Liquid silicone rubber coating composition for application to air bags

Abstract: The instant invention pertains to a liquid silicone rubber coating composition for application to air bags that is comprised of (A) a diorganopolysiloxane having at least 2 alkenyl groups in each molecule, (B) an organopolysiloxane resin, (C) an inorganic filler, (D) an organohydrogenpolysiloxane having at least 2 silicon-bonded hydrogen atoms in each molecule, (E) a platinum group metal catalyst, and (F) an epoxy group-containing organosilicon compound. The liquid silicone rubber coating composition of the instant invention is capable of coating synthetic air bag fabrics without the use of a diluting solvent, and at the same time has an excellent adhesiveness for and infiltrability into synthetic air bag fabrics.

Description: Air bags have recently entered into widespread practical application as occupant protection safety devices in automobiles. Air bags are typically fabricated from a base fabric of chloroprene rubber-coated nylon fabric. However, with chloroprene rubber-coated base fabrics it is difficult to reduce the weight and the properties deteriorate with the passage of long periods of time. Air bag base fabrics coated with silicone rubber compositions have also been proposed very recently. For example Japanese Patent Application Laid Open Kokai Numbers Sho 63-78744 [78,744/1988] and Hei 3-243442 [243,442/1991] disclose air bags coated with silicone rubber compositions. These silicone rubber composition-coated air bag base fabrics have excellent high-temperature properties. However, to obtain a uniform, thin film coating with a satisfactory bonding strength to the base fabric, a diluting organic solvent must be used to apply these silicone rubber compositions to the base fabrics of synthetic fiber used for air bags, for example nylon 66. To assure satisfactory infiltration into the base fabric and thin-film coatability, these silicone rubber compositions must be diluted with an organic solvent such as toluene, xylene, and others. This is a problem sought to be solved by the present invention. US-A 4 087 585 discloses a self-adhering silicone composition comprising a vinyl-containing polyorganosiloxane, a silicon-bonded hydrogen containing organosilicon compound, a platinum catalyst, a vinyl and hydroxyl containing polysiloxane and an epoxy-containing, alkoxy silane. From EP-A 0 451 946 storage stable one-part organosiloxane compositions are known which comprise a liquid polydiorganosiloxane having at least two alkenyl radicals, an organohydrogen siloxane, a platinum containing catalyst, an inhibitor which is the essential feature of this application, and an adhesion promotor, which is an alkoxy-substituted alkoxy silane. The solution of the instant invention is to provide a liquid silicone rubber coating composition for application to air bags that can be coated on the synthetic fiber fabrics used for air bags without the use of diluting solvent. The silicone rubber composition of the instant invention contains specific organosilicon compounds that exhibit excellent infiltrability and thin-film coatability as well as a strong adherence for the synthetic fabrics used for air bags. The instant invention relates to the use of a liquid silicone rubber composition comprised of (A) an essentially straight-chain organopolysiloxane having at least two alkenyl groups in each molecule, (B) 5 to 80 weight parts per 100 weight parts of (A) of an organopolysiloxane resin comprised of (CH₃)₃SiO 1/2 units and SiO 4/2 units ; (CH₃)₃SiO 1/2 units, (CH₂=CH)SiO 3/2 units and SiO 4/2 units; (CH₂=CH)(CH₃)₂SiO 1/2 units and SiO 4/2 units or (CH₂=CH)(CH₃)₂SiO 1/2 units, (CH₂=CH)SiO 3/2 units and SiO 4/2 units, (C) 5 to 100 weight parts per 100 weight parts of (A) of an inorganic filler, (D) an organohydrogenpolysiloxane having at least 2 silicon- bonded hydrogen atoms in each molecule, in a quantity sufficient for the ratio between the number of moles of silicon-bonded hydrogen atoms in the organohydrogenpolysiloxane and the number of moles of alkenyl groups in component (A) to have a value of 0.6:1 to 20:1, (E) a platinum group metal catalyst in a quantity providing 0.1 to 500 weight parts as platinum group metal per 1,000,000 weight parts component (A), and (F) 0.1 to 20 weight parts per 100 weight parts of (A) ot an epoxy group-containing organosilicon compound for application to airbags. Specifically, the instant invention