,所述气囊包括基布,其中所述基布的至少一部分用包括下述物质的反应产物的涂料制剂涂布:(a)至少一种具有不饱和C=C键的有机聚合物和(b)混合硅酮聚合物,所述的混合硅酮聚合物包括含乙烯基的聚硅氧烷、铂催化剂和液体有机氢聚硅氧烷交联剂。
21.根据权利要求20所述的气囊,其中所述的气囊包括一片式提花机织垫体。
22.根据权利要求20所述的气囊,其中所述的气囊包括一片式多臂机织垫体。
23.根据权利要求20所述的气囊,其中所述气囊在充气后大约12秒测量时所显示的充气保留水平为其初始充气压力的至少70%。
24.一种在气囊基布上形成交联聚合物的方法,所述方法包括下述步骤:
(a)提供混合硅酮聚合物,所述混合硅酮聚合物包括含乙烯基的聚硅氧烷、铂催化剂和液体有机氢聚硅氧烷交联剂;
(b)将所述混合硅酮聚合物与液体有机聚合物混合产生聚合物分散体,其中所述液体有机聚合物具有至少一个不饱和碳-碳双键;
(c)将聚合物分散体涂布在气囊基布上;和
(d)在催化剂的存在下,将聚合物分散体加热反应,在所述气囊基布上形成交联的聚合物网络。
25.根据权利要求24所述的方法,其中所述的有机聚合物的存在量为所述交联的聚合物网络的大约2%到大约20%。
26.根据权利要求25所述的方法,其中所述的有机聚合物的存在量为所述交联的聚合物网络的大约5%到大约12%。
27.根据权利要求26所述的方法,其中所述的有机聚合物的存在量为所述交联的聚合物网络的大约5%。
28.根据权利要求24所述的方法,其中所述的气囊基布是一片式机织提花气囊。
29.根据权利要求24所述的方法,其中所述的步骤(c)通过刮涂完成。
30.根据权利要求24所述的方法,其中所述的步骤(d)在大约150℃到大约200℃的温度完成。
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WO2006104769A3 (en) 2007-06-21
CN101151339B (zh) 2010-08-25
GB2442121A (en) 2008-03-26
WO2006104769A2 (en) 2006-10-05
US7407898B2 (en) 2008-08-05

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