TW201632669A - Fabric for making airbags and method of making same - Google Patents

Abstract

A woven fabric comprising a base yarn and a secondary yarn, wherein the secondary yarn is interwoven into the base yarn, and wherein the secondary yarn has a melting point that is lower than the melting point of base yarn. Also disclosed is a method of making a base yarn and a secondary yarn, wherein the secondary yarn is interwoven into the base yarn, and wherein the secondary yarn has a melting point that is lower than the melting point of base yarn.

Description

Fabric for manufacturing airbag and manufacturing method thereof Related application

The present application claims priority to US Provisional Application No. 61/944,899, filed on Feb. 26, 2014.

This invention relates to woven fabrics formed from multi-polymer based yarns that can be used to produce airbags.

Inflatable airbags are a key component of vehicle safety systems. As used herein, "airbag" means an inflatable passive safety constraint for use in automobiles and many other forms of transportation, including military and aerospace applications. Airbags are a form of inflatable passive safety restraint that is now a standard in automotive use. In recent years, the number of airbags and the coverage of such airbags have increased. A variety of airbag configurations in use include airbags for front seat areas, for side impact protection, for rear seat use, for use in ceiling area air curtains, and for use in inflatable seat belts.

To meet the requirements for effective inflation, airbag fabrics must have controlled low gas permeability. While fabric properties such as linear density of yarn, twist coefficient, textured structure, and thickness and weight all affect breathability, it is often desirable to add a coating or additional layer to the airbag fabric to meet industry standards.

In order to meet the requirements of effective inflation, airbag fabrics must have resistance to air passage. The ability to test by gas permeability and porosity. Therefore, it is required to weave a nylon or polyester airbag having a very low porosity and a correspondingly low gas permeability. While fabric properties such as linear density of yarn, twist coefficient, textured structure, and thickness and weight all affect breathability, it is often desirable to add a coating or additional layer to the airbag fabric to meet industry standards.

Polyester and polyamide fabrics are known which have various coatings to reduce permeability. U.S. Patent No. 5,897,929 describes a polyester or polyamide fabric coated with pores of a polyamide material. U.S. Patent No. 5,110,666 describes a fabric substrate that is typically coated with a polycarbonate-polyether polyurethane that provides some permeability, flexibility, toughness, heat resistance and other characteristics. U.S. Patent No. 5,076,975 describes a forming operation for forming an elastomer coated fabric having a defined shape. U.S. Patent No. 5,763,330 describes a method of extrusion coating a polyethylene resin onto a nylon fabric.

The braid of the conventionally processed air bag may also be coated with an elastic material (especially a polyoxymethylene rubber) to manage the breathability of the fabric. In addition, the coating method is a slow and laborious method that increases the cost of the airbag cushion fabric and is also expensive for typical polyoxyxene elastomers used in coating. Therefore, alternatives to coating have been sought in the past few years. However, such alternatives involve other method steps and more complexity. In addition, no replacement technology has been commercially successful and does not achieve the best performance of all the key performance parameters required in airbag pad applications.

Accordingly, there is a need in the art for an airbag fabric that does not require a coating and that still meets key performance criteria such as low gas permeability and porosity.

This invention relates to a woven fabric comprising a plurality of polymeric yarns and a method of producing and using such woven fabrics.

Accordingly, in one aspect of the invention, a braid comprising a ground yarn and a second yarn, wherein the second yarn is interwoven into the ground yarn, and wherein the melting point of the second yarn is lower than the melting point of the ground yarn.

In one non-limiting embodiment, the braid contains a gap and at least one of the second yarns The portion has been melted such that the gap between the ground yarns is bridged by the molten portion of the second yarn.

In another non-limiting embodiment, the fabric has a basis weight in the range of from 80 to 450 grams per square meter.

In another non-limiting embodiment, the second yarn is present in the fabric in the range of 10 to 40% by weight.

In another non-limiting embodiment, the ground yarn is formed from polyamide fibers. In another non-limiting embodiment, the ground yarn is formed from polyester fibers.

In another non-limiting embodiment, the second yarn has a linear mass density in the range of 20 to 800 decitex.

In another non-limiting embodiment, the second yarn is formed from a polyolefin fiber. In another non-limiting embodiment, the second yarn is formed from high density polyethylene fibers.