solves the problem in the art by providing a liquid silicone rubber coating composition that is highly coatable into thin films without the use of solvent and that is resistant to the shock accompanying expansion/inflation and particularly high-temperature expansion. The diorganopolysiloxane, component (A), used in the instant invention is the base component of the total composition. This diorganopolysiloxane must contain at least 2 alkenyl groups in each molecule in order for this composition to cure into a rubbery elastic silicone rubber coating membrane. The diorganopolysiloxane (A) comprises essentially straight-chain organopolysiloxane with the average unit formula R n SiO (4-n)/2 wherein R is selected from substituted and unsubstituted monovalent hydrocarbon groups and n has a value of 1.9 to 2.1. R may be exemplified by alkyl groups such as methyl, ethyl, propyl, and others; alkenyl groups such as vinyl, allyl, and others; aryl groups such as phenyl, and others; and haloalkyl groups such as 3,3,3-trifluoropropyl and others. The diorganopolysiloxane (A) should have a viscosity at 25°C of at least 100 centipoise (1 d PA.s). When such factors as the strength of the silicone rubber coating membrane, and blendability are taken into account, the viscosity of diorganopolysiloxane (A) at 25°C is preferably from 1,000 centipoise (1 Pa.s) to 100,000 centipoise (100 Pa.s). The diorganopolysiloxane (A) may be exemplified dimethylvinylsiloxy- endblocked dimethylpolysiloxanes, dimethylvinylsiloxy-endblocked dimethylsiloxane-methylvinylsiloxane copolymers, and dimethylvinylsiloxy-endblocked dimethylsiloxanemethylphenylsiloxane copolymers. The organopolysiloxane resin, component (B), functions to increase the mechanical strength of the silicone rubber coating membrane and in particular to increase the infiltrability and adherence of the instant invention's silicone rubber coating composition for synthetic air bag fabrics. The organopolysiloxane resin (B) is comprised of the (CH₃)₃SiO 1/2 unit and SiO 4/2 unit; the (CH₃)₃SiO 1/2 unit, (CH₂=CH)SiO 3/2 unit, and SiO 4/2 unit; the (CH₂=CH)(CH₃)₂SiO 1/2 unit and SiO 4/2 unit; and of the (CH₂=CH)(CH₃)₂SiO 1/2 unit, (CH₂=CH)SiO 3/2 unit, and SiO 4/2 unit. Among these resins, the vinyl-containing resins are preferred because they lead to an improvement in the strength of the silicone rubber coating membrane. The organopolysiloxane resin (B) should be added at 5 to 80 weight parts per 100 weight parts of (A) and preferably at 10 to 80 weight parts per 100 weight parts of (A) in order to achieve the goal of improving the infiltrability into the synthetic fabric while simultaneously improving the thin-film coatability. The inorganic filler, component (C), may be selected from those fillers known in the silicone rubber art for reinforcement, viscosity adjustment, improving the heat resistance, improving the flame retardancy, and so forth. The inorganic filler (C) may be exemplified by reinforcing fillers such as fumed titanium oxide and microparticulate silicas, for example. fumed silica, precipitated silica, and calcined silica; by nonreinforcing fillers such as quartz powder, diatomaceous earth, iron oxide, aluminum oxide, calcium carbonate, and magnesium carbonate; and by the preceding fillers that have been treated with an organosilicon compound such as organosilane or organcpolysiloxane. Among these fillers, the ultramicroparticulate silicas with particle diameter ≥ 50 millimicrons (nanometer) and specific surface area ≥ 50 m²/g are preferred. Surface-treated silica is even more preferred. A surface-treated silica is a silica whose surface has been preliminarily treated with organosilane, organosilazane, or diorganocyclopolysiloxane. The quantity of addition of this component will vary with the type of inorganic filler, but as a general matter will fall within the range of 5 to 100 weight parts per 100 weight parts component (A). When microparticulate silica is used as the inorganic filler, this component should be added within the range of 5 to 15 weight parts per 100 weight parts component (A). The addition of more than 15 weight parts microparticulate silica will make the viscosity of the composition of the instant invention too high and will render solventless coating onto the air bag base fabric essentially impossible. On the other hard, the mechanical strength of the silicone rubber coating membrane falls off at below 5 weight parts of microparticulate