CN113856986B - 保压性高的帘式安全气囊用气袋制备方法及获得的气袋 - Google Patents

保压性高的帘式安全气囊用气袋制备方法及获得的气袋 Download PDF

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CN113856986B
CN113856986B CN202110938419.1A CN202110938419A CN113856986B CN 113856986 B CN113856986 B CN 113856986B CN 202110938419 A CN202110938419 A CN 202110938419A CN 113856986 B CN113856986 B CN 113856986B
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庄建国
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KOLON (NANJING) SPECIAL TEXTILE CO Ltd
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Abstract

本发明涉及一种保压性高的帘式安全气囊用气袋制备方法，包括以下步骤：准备帘式安全气囊用气袋的平纹涂胶面料；将平纹涂胶面料按照一定的图形进行裁剪；喷涂、粘合；自动取样设备将粘合一起的上下平纹层涂胶面料取走放置到固定的位置调湿处理；调试完毕后，运送到缝纫工序；缝纫机按照设定的程序对上下层平纹涂胶面料的涂胶部位进行缝纫成帘式安全气囊用气袋。本发明还涉及根据上述方法获得的保压性高的帘式安全气囊用气袋。

Description

保压性高的帘式安全气囊用气袋制备方法及获得的气袋
技术领域
本发明涉及一种帘式安全气囊用气袋的制备方法，更具体地，涉及一种保压性高的帘式安全气囊用气袋制备方法及由该方法获得的保压性高的帘式安全气囊用气袋。
背景技术
帘式安全气囊是目前广泛应用的被动安全系统的重要组成部分。近年来，随着汽车市场的扩大及安全性要求的提高，帘式安全气囊的及装配率也越来越高。
传统帘式安全气囊用面料的涂胶量大时，保压性高，但是由面料做成的气袋折叠时，气袋折叠尺寸大，占用大量的空间。采用的一次成型气袋由于上下层闭合区是织造出来，经过表面涂胶造成闭合区域和展开区域平整性不一致，从而带来气袋保压性有时候达不到理想的效果。
发明内容
在本发明的一个方面，提供了一种保压性高的帘式安全气囊用气袋的制备方法，该方法包括以下步骤：
准备帘式安全气囊用气袋的平纹涂胶面料；
将所述平纹涂胶面料按照一定的图形进行裁剪；
将裁剪好的所述平纹涂胶面料涂胶面面对面上下层对齐摆放在自动喷胶机设备上，启动自动喷胶机，自动喷胶机上层加压板利用负压将上层平纹涂胶面料吸离下层平纹涂胶面料，喷胶头根据设定的程序在下层平纹涂胶面料表面上进行喷胶，喷完硅胶后自动移动转移到下一个工位进行喷胶；
喷完胶的工位的所述上层加压板下降加压，将上下层平纹涂胶面料通过喷在所述下层平纹涂胶面料表面上的硅胶粘合在一起；
将通过硅胶胶条粘合在一起的上下平纹层涂胶面料进行调湿处理；
将调湿后的粘合在一起的上下平纹层涂胶面料运送到缝纫工序；以及
将上下层平纹涂胶面料的涂胶部位进行缝纫，制成帘式安全气囊用气袋。