In another non-limiting embodiment, the braid has a gas permeability that is at least 50% lower than the air permeability of at least a portion of the second yarn prior to melting, such that the gap between the bottom yarns is melted by the second yarn. Partially bridged.

In another non-limiting embodiment, the braid has a gas permeability that is at least 75% lower than the permeability of at least a portion of the second yarn prior to melting, such that the gap between the loops is melted by the second yarn. Partially bridged.

In another non-limiting embodiment, an airbag incorporating a braid from various embodiments of the present invention is disclosed.

In another aspect of the invention, a melted fabric comprising a woven fabric comprising a ground yarn, wherein the ground yarn comprises a gap, and a filler material at least partially filling a gap in the ground yarn, is disclosed.

Another aspect of the invention pertains to a method of making a treated fabric. The method comprises the steps of interlacing a base yarn and a second yarn to form a braid, wherein the second yarn has a lower melting point than the base yarn and heating the braid to a temperature above the melting point of the second yarn and below the melting point of the ground yarn Temperature wherein at least a portion of the second yarn is melted to form a treated fabric. In another non In a limiting embodiment, a treated fabric formed by this method is disclosed. In another non-limiting embodiment, an airbag formed from a treated fabric of this method is disclosed.

10‧‧‧Black yarn

20‧‧‧White yarn

30‧‧‧PE yarn

40‧‧‧Nylon 6,6 yarn

50‧‧‧PE components

60‧‧‧Nylon 6,6 yarn

The exemplary embodiments of the present invention are described by way of example, and the description

Figure 1 is a graph depicting the relationship between the amount of HDPE in a fabric and its heat resistance.

Figure 2 is a fabric design in accordance with the present invention.

Figure 3 is an image obtained by scanning electron microscopy of a fabric design in accordance with the present invention.

4A is another image of a fabric design in accordance with the present invention in which the second yarn is shown to be molten and present on one side of the fabric.

Figure 4B is another image of a fabric design in accordance with the present invention in which the ground yarn is shown to be woven and present on one side of the fabric.

In certain embodiments, the present invention is directed to a treated knit fabric and method of making the same, wherein the fabric is formed from a bottom yarn and at least one second yarn. The resulting fabric exhibits reduced gas permeability and porosity when compared to a woven fabric made only of a base fabric or a woven fabric formed from a base fabric and at least one second yarn.

All of the patents, patent applications, test procedures, priority documents, articles, publications, manuals, and other documents cited herein are incorporated by reference to the extent that the disclosures This incorporation is permitted in the permissions.

The woven fabric of the present invention comprises a ground yarn. The ground yarn can be present in a range of from 60 to 99.9% by weight of the woven fabric. In certain embodiments, the ground yarn can be, for example, between 60 and 99.5%, 60 to 99%, 60 to 95%, 60 to 90%, 60 to 85%, 60 to 80%, 60 to 75%, 65 Up to 99.9%, 65 to 99.5%, 65 to 99%, 65 to 95%, 65 to 90%, 65 to 85%, 65 to 80%, 70 to 99.9%, 70 to 99.5%, 70 to 99%, 70 To 95%, 70 to 90%, 70 to 85%, 70 to 80%, 75 to 99.9%, 75 to 99.5%, 75 to 99%, 75 to 95%, 75 to 90%, 80 to 99.9%, 80 to 99.5%, 80 to 99% and The amount in the range of 80 to 95% (all based on the weight of the woven fabric) is present. The ground yarn can be selected from any suitable synthetic yarn. Examples of suitable synthetic yarns that can be used for the ground yarn include yarns formed from polyamide or polyester fibers.

Suitable polyamide fibers have a basis weight of from 100 to 950 dtex, such as from 200 to 900 dtex, from 250 to 850 dtex, from 300 to 850 dtex, from 350 to 850 dtex, from 400 to 850 dtex, from 400 to 800 Linear mass density in the range of 450 to 800 dtex. Suitable polyamide fibers include those formed from nylon 6,6, nylon 6, nylon 6,12, nylon 12, nylon 4,6 or copolymers or blends thereof. In one non-limiting embodiment of the invention, the ground yarn is formed from nylon 6,6 fibers.