silica. Component (D), an organopolysiloxane that contains at least 2 silicon-bonded hydrogen atoms in each molecule, is a crosslinker for the composition of the instant invention. The organopolysiloxane (D) may be exemplified by trimethylsiloxy- endblocked methylhydrogenpolysiloxanes, trimethylsiloxy-endblocked dimethylsiloxane-methylhydrogensiloxane copolymers, dimethylphenylsiloxy-endblocked methylphenylsiloxane-methylhydrogensiloxane copolymers, cyclic methylhydrogenpolysiloxanes, and copolymers that contain the dimethylhydrogensiloxy unit and SiO 4/2 unit. The organohydrogenpolysiloxane (D) should be added in a quantity that the ratio between the number of moles of silicon-bonded hydrogen atoms in this organohydrogenpolysiloxane and the number of moles of alkenyl groups in component (A) has a value of 0.6:1 to 20:1. The platinum group metal catalyst, component (E), used by the instant invention is a curing catalyst for the composition of the instant invention. The platinum group metal catalyst (E) may be exemplified by platinum micropowder, platinum black, chloroplatinic acid, platinum tetrachloride, olefin complexes of chloroplatinic acid, alcohol solutions of chloroplatinic acid, complexes between chloroplatinic acid and alkenylsiloxanes, rhodium compounds, and palladium compounds. The platinum group metal catalyst (E) should be added generally at 0.1 to 500 weight parts as platinum group metal per 1,000,000 weight parts component (A), and is preferably used at 1 to 50 weight parts as platinum group metal per 1,000,000 weight parts component (A). The reaction will not develop adequately at less than 0.1 weight parts, while additions in excess of 500 weight parts are uneconomical. The epoxy-containing organosilicon compound, component (F), functions to improve adherence by the composition of the instant invention for the synthetic fiber fabrics used to make air bags. The epoxy-containing organosilicon compound (F) may be exemplified by epoxy-containing organoalkoxysilanes such as gamma- glycidoxypropyltrimethoxysilane, 3,4-epoxycyclohexylethyltrimethoxysilane, and others; and by epoxy- containing organopolysiloxanes such as epoxy-containing organopolysiloxanes that also contain silicon-bonded vinyl and alkoxy groups, epoxy-containing organopolysiloxanes that also contain silicon-bonded hydrogen, epoxy-containing organopolysiloxanes that also contain silicon-bonded hydrogen and alkoxy, and others. The epoxy-containing organopolysiloxanes may be further exemplified by: or wherein Me represents methyl and Vi represents vinyl. In addition to the aforementioned components (A) to (F), the composition used according to the instant invention may also contain a component (G) that may be exemplified by alkyne alcohols such as 3-methyl-1-butyn-3-ol, 3,5-dimethyl-1-hexyn-3-ol, and phenylbutynol; ene-yne compounds such as 3-methyl-3-penten-1-yne and 3,5-dimethyl-3- hexen-1-yne; tetramethyltetrahexenyl-cyclotetrasiloxane; benzotriazole; and others. The composition used according to the instant invention an be simply prepared by mixing the aforementioned components (A) to (F) or components (A) to (G) to homogeneity in a mixer such as a kneader mixer, pressure kneader mixer, Ross™ mixer, and so forth. Various additives can be optionally admixed at this point within a range that does not impair the object of the instant invention, for example, pigments, heat stabilizers, and others. In order to obtain a solvent-free, silicone rubber-coated air bag base fabric, the composition of the instant invention is coated on a synthetic air bag fabric and cured. Useful fabrics may be exemplified by, but not limited to fabrics made of polyamide fibers such as nylon 6, nylon 66, and nylon 46; aramide fiber fabrics; fabrics made of polyester fiber such as polyalkylene terephthalate; polyetherimide fiber fabrics; sulfone fiber fabrics; carbon fiber fabrics, and others. Fabric made of nylon 66 fiber is the most preferred among the preceding synthetic air bag fabrics. The silicone rubber-coated air bag base fabric can be prepared by coating the composition as described above on the synthetic air bag fabric and introducing this into a hot-air drying oven for curing. Application of the composition of the instant invention to synthetic air bag fabrics will provide a silicone rubber coating membrane that is thoroughly infiltrated into the fabric and that is uniformly and evenly coated in the form of a thin film. The coating weight of the