在一个实施方案中，本发明的喷胶、粘合工序用硅胶由A和B两个组分构成。A组分粘度170-220 Pa·S；B组分的粘度200-250 Pa·S；A和B按照1：1重量比混合，搅拌后的粘度为190-240Pa· S，以上测试方法为剪切流变仪10l/s条件下剪切粘度值。
在一个实施方案中，本发明中的平纹涂胶面料用长丝的细度为470-700dtex，平纹涂胶面料的经向密度为160-209根/10cm，平纹涂胶面料的纬向密度为160-209根/10cm，平纹涂胶面料的涂胶量为25-40g/min。
在一个实施方案中，本发明中的自动喷胶机的喷胶头喷胶的速度为20-32m/min，喷胶头在涂胶面料上移动的速度为30-45m/min，粘合后两层涂胶面料中间的胶条宽度7-10mm，胶条的厚度是0.7-1.2mm。
在一个实施方案中，本发明中的缝纫线可由3根长丝加捻而成，总的细度为1200-1600dtex，捻度为150-250捻/m，缝纫线的拉伸强度>80N，缝纫的规格为：缝纫线35-50根/10cm。
在一个实施方案中，本发明中的帘式安全气囊用气袋的体积为30L-50L。气袋体积的测试方法：采用PE圆形小球，小球的规格为160g/L。首先测量气袋的重量为A，将PE小球装入气袋中，测试小球塞满后连同帘式气袋的重量为B，然后根据下列公式换算气袋的体积：
V=（B-A）/160
所述帘式安全气囊用气袋喷胶、粘合用硅胶由A和B两个组分构成。A组分粘度170-220 Pa·S；B组分的粘度200-250 Pa·S。A和B按照1：1重量比混合、搅拌后的粘度为180-240Pa·S。若硅胶混合后粘度小于180Pa·S，和上下层涂胶面料粘合后，牢度不好，造成帘式安全气囊用气袋的保压性不好。若硅胶混合后粘度大于240Pa·S，一方面影响涂胶头出胶速度，同时造成爆破过程中把上下层平纹涂胶面料上的硅胶从平纹涂胶面料上剥离，造成气袋保压性下降。
所述帘式安全气囊用气袋的上下层涂胶面料为平纹涂胶面料，平纹涂胶面料用长丝的细度：470-700dtex；平纹涂胶面料的经向密度：160-209根/10cm；平纹涂胶面料的纬向密度：160-209根/10cm；平纹涂胶面料的涂胶量：25-40g/m2。平纹涂胶面料的细度和经纬向密度都是常用的气囊用面料规格。若平纹涂胶面料的涂胶量<25g/m2，做成气袋后，由于涂胶量少，保压性下降。若平纹涂胶面料的涂胶量>40g/m2，做成气袋后，气袋太硬，不容易折叠，同时占用大量的空间。
所述帘式安全气囊用气袋制备方法中的自动喷胶、粘合设备的喷胶头喷胶的速度为20-32m/min；喷胶头在涂胶面料上移动的速度为30-45m/min；粘合后两层涂胶面料中间的胶条宽度7mm-10mm，胶条的厚度是0.7mm-1.2mm。若喷胶头喷胶的速度<20 m /min，喷胶头在涂胶面料上移动的速度>45m/min，则硅胶在面料上面的硅胶量少，粘合后胶条的宽度<7mm，胶条的厚度<0.7mm，影响气袋的保压性和剥离性。若喷胶头喷胶的速度>32/min，喷胶头在涂胶面料上移动的速度<30m/min，则硅胶在面料上面的硅胶量大，粘合后胶条的宽度>10mm，胶条的厚度>1.2mm，造成硅胶胶条太硬，影响气袋的折叠性。
本发明中的帘式安全气囊用气袋的缝纫线由3根长丝加捻而成，总的细度为1200-1600dtex，捻度为150-250捻/m，缝纫线的拉伸强度>80N。缝纫的尺寸：35 -50根/10cm。缝纫线采用目前常用缝纫线的规格。若缝纫时候的规格<35根/10cm，则气袋上下层平纹涂胶面料较容易剥离，影响气袋的保压性。若缝纫时候的规格>50根/10cm，则缝纫时候针穿透太多，造成上下层平纹涂胶面料间胶条针眼太大，对胶条损伤太大，影响胶条的密闭效果，造成气袋保压性下降。