Suitable polyester fibers have a basis weight of from 200 to 950 dtex, such as from 300 to 900 dtex, from 300 to 850 dtex, from 350 to 850 dtex, from 400 to 850 dtex, from 400 to 800 dtex, and from 450 to 800 dtex. Linear mass density in the range of 500 to 800 dtex. Suitable polyester fibers include the polyester fibers formed from the following: polyethylene terephthalate (PET), polybutylene terephthalate, polyethylene naphthalate, polyethylene naphthalate Butyl ester, polyethylidene-1,2-bis(phenoxy)ethane-4,4'-dicarboxylate, poly(1,4-cyclohexyl-dimethylene terephthalate) And a copolymer comprising at least one type of repeating unit of the above-mentioned polymers, such as polyethylene terephthalate/polyethylene isophthalate copolyester, polybutylene terephthalate Ester/polybutylene naphthalate butyl acrylate copolyester, polybutylene terephthalate/polydecane dicarboxylic acid butyl acrylate copolyester or copolymer or blend thereof. In one non-limiting embodiment of the invention, the ground yarn is formed from PET fibers.

The woven fabric of the present invention further comprises a second yarn which is present in a range which produces from 0.1 to 40% by weight of the woven fabric. In certain embodiments, the second yarn can be, for example, between 0.1 and 35%, 0.1 to 30%, 0.1 to 25%, 0.1 to 20%, 0.5 to 40%, 0.5 to 35%, 0.5 to 30%, 0.5 to 25%, 0.5 to 20%, 1 to 40%, 1 to 35%, 1 to 30%, 1 to 25%, 1 to 20%, 5 to 40%, 5 to 35%, 5 to 30%, 5 to 25%, 5 to 20%, 10 to 40%, 10 to 35%, 10 to 30%, 10 to The amounts in the range of 25%, 10 to 20%, 15 to 40%, 15 to 35%, 15 to 30%, 20 to 40%, and 20 to 35% (all based on the weight of the woven fabric) are present. The second yarn may be selected from any suitable synthetic yarn having a melting point below the melting point of the base yarn. Suitable second yarns include synthetic yarns having a linear mass density in the range of 20 to 800 dtex and a melting point in the range of 60 degrees Celsius to 160 degrees Celsius. In certain embodiments, the second yarn can have, for example, between 100 and 700 dtex, 150 to 500 dtex, 200 to 600 dtex, 250 to 550 dtex, 300 to 550 dtex, and 300 to 500 dtex. Linear mass density within the range. In other embodiments, the second yarn may have, for example, between 80 degrees Celsius and 160 degrees Celsius, 90 degrees Celsius to 160 degrees Celsius, 100 degrees Celsius to 160 degrees Celsius, 110 degrees Celsius to 160 degrees Celsius, 120 degrees Celsius to 160 ° C, 60 ° C to 155 ° C, 80 ° C to 155 ° C, 90 ° C to 155 ° C, 100 ° C to 155 ° C, 110 ° C to 155 ° C, 120 ° C to 155 Celsius Melting point, in the range of 80 ° C to 150 ° C, 90 ° C to 150 ° C, 100 ° C to 150 ° C, 110 ° C to 150 ° C and 120 ° C to 150 ° C. Examples of suitable synthetic yarns are formed from polyolefin and copolyamide monofilament stitching yarns. Suitable polyolefin yarns include, but are not limited to, polyolefin yarns formed from polyethylene or high density polyethylene (HDPE) fibers. In one non-limiting embodiment of the invention, the ground yarn is formed from HDPE fibers.

The second yarn may also comprise fibers and filaments of different materials. If a second yarn of more than one type of fiber or filament is used, only one of its fiber or filament types would need to have a melting point below the melting point of the ground yarn. In one non-limiting embodiment, the second yarn may comprise a mixture of polyamidamine and polyolefin fibers and filaments.

The fibers used to form the bottom and second yarns may also contain various additives for the production and processing of the fibers. Suitable additives include, but are not limited to, heat stabilizers, antioxidants, light stabilizers, smoothing agents, antistatic agents, plasticizers, thickeners, pigments, flame retardants, or combinations thereof.