silicone rubber composition will generally be below 80 g/m². Moreover, after thermosetting the flexibility will be excellent, and the silicone rubber coating membrane and synthetic air bag fabric will be firmly bonded into a single body at a bonding strength of at least 1.5 kgf/cm. An air bag base fabric coated with the composition of the instant invention does not suffer from changes at the fold regions during storage of the air bag and does not suffer from delamination of the silicone rubber coating membrane upon challenge by the severe abrasion that occurs when the air bag is activated. So that those skilled in the art can understand and appreciate the invention taught herein, the following examples are presented, being it understood that these examples should not be used to limit the scope of this invention found in the claims attached hereto. In the following examples, parts denotes weight parts, the viscosity is the value at 25°C, "Me" denotes the methyl group, and "Vi" denotes the vinyl group. EXAMPLE 1 The following components were introduced into a Ross mixer: 100 parts dimethylvinylsiloxy-endblocked dimethylpolysiloxane with viscosity OF 2,000 centipoise (2 Pa.s) and 30 parts vinyl-containing methylpolysiloxane resin comprised of the Vi(Me)₂SiO 1/2 unit and SiO 4/2 unit (Vi group content = 5.6%, viscosity = 230 centipoise [2.3 d Pa.s]). 12 parts fumed silica with specific surface = 200 m²/g, 5 parts hexamethyldisilazane as surface treatment agent for the silica, and 2 parts water were then added with mixing to homogeneity. Heat-treatment in vacuo afforded a flowable liquid silicone rubber base. A liquid silicone rubber coating composition for application to air bags was then prepared by adding to 100 parts of the aforesaid liquid silicone rubber base with mixing to homogeneity: 6 parts methylhydrogenpolysiloxane with the average molecular formula Me₃SiO(MeHSiO)₆(Me₂SiO)₄SiMe₃ 0.5 parts chloroplatinic acid/divinyltetramethyldisiloxane complex (platinum concentration = 0.4 weight%), 0.4 parts 3,5-dimethyl-1-hexyn-3-ol (cure inhibitor), and 1 part gamma-glycidoxypropyltrimethoxysilane (adhesion promoter). The resulting composition had a viscosity of 25,000 centipoise (25 Pa.s). The resulting composition was coated on a nylon 66 fiber fabric (420 denier [4.67 X 10⁻⁵ kg/m]) and cured by heating for 2 minutes in an oven at 180°C. The silicone rubber coating composition was coated on the air bag fabric using a coater at the minimum amount that afforded an even, uniform coating. Two coated surfaces of this coated air bag base fabric were overlaid and bonded via a roomtemperature-curable silicone rubber adhesive (SE9145 RTV from Toray Dow Corning Silicone Company™, Limited). After curing for 7 days at room temperature, a sample with a width of 2.5 cm and a length of 10 cm was cut out and this sample was subjected to peel testing in order to measure the bonding strength. Abrasion testing was also carried out using a Scott™ abrasion tester. After 1,000 rubbing strokes at a pressing force of 2 kgf, the silicone rubber coating thin film was visually inspected for delamination from the fabric surface. Air bag inflation testing was also carried out. In this test, the air bag was instantaneously inflated by injecting hot air (170°C to 180°C) into the air bag at a pressure of 7 to 8 kg/cm². A visual inspection was then carried out for the occurrence of delamination of the silicone rubber coating thin film. The infiltrability was measured as follows. The synthetic air bag fabric was cut into a strip having a width of 2 cm and a length of 10 cm. This strip was hung vertically, and the lower end was immersed by 0.5 mm into the liquid silicone rubber composition. The strip was then allowed to stand in this condition for 24 hours at room temperature, after which the distance was measured by which the liquid silicone rubber composition had infiltrated into the base fabric. A small quantity of pigment was added to the liquid silicone rubber composition in order to facilitate determination of the zone of infiltration by the liquid silicone rubber composition into the base fabric. The results of the various measurement results are reported in Table 1. COMPARISON EXAMPLE 1 A silicone rubber coating composition was prepared as in Example 1, but in this case adding dimethylvinylsiloxy-endblocked dimethylpolysiloxane with viscosity of 2,000 centipoise (2 Pa.s) in place of the vinyl-containing methylpolysiloxane resin