本发明的帘式安全气囊用气袋的体积为30L-50L。若帘式气囊用气袋的体积<30L，安全帘式气囊爆破时候，产生的气体对气袋产生膨胀的厚度小，起不到对人体头部的保护作用。若帘式安全气囊用气袋的体积>50L，气囊爆破时候产生的气体充满整个气袋时间较长，不能够在有效时间内膨胀气袋，从而起不到对人体头部保护作用。
本发明中，调湿处理的温度为23±5℃，相对湿度为40%-60%。
在本发明的另一方面，提供了一种根据上述方法获得的保压性高的帘式安全气囊用气袋。
本发明的帘式安全气囊用气袋，气袋充压经过6S后，气袋内气体的保压性≥60%。若保压性<60%，则汽车侧面碰撞翻滚后，2次、3次翻滚后，安全帘式气囊内气体泄漏过快，起不到对人体头部保护作用。
本发明的帘式安全气囊用气袋，胶条的厚度差异率≤20%。胶条的厚度差异率≥大于20%，则气袋折叠成条状后，各个位置间直径差异大，一方面不利于均匀地放置在空间内，同时各个位置间气体的保压性不一致，导致气袋保压性下降。
本发明的帘式安全气囊用气袋，涂胶面料上下层硅胶粘合部分的剥离度≥1300N。按照ISO13934-1方法，以胶条为对称，将有缝纫线的气袋的上下平纹层涂胶面料裁剪成长16cm，宽5cm的试样。展开后变成长32cm，宽5cm的试样放入拉力机测试，以胶条破裂或者胶条粘合平纹涂胶面料的硅胶一起从涂胶面料表面剥离为最终结果。涂胶面料上下层硅胶粘合部分的剥离度＜1300N，则气袋爆破时候，高温高压产生的气体容易对硅胶粘合部分产生破坏，影响保压效果。
附图说明
通过结合附图阅读具体实施方式，本发明将得到更好的理解，而且其它的特征和优点将变得显而易见，其中：
图1为本发明的保压性高的帘式安全气囊用气袋的示意图。
图2为本发明的保压性高的帘式安全气囊用气袋的剖视示意图。
具体实施方式
下面结合附图和具体实施例，进一步阐述本发明。应该理解，下面给出的实施例仅为举例说明本发明用，不应解释为对本发明的任何限制。本发明的范围由所附的权利要求书进行限定。
应当理解，本发明的附图仅用来便于描述本发明，未必按比例绘制。
还应当理解，本发明中可能出现的方向性术语，如“上面”、“下面”、“右”、“左”、“前”、“后”、“底”、“顶”、“上部”、“下部”等等仅为方便于描述本发明，不应以任何方式解释为对本发明的限制。
如图1、2所示，本发明的保压性高的帘式安全气囊用气袋100包括气袋用平纹面料10。平纹涂胶面料10可采用本领域已知的气囊面料，如聚酰胺66长丝和聚酯，纤度可在470-700dtex之间，平纹涂胶面料的硅胶可采用本领域已知的硅胶。
本发明的保压性高的帘式安全气囊用气袋100在中间部分还包括硅胶涂层20。硅胶层20采用粘度为180-240Pa·S的硅胶喷涂在所述气袋用平纹涂胶面料的涂胶面上形成。
实验方法：
1、气袋的体积：
帘式气袋体积的测试方法：采用PE圆形小球，小球的规格为160g/L。首先测量气袋的重量为A，将PE小球装入气袋中，测试小球塞满后连同帘式气袋的重量为B，然后根据下列公式换算气袋的体积：
V=（B-A）/160
2、气袋的保压性：
按照ASTMD7559/7559M-09的测试方法，设定初始压力为75KPa，给气袋充压，在压力峰值达到平稳状态时记录为平稳压力V1，峰值压力开始下降，测量6S（6秒）后气袋内气体的压力V2，根据公式（V1-V2）/V1×100来计算气袋的保压率。
3、胶条的厚度差异率：