The woven fabric of the present invention can be formed from warp and weft yarns using weaving techniques known in the art. Suitable weaving techniques include, but are not limited to, plain weave, twill weave, satin weave, modified weave or multi-axial weave of these types. Suitable weaving machines for weaving include water jet loom, air jet loom or sword looms. Suitable braids of the present invention have a total basis weight in the range of from 80 to 450 grams per square meter. In certain embodiments, the braid may have a total basis weight of from 100 to 450 grams per square meter, from 100 to 400 grams per square meter, from 100 to 350 grams per square meter, from 150 to 450 grams per square meter. 150 to 400 g/m2, 150 to 350 g/m2, 200 to 450 g/m2, 200 to 400 g/m2, 200 to 350 g/m2, 250 to 450 g / m ^ 2 , 250 to 400 g / m ^ 2 and 250 to 350 g / m ^ 2 range.

Table 1 summarizes suitable embodiments of the invention.

In one embodiment of the invention, the second yarn is interwoven into the bottom yarn, wherein at least a portion of the second yarn has been melted such that the gap between the bottom yarns is bridged by the molten portion of the second yarn. Without being bound by any particular theory, it is believed that the molten portion of the second yarn fills the gap in the braid to reduce the gas permeability and porosity of the braid.

In one embodiment of the invention, the woven fabric has a gas permeability that is at least 50% lower than the woven fabric formed from the same woven fabric of the same woven fabric. In another embodiment of the invention, the woven fabric has a gas permeability that is at least 75% lower than the woven fabric formed from the same woven fabric of the same woven fabric. In other embodiments, the woven fabric has a gas permeability that is less than the permeability of the woven fabric formed from the same yarn structure only by the bottom yarn: at least 80%, at least 85%, at least 90%, and at least 95%.

In one embodiment of the invention, the porosity of the woven fabric is at least 50% lower than the porosity of the woven fabric formed from the same yarn structure only by the ground yarn. In another embodiment of the invention, the porosity of the woven fabric is at least 75% lower than the porosity of the woven fabric formed from the same yarn structure only by the ground yarn. In other embodiments, the porosity of the woven fabric is less than the porosity of the woven fabric formed from only the bottom woven fabric in the same fabric structure: at least 80%, at least 85%, at least 90%, and at least 95%.

In one embodiment of the invention, the braid has a gas permeability that is at least 50% lower than the air permeability of at least a portion of the second yarn prior to melting, such that the gap between the bottom yarns is melted by the second yarn. bridging.

In one embodiment of the invention, the woven fabric has a gas permeability at least 75% lower than the woven fabric of at least a portion of the second yam prior to melting, such that the gap between the yams is melted by the second yarn. bridging. In other embodiments, the braid is at least less gas permeable than the at least a portion of the second yarn prior to melting, such that the gap between the loops is bridged by the molten portion of the second yarn: at least 80%, at least 85%, at least 90% and at least 95%.

In one embodiment of the invention, the porosity of the woven fabric is at least 50% lower than the porosity of the woven fabric prior to melting of at least a portion of the second yarn such that the gap between the yams is melted by the fused portion of the second yarn bridging. In another embodiment of the invention, the porosity of the woven fabric is at least 75% lower than the porosity of the woven fabric prior to melting of at least a portion of the second yarn, such that the gap between the yams is melted by the second yarn. Partially bridged. In other embodiments, the porosity of the braid is at least less than the porosity of the knitted fabric prior to melting of at least a portion of the second yarn such that the gap between the bottom yarns is bridged by the molten portion of the second yarn: at least 80%, at least 85%, at least 90% and at least 95%.

In another aspect of the invention, a melted fabric comprising a woven fabric comprising a ground yarn, wherein the ground yarn comprises a gap; and a filler material at least partially filling a gap in the bottom yarn is disclosed.

In such embodiments, and as described above, the ground yarn may be present in a range of from 60 to 99.9% by weight of the melted fabric. As mentioned above, the ground yarn can be selected from any suitable synthetic yarn. Examples of suitable synthetic yarns that can be used for the ground yarn include yarns formed from polyamide or polyester fibers.

Suitable polyamide fibers have a linear mass density in the range of from 100 to 950 dtex. Suitable polyamide fibers include nylon 6,6, nylon 6, nylon 6,12, nylon 12, Nylon 4, 6 or a copolymer or blend thereof forms the same fibers. In one non-limiting embodiment of the invention, the ground yarn is formed from nylon 6,6 fibers.

Suitable polyester fibers have a linear mass density in the range of from 200 to 950 dtex. Suitable polyester fibers include polyethylene terephthalate (PET), polybutylene terephthalate, polyethylene naphthalate, polybutylene naphthalate, polyethylene-1 , 2-bis(phenoxy)ethane-4,4'-dicarboxylate, poly(1,4-cyclohexyl-dimethylene terephthalate) and comprising the polymerization mentioned above a copolymer of at least one type of repeating unit, such as polyethylene terephthalate/isophthalate copolyester, polybutylene terephthalate/naphthalate copolyester, Polyester fibers formed from polybutylene terephthalate/decane dicarboxylate copolyester or copolymers or blends thereof. In one non-limiting embodiment of the invention, the ground yarn is formed from PET fibers.

The molten fabric of the present invention further comprises a filler material which can be present in the range of from 0.1 to 40% by weight of the treated fabric. In certain embodiments, the filler material can be, for example, between 0.1 and 35%, 0.1 to 30%, 0.1 to 25%, 0.1 to 20%, 0.5 to 40%, 0.5 to 35%, 0.5 to 30%, 0.5. Up to 25%, 0.5 to 20%, 1 to 40%, 1 to 35%, 1 to 30%, 1 to 25%, 1 to 20%, 5 to 40%, 5 to 35%, 5 to 30%, 5 Up to 25%, 5 to 20%, 10 to 40%, 10 to 35%, 10 to 30%, 10 to 25%, 10 to 20%, 15 to 40%, 15 to 35%, 15 to 30%, 20 The amount in the range of 40% and 20 to 35% (all based on the weight of the melted fabric) is present. The filler material can be selected from any suitable synthetic polymer having a melting point below the melting point of the base yarn. Examples of suitable synthetic polymers are polyolefins, such as those described above. Suitable polyolefins include, but are not limited to, those polyolefins formed from polyethylene or high density polyethylene (HDPE) fibers. In one non-limiting embodiment of the invention, the filler material is HDPE.

The present invention also provides an airbag formed from the woven fabric and the melted fabric disclosed herein. The term airbag as used herein includes an airbag cushion. Airbag pads are typically formed from multiple tissues and can be inflated quickly.

The invention also provides a method of making a treated fabric. Treated fabrics from such methods can be used to produce airbags. Knits that can be used in many industrial applications, such as airbags, require fabrics that meet mechanical and performance criteria while limiting overall fabric weight and cost.

In such methods, the ground yarn is interwoven with the second yarn to form a braid, wherein the second yarn has a melting point lower than the melting point of the base yarn. Various methods and devices for weaving yarns are known and can be used to produce the fabrics of the present invention. Suitable weaving techniques include, but are not limited to, plain weave, twill weave, satin weave, modified weave or multi-axial weave of these types. Suitable weaving machines include, but are not limited to, water jet loom, air jet loom or sword looms. As noted above, suitable braids of the present invention have a basis weight in the range of from 80 to 450 grams per square meter.

In one embodiment, the braid is heated to a temperature above the melting point of the second yarn and below the melting point of the ground yarn, wherein at least a portion of the second yarn is melted to form a treated fabric. Various methods for melting a portion of the second yarn can be used. In one non-limiting embodiment, the braid is calendered to melt or soften the second yarn such that the gap of the braid is filled with the second yarn that is melted or softened.

As will be appreciated by those skilled in the art after reading the present invention, alternative methods and apparatus for the methods and apparatus exemplified herein that result in melting at least a portion of the second yarn are available and the invention encompasses its use.

As mentioned above, the ground yarn can be present in the range of from 60 to 99.9% by weight of the woven fabric. The ground yarn can be selected from any suitable synthetic yarn. Examples of suitable synthetic yarns that can be used for the ground yarn include yarns formed from polyamide or polyester fibers.

As noted above, suitable polyamide fibers have a linear mass density in the range of from 100 to 950 dtex. Suitable polyamide fibers include those formed from nylon 6,6, nylon 6, nylon 6,12, nylon 12, nylon 4,6 or copolymers or blends thereof. In one embodiment of the invention, the bottom yarn is formed from nylon 6,6 fibers.