胶条厚度差异率测试的方法是利用SEM（50倍率）对气袋断面10个不同位置的胶条厚度测试，厚度差异率等于最大厚度和最小厚度的差异和最大厚度的比值。
实施例：
实施例1
将长丝纤度为470dtex，密度为202根/10cm，涂胶量为40g/m2的聚酰胺66平纹织物按照一定的尺寸裁剪后，上下层对齐摆放在自动喷胶机设备上，启动自动喷胶机，自动喷胶机上层加压板利用负压将上层平纹涂胶面料吸离下层平纹涂胶面料，采用6轴机械手将粘度为180Pa·S组分A和粘度为210Pa·S组分B硅胶经过自动混胶头混合后喷在下层裁剪好面料的硅胶面上。喷胶头的速度为28m/min，移动速度为32m/min。喷完胶的工位上层加压板下降加压，将上下层涂胶面料通过喷在所述下层平纹涂胶面料表面上的硅胶粘合在一起，加压后胶条的宽度为10mm，胶条的厚度为1mm。自动取样设备将粘合一起的上下层涂胶面料取走放置到固定的位置调湿处理。缝纫线按照38根/10cm的规格在硅胶条处按照规定的程序进行缝纫成帘式气袋。气袋的各种物性参照下表1。
实施例2
采用长丝纤度为550Dtex，密度为180根/10cm，涂胶量为35g/m2的聚酰胺66平纹织物按照一定的尺寸裁剪后，上下层对齐摆放在自动喷胶机设备上，启动自动喷胶机，自动喷胶机上层加压板利用负压将上层平纹涂胶面料吸离下层平纹涂胶面料，采用6轴机械手将粘度为190Pa·S组分A和粘度为225Pa·S组分B硅胶经过自动混胶头混合后喷在下层裁剪好面料的硅胶面上。喷胶头的速度为26m/min，移动速度为35m/min。喷完胶的工位上层加压板下降加压，将上下层涂胶面料通过喷在所述下层平纹涂胶面料表面上的硅胶粘合在一起，加压后胶条的宽度为9mm，胶条的厚度为0.92mm。自动取样设备将粘合一起的上下层涂胶面料取走放置到固定的位置调湿处理。缝纫线按照42根/10cm的规格在硅胶条处按照规定的程序进行缝纫成帘式气袋。气袋的各种物性参照下表1。
实施例3
采用长丝纤度为700dtex，密度为160根/10cm，涂胶量为30g/m2的聚酰胺66平纹织物。按照一定的尺寸裁剪后，上下层对齐摆放在自动喷胶机设备上，启动自动喷胶机，自动喷胶机上层加压板利用负压将上层平纹涂胶面料吸离下层平纹涂胶面料，采用6轴机械手将粘度为200Pa·S组分A和粘度为240Pa·S组分B硅胶经过自动混胶头混合后喷在下层裁剪好面料的硅胶面上。喷胶头的速度为23m/min，移动速度为41m/min。喷完胶的工位上层加压板下降加压，将上下层涂胶面料通过喷在所述下层平纹涂胶面料表面上的硅胶粘合在一起，加压后胶条的宽度为7.5mm，胶条的厚度为0.8mm。自动取样设备将粘合一起的上下层涂胶面料取走放置到固定的位置调湿处理。缝纫线按照47根/10cm的规格在硅胶条处按照规定的程序进行缝纫成帘式气袋。气袋的各种物性参照下表1。
实施例4
采用长丝纤度为550dtex，密度为200根/10cm，涂胶量为35g/m2的聚酯平纹织物。按照一定的尺寸裁剪后，上下层对齐摆放在自动喷胶机设备上，启动自动喷胶机，自动喷胶机上层加压板利用负压将上层平纹涂胶面料吸离下层平纹涂胶面料，采用6轴机械手将粘度为190Pa·S组分A和粘度为225Pa·S组分B硅胶经过自动混胶头混合后喷在下层裁剪好面料的硅胶面上。喷胶头的速度为26m/min，移动速度为35m/min。喷完胶的工位上层加压板下降加压，将上下层涂胶面料通过喷在所述下层平纹涂胶面料表面上的硅胶粘合在一起，加压后胶条的宽度为9mm，胶条的厚度为0.92mm。自动取样设备将粘合一起的上下层涂胶面料取走放置到固定的位置调湿处理。缝纫线按照42根/10cm的规格在硅胶条处按照规定的程序进行缝纫成帘式气袋。气袋的各种物性参照下表1。