Suitable polyester fibers have a linear mass density in the range of from 200 to 950 dtex. Suitable polyester fibers include polyethylene terephthalate (PET), polybutylene terephthalate, polyethylene naphthalate, polybutylene naphthalate, polyethylene-1 , 2-bis(phenoxy)ethane-4,4'-dicarboxylate, poly(1,4-cyclohexyl-dimethylene terephthalate) and comprising the polymerization mentioned above a copolymer of at least one type of repeating unit, such as polyethylene terephthalate/isophthalate copolyester, polybutylene terephthalate/naphthalate copolyester, Polyester fibers formed from polybutylene terephthalate/decane dicarboxylate copolyester or copolymers or blends thereof. In one embodiment of the invention, the ground yarn is formed from PET fibers.

The knit of this method further comprises a second yarn which, as described above, can be present in the range of from 0.1 to 40% by weight of the knit. The second yarn may be selected from any suitable synthetic yarn having a melting point below the melting point of the base yarn. Suitable second yarns include synthetic yarns having a linear mass density in the range of 20 to 800 dtex and a melting point in the range of 60 degrees Celsius to 160 degrees Celsius. Examples of suitable synthetic yarns are formed from polyolefin and copolyamide monofilament stitching yarns. Suitable polyolefin yarns include, but are not limited to, polyolefin yarns formed from polyethylene or high density polyethylene (HDPE) fibers. In one embodiment of producing the airbag of the present invention, the ground yarn is formed from HDPE fibers.

The second yarn may also be composed of fibers and filaments of different materials. If a second yarn of more than one type of fiber or filament is used, only one of its fiber or filament types would need to have a melting point below the melting point of the ground yarn. In one non-limiting embodiment, the second yarn may comprise a mixture of polyamidamine and polyolefin fibers and filaments.

The fibers used to form the bottom and second yarns may also contain various additives for the production and processing of the fibers. Suitable additives include, but are not limited to, heat stabilizers, antioxidants, light stabilizers, smoothing agents, antistatic agents, plasticizers, thickeners, pigments, flame retardants, or combinations thereof.

Treated fabrics that require the method of the present invention have significantly lower gas permeability and/or porosity than braids formed only from the ground yarn. This will allow the treated fabric disclosed herein to be It is not used in industrial applications such as airbags where coating, film or nonwovens are not required. In one embodiment of the method, the treated fabric has a gas permeability that is at least 50% lower than the air permeability of the woven fabric formed from the same yarn structure only by the ground yarn. As described above, other embodiments encompass a treated fabric having a gas permeability that is less than the breathability of a woven fabric formed from only the bottom yarn in the same fabric structure: at least 75%, at least 80%, at least 85%, at least 90%. And at least 95%. In another embodiment of the invention, the treated fabric has a porosity that is at least 50% lower than the porosity of the woven fabric formed from the same yarn structure only by the bottom yarn. As noted above, other embodiments encompass a woven or treated fabric having a porosity that is less than the porosity of the woven fabric formed from only the bottom woven fabric of the same fabric structure: at least 75%, at least 80%, at least 85%, At least 90% and at least 95%.

In one embodiment of the method of the present invention, the treated fabric has a gas permeability at least 50% lower than the air permeability of at least a portion of the second yarn prior to melting, such that the gap between the ground yarns is by the second yarn The molten portion is bridged. Also, as described above, other embodiments encompass that the gas permeability is at least less than the gas permeability of at least a portion of the second yarn before being melted, such that the gap between the bottom yarns is bridged by the molten portion of the second yarn. Treated fabric: at least 75%, at least 80%, at least 85%, at least 90%, and at least 95%.

In another embodiment of the method of the present invention, the treated fabric has a porosity that is at least 50% lower than the porosity of the knitted fabric prior to melting of at least a portion of the second yarn, such that the gap between the ground yarns is second The molten portion of the yarn is bridged. Also, as described above, other embodiments contemplate that the porosity is at least less than the porosity of the knitted fabric prior to melting of at least a portion of the second yarn such that the gap between the ground yarns is bridged by the molten portion of the second yarn Treated fabric: at least 75%, at least 80%, at least 85%, at least 90%, and at least 95%.

The weave design and structure specifies where the second yarn will produce a fabric structure after calendering. For example, plain weave will produce a uniform distribution of the second yarn throughout the fabric structure. We can choose the weave design according to the needs of the final use of the fabric. Figure 4 shows a fabric forming textured design in which a second yarn is primarily found on one side of the fabric. As shown in the figure It can be seen in 4A that after calendering, the second yarn forms a layer 50 on one side of the fabric. As can be seen in Figure 4B, the original yarn is held in a woven form 60 on the other side of the fabric. The mechanical properties of the fabric are primarily indicated by the ground yarn, which in the non-limiting embodiment may be nylon 6,6. The second yarn, which may be polyethylene in a non-limiting embodiment, contributes primarily by closing the inter-yarn gap and by contributing to the heat resistance of the fabric. Additives can also be used with the molten component to further enhance the heat resistance of the fabric structure.

Instance

The following examples demonstrate the invention and its ability to be used. The invention is capable of other and various embodiments and modifications may Accordingly, the examples are considered to be illustrative in nature and not limiting.

testing method

Fabric Heat Resistance Measurement: Fabric Tolerance Thermal Particle Penetration Tolerance According to Barnes and Rawson [Barnes, JA, and Rawson, NJ Proc. 8th World Textile Congress, Industrial, Technical and High Performance Textiles, University of Huddersfield, July 1998 Test methods described in 15-16, pages 329-338]. Briefly, a series of steel penetrator having a mass of 0.9 to 44 g is used to apply a thermal load to the fabric sample. Record the static time required for each heated penetrator to penetrate the fabric, and calculate the conversion rate converted to incident energy according to Equation 1: E = mρ ΔT (Equation 1)

Where E = energy (J), m = mass (kg), ρ = specific heat capacity [J / (kg * K)], and ΔT (K) is the difference between the initial temperature of the penetrator and the ambient temperature. A plot of melting time versus incident energy is then constructed to give a reliable measure of the comparative performance of the fabric sample.

Breathability of fabric: The breathability of the fabric was determined according to ASTM D737.

Example 1:

Plain weave fabric made of nylon 6,6 base yarn and high density polyethylene (HDPE) second The yarns are stitched together to form a braid. The braid is heated to a temperature of 135 degrees Celsius. A portion of the HDPE second yarn was observed to melt and fill the gap of the braid.

Example 2

The fabric was also tested for heat resistance to the fabric from the first test. A typical airbag fabric is coated with a polyoxymethylene-based elastomer to increase the heat resistance of the base fabric. As shown in the table depicted in Figure 1, increasing the amount of HDPE in the fabric results in a higher heat resistance of the fabric.

In a second test, a multifilament PE yarn was used for the fabric construction, which was then melted by calendering to reduce the breathability of the fabric.

The fabric design is illustrated in Figure 2, in which the black yarn 10 represents the PE described in all of the structures in the above table, and the white yarn 20 represents the nylon 6,6. When the structure is delayed at a temperature just above the melting point of the PE yarn, it produces a closure via the SEM cross-section shown in Figure 3. A vent structure in which the nylon 6,6 yarn 40 is visible in its original form and the PE yarn 30 is shown to be molten and filled with a gap in the nylon 6,6 yarn.

This fabric structure is used to enable the PE component 50 to be primarily retained on one side of the fabric as seen in the light micrographs depicted in Figure 4A. Figure 4B shows that the nylon 6,6 yarn 60 is still woven on the other side of the fabric. In another non-limiting embodiment, a fabric construct can be used in which the second yarn is woven to be embedded within the bottom yarn.

It should be noted that the ratios, concentrations, amounts, and other digital data herein may be expressed in a range format. It is to be understood that such range format is used for convenience and convenience, and therefore should be construed in a flexible manner to include not only the stated value as a limitation of the scope, but also all individual values or sub-ranges Each value and sub-range is clearly stated in general. For example, a concentration range of "about 0.1% to about 5%" should be interpreted to include not only the concentration of about 0.1% by weight to about 5% by weight, which is explicitly stated, but also individual concentrations within the indicated range (eg, 1%, 2%, 3%, and 4%) and sub-ranges (eg, 0.5%, 1.1%, 2.2%, 3.3%, and 4.4%). The term "about" can include ±1%, ±2%, ±3%, ±4%, ±5%, ±8%, or ±10% of the modified value. In addition, the phrase "about "x" to "y"" includes "about "x" to about "y"". Although the illustrative embodiments of the present invention have been specifically described, it is understood that the present invention is capable of other and various embodiments and various modifications may be apparent to those skilled in the art It is made without departing from the spirit and scope of the invention. Therefore, the scope of the claims of the present invention is not intended to be limited to the examples and descriptions set forth herein, but the scope of the claims is intended to cover all features of the patentable novelity present in the present invention, including The technician is considered to be all the features of its equivalent.