比较例1
将长丝纤度为470dtex，密度为202根/10cm，涂胶量为40g/m2的聚酰胺66平纹织物。按照一定的尺寸裁剪后，直接缝纫。缝纫线按照38根/10cm的规格在按照规定的程序进行缝纫成帘式气袋。由于气袋保压性不好，保压性实验时达不到平稳压力。气袋的各种其他物性参照下表1。
比较例2
将长丝纤度为470dtex，密度为202根/10cm，涂胶量为40g/m2的聚酰胺66平纹织物。按照一定的尺寸裁剪后，上下层对齐摆放在自动喷胶机设备上，启动自动喷胶机，自动喷胶机上层加压板利用负压将上层平纹涂胶面料吸离下层平纹涂胶面料，采用3轴机械手将粘度为180Pa·S组分A和粘度为210Pa·S组分B硅胶经过自动混胶头混合后喷在下层裁剪好面料的硅胶面上。喷胶头的速度为28m/min，移动速度为32m/min。喷完胶的工位上层加压板下降加压，将上下层涂胶面料通过喷在所述下层平纹涂胶面料表面上的硅胶粘合在一起，加压后胶条的宽度为10mm，胶条的厚度为1mm。自动取样设备将粘合一起的上下层涂胶面料取走放置到固定的位置调湿处理。缝纫线按照38根/10cm的规格在硅胶条处按照规定的程序进行缝纫成帘式气袋。气袋的各种物性参照下表1。
比较例3
将长丝纤度为470Dtex，密度为202根/10cm，涂胶量为40g/m2的聚酰胺66平纹织物。按照一定的尺寸裁剪后，上下层对齐摆放在自动喷胶机设备上，启动自动喷胶机，自动喷胶机上层加压板利用负压将上层平纹涂胶面料吸离下层平纹涂胶面料，采用6轴机械手将粘度为180Pa· S组分A和粘度为210Pa· S组分B硅胶经过自动混胶头混合后喷在下层裁剪好面料的硅胶面上。喷胶头的速度为18m/min，移动速度为47m/min。喷完胶的工位上层加压板下降加压，将上下层涂胶面料通过喷在所述下层平纹涂胶面料表面上的的硅胶粘合在一起，加压后胶条的宽度为6.8mm，胶条的厚度为0.65mm。自动取样设备将粘合一起的上下层涂胶面料取走放置到固定的位置调湿处理。缝纫线按照38根/10cm的规格在硅胶条处按照规定的程序进行缝纫成帘式气袋。气袋的各种物性参照下表1。
比较例4
采用长丝纤度为550dtex，密度为180根/10cm，涂胶量为35g/m2的聚酰胺66平纹织物按照一定的尺寸裁剪后，上下层对齐摆放在自动喷胶机设备上，启动自动喷胶机，自动喷胶机上层加压板利用负压将上层平纹涂胶面料吸离下层平纹涂胶面料，采用6轴机械手将粘度为190Pa· S组分A和粘度为225Pa· S组分B硅胶经过自动混胶头混合后喷在下层裁剪好面料的硅胶面上。喷胶头的速度为26m/min，移动速度为35m/min。喷完胶的工位上层加压板下降加压，将上下层涂胶面料通过喷在所述下层平纹涂胶面料表面上的硅胶粘合在一起，加压后胶条的宽度为9mm，胶条的厚度为0.92mm。自动取样设备将粘合一起的上下层涂胶面料取走放置到固定的位置调湿处理。缝纫线按照25根/10cm的规格在硅胶条处按照规定的程序进行缝纫成帘式气袋。气袋的各种物性参照下表1。
比较例5