Claims (39)

A woven fabric comprising: a) a ground yarn; and b) a second yarn, wherein the second yarn is interwoven into the ground yarn, and wherein the second yarn has a melting point lower than a melting point of the ground yarn. The braid of claim 1, wherein the braid contains a gap and at least a portion of the second yarn has been melted such that a gap between the bottom yarns is bridged by the molten portion of the second yarn. A braid of claim 1 wherein the fabric has a basis weight in the range of from 80 to 450 grams per square meter. The braid of claim 1, wherein the second yarn is present in the fabric in a range from 10 to 40% by weight. The braid of claim 1, wherein the ground yarn is formed of polyamide fibers. The woven fabric of claim 1, wherein the undertext is formed of nylon 6,6 fibers. The braid of claim 1, wherein the ground yarn is formed of polyester fibers. The woven fabric of claim 1, wherein the undertext is formed of polyethylene terephthalate fibers. The braid of claim 1, wherein the second yarn has a linear mass density in the range of from 20 to 800 decitex. The woven fabric of claim 1, wherein the second yarn is formed of polyolefin fibers. The woven fabric of claim 1, wherein the second yarn is formed of high density polyethylene fibers. The woven fabric of claim 2, wherein the woven fabric has a gas permeability at least 50% lower than a gas permeability of the woven fabric before at least a portion of the second yarn is melted, such that a gap between the yarns is obtained by the first The molten portion of the second yarn is bridged. The woven fabric of claim 2, wherein the woven fabric has a gas permeability at least 75% lower than a gas permeability of the woven fabric before at least a portion of the second yarn is melted, such that a gap between the yarns is obtained by the first The molten portion of the second yarn is bridged. An airbag comprising the braid of any one of claims 1 to 13. A melted fabric comprising: a) a knit comprising a ground yarn, wherein the ground yarn comprises a gap; and b) a filler material at least partially filling the gaps in the ground yarn. The melted fabric of claim 15, wherein the filler material is present in a range from 10 to 40% by weight of the melted fabric. The melted fabric of claim 15, wherein the ground yarn is formed of polyamide fibers. The melted fabric of claim 15, wherein the ground yarn is formed of nylon 6,6 fibers. The melted fabric of claim 15, wherein the ground yarn is formed of polyester fibers. The melted fabric of claim 15, wherein the ground yarn is formed of polyethylene terephthalate fibers. The melted fabric of claim 15 wherein the filler material is formed from a polyolefin. The melted fabric of claim 15 wherein the filler material is formed from high density polyethylene. An airbag comprising the melted fabric of any one of claims 15 to 22. A method of making a treated fabric comprising the steps of: a) interlacing a base yarn and a second yarn to form a braid, wherein a melting point of the second yarn is lower than a melting point of the ground yarn; and b) heating the braid to a temperature above the melting point of the second yarn and below the melting point of the ground yarn, wherein at least a portion of the second yarn is melted to form a treated fabric. The method of claim 24, wherein at least a portion of the second yarn is melted such that a gap between the ground yarns is bridged by the molten portion of the second yarn. The method of claim 24, wherein the treated fabric is at least more breathable than the step The woven fabric formed in (a) has a gas permeability of 50% lower. The method of claim 24, wherein the treated fabric has a gas permeability that is at least 75% lower than the gas permeability of the knitted fabric formed in step (a). The method of claim 24, wherein the braid has a basis weight in the range of from 80 to 450 grams per square meter. The method of claim 24, wherein the second yarn is present in the braid in a range from 1 to 40% by weight. The method of claim 24, wherein the ground yarn is formed from polyamide fibers. The method of claim 24, wherein the undertext is formed from nylon 6,6 fibers. The method of claim 24, wherein the ground yarn is formed of polyester fibers. The method of claim 24, wherein the ground yarn is formed from polyethylene terephthalate fibers. The method of claim 24, wherein the second yarn has a linear mass density in the range of 20 to 800 dtex. The method of claim 24, wherein the second yarn is formed from polyolefin fibers. The method of claim 24, wherein the second yarn is formed from polyethylene fibers. The method of claim 24, wherein the second yarn is formed from high density polyethylene fibers. A treated fabric formed by the method of any one of claims 24 to 37. An airbag formed from the treated fabric of claim 38.