采用长丝纤度为700dtex，密度为160根/10cm，涂胶量为30g/m2的聚酰胺66平纹织物。按照一定的尺寸裁剪后，上下层对齐摆放在自动喷胶机设备上，启动自动喷胶机，自动喷胶机上层加压板利用负压将上层平纹涂胶面料吸离下层平纹涂胶面料，采用6轴机械手将粘度为200Pa· S组分A和粘度为240Pa· S组分B硅胶经过自动混胶头混合后喷在下层裁剪好面料的硅胶面上。喷胶头的速度为23m/min，移动速度为41m/min。喷完胶的工位上层加压板下降加压，将上下层涂胶面料通过喷在所述下层平纹涂胶面料表面上的硅胶粘合在一起，加压后胶条的宽度为7.5mm，胶条的厚度为0.8mm。自动取样设备将粘合一起的上下层涂胶面料取走放置到固定的位置调湿处理。缝纫线按照55根/10cm的规格在硅胶条处按照规定的程序进行缝纫成帘式气袋。气袋的各种物性参照下表1。
比较例6
采用长丝纤度为550dtex，密度为200根/10cm，涂胶量为20g/m2的聚酯平纹织物。按照一定的尺寸裁剪后，上下层对齐摆放在自动喷胶机设备上，启动自动喷胶机，自动喷胶机上层加压板利用负压将上层平纹涂胶面料吸离下层平纹涂胶面料，采用6轴机械手将粘度为140Pa· S组分A和粘度为155Pa· S组分B硅胶经过自动混胶头混合后喷在下层裁剪好面料的硅胶面上。喷胶头的速度为34m/min，移动速度为28m/min。喷完胶的工位上层加压板下降加压，将上下层涂胶面料通过喷在所述下层平纹涂胶面料表面上的硅胶粘合在一起，加压后胶条的宽度为12mm，胶条的厚度为1.25mm。自动取样设备将粘合一起的上下层涂胶面料取走放置到固定的位置调湿处理。缝纫线按照42根/10cm的规格在硅胶条处按照规定的程序进行缝纫成帘式气袋。气袋的各种物性参照下表1。
Figure DEST_PATH_IMAGE001
应当理解，对本申请所述的优选实施例的各种修改和变型对于本领域的技术人员而言将是显而易见的。可在不脱离本发明的精神和范围且不减损其伴随的优点的情况下做出此类修改和变型。因此，此类修改和变型同属于所附权利要求书涵盖的范围。

Claims (4)

1.一种保压性高的帘式安全气囊用气袋制备方法，其特征在于，该方法包括以下步骤：
准备帘式安全气囊用气袋的平纹涂胶面料；
将所述平纹涂胶面料按照一定的图形进行裁剪；
将裁剪好的所述平纹涂胶面料涂胶面面对面上下层对齐摆放在自动喷胶机设备上，启动自动喷胶机，自动喷胶机上层加压板利用负压将上层平纹涂胶面料吸离下层平纹涂胶面料，喷胶头根据设定的程序在下层平纹涂胶面料表面上进行喷胶，喷完硅胶后自动移动转移到下一个工位进行喷胶；
喷完胶的工位的所述上层加压板下降加压，将上下层平纹涂胶面料通过喷在所述下层平纹涂胶面料表面上的硅胶粘合在一起；
将通过硅胶条粘合在一起的上下层平纹涂胶面料进行调湿处理；
将调湿后的粘合在一起的上下层平纹涂胶面料运送到缝纫工序；以及
将上下层平纹涂胶面料在所述硅胶条处进行缝纫，制成帘式安全气囊用气袋，其中所述自动喷胶机的喷胶速度为20-32m/min，喷胶头在面料上移动的速度为30-45m/min，喷胶后所述硅胶条宽度7mm-9mm，硅胶条的厚度0.7mm-1.2mm，且硅胶条的厚度差异率≤20%。
2.根据权利要求1所述的保压性高的帘式安全气囊用气袋制备方法，其特征在于，所述气袋的体积为30L-50L。
3.根据权利要求1所述的保压性高的帘式安全气囊用气袋制备方法，其特征在于，缝纫线的细度为1500-1800dtex，3根一起加捻，捻度为150-250捻/m，缝纫的规格为：缝纫线35-50根/m。
4.根据权利要求1所述的保压性高的帘式安全气囊用气袋制备方法，其特征在于，调湿的温度为23±5℃，相对湿度为40%-60%。
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