used in Example 1. The properties of this composition were measured as in Example 1, and these results are also reported below in Table 1. COMPARISON EXAMPLE 2 A silicone rubber coating composition was prepared as in Example 1, but in this case omitting the gamma- glycidoxypropyltrimethoxysilane used in Example 1. The properties of this composition were measured as in Example 1, and these results are also reported below in Table 1. EXAMPLE COMPARISON EXAMPLE 1 1 2 Hardness of the Silicone Rubber (JIS A) 50 34 56 Minimum Coating Quantity (g/m²) 40 100 45 Bonding Strength (kgf/cm) 2.5 0.7 0.3 Scott Abrasion Test passed test delamination of the silicone rubber film delamination of the silicone rubber film Air Bag Inflation Test passed test delamination of the silicone rubber film delamination of the silicone rubber film Infiltrability (cm) 2.4 0.9 1.9 EXAMPLE 2 The silicone rubber coating compositions of Example 1, Comparison Example 1, and Comparison Example 2 were respectively coated as in Example 1 on polyester fiber air bag fabric (420 denier [4.67 x 10⁻⁵ kg/m]. Property measurement was conducted as in Example 1, and the results of these evaluations are reported in Table 2. EXAMPLE COMPARISON EXAMPLE Example 2 1 2 Hardness of the Silicone Rubber (JIS A) 50 34 56 Minimum Coating Quantity (g/m²) 44 109 47 Bonding Strength (kgf/cm) 2.2 0.7 0.4 Scott Abrasion Test passed test delamination of the silicone rubber film delamination of the silicone rubber film Air Bag Inflation Test passed test delamination of the silicone rubber film delamination of the silicone rubber film Infiltrability (cm) 2.2 0.7 1.7 EXAMPLE 3 The following components were introduced into a Ross™ mixer: 100 parts dimethylvinylsiloxy-endblocked dimethylpolysiloxane with viscosity of 12,000 centipoise and 20 parts vinyl-containing methylpolysiloxane resin composed of the Vi(Me)₂SiO 1/2 unit and SiO 4/2 unit (Vi weight = 5.6%, viscosity = 230 centipoise [2.3 d Pa.s]). A flowable liquid silicone rubber base was then prepared by the introduction with mixing to homogeneity of 10 parts fumed silica with specific surface = 200 m²/g that had been preliminarily treated with hexamethyldisilazane. The following were then added to 100 parts of the aforesaid liquid silicone rubber base with mixing to homogeneity: 3 parts methylhydrogenpolysiloxane (silicon-bonded hydrogen content = 1.57 weight%) with the average molecular formula Me₃SiO(MeHSiO)₂₅SiMe₃ 0.5 parts chloroplatinic acid/divinyltetramethyldisiloxane complex (platinum concentration = 0.4 weight%), 0.1 part methyltris(3-methyl-1-butyn-3-oxy)silane (cure inhibitor), and 1 part of the following organosilicon compound (adhesion promoter). wherein Me represents methyl and Vi represents vinyl. The resulting liquid silicone rubber composition had a viscosity of 50,000 centipoise (50 Pa.s). The resulting composition was coated on a nylon 66 fiber fabric as in Example 1, and the bondability and thin-film coatability were evaluated also as in Example 1. The results of the evaluations are reported in Table 3. COMPARISON EXAMPLE 3 A silicone rubber coating composition was prepared as in Example 3, but using dimethylvinylsiloxy-endblocked dimethylpolysiloxane with viscosity of 12,000 centipoise (12 Pa.s) in place of the vinyl-containing methylpolysiloxane resin used in the silicone rubber coating composition of Example 3. The results of the evaluations are reported in Table 3. COMPARISON EXAMPLE 4 A silicone rubber coating composition was prepared as in Example 3, but in this case omitting the adhesion promoter used in the silicone rubber coating composition of Example 3. The results of the evaluations are reported in Table 3. PRESENT INVENTION COMPARISON EXAMPLES Example 3 3 4 Hardness of the Silicone Rubber (JIS A) 44 30 51 Minimum Coating Quantity (g/m²) 45 120 48 Bonding Strength (kgf/cm) 2.2 0.9 0.4 Scott Abrasion Test passed test delamination of the silicone rubber film delamination of the silicone rubber film Air Bag Inflation Test passed test delamination of the silicone rubber film delamination of the silicone rubber film Infiltrability (cm) 1.8 0.6 1.4 Because the instant invention's liquid silicone rubber coating composition for air bags is composed of components (A) to (F) and in particular because it contains the organosiloxane resin of component (B) and the epoxy-containing organosilicon compound of component (F), it exhibits an excellentinfiltrability and bonding strength for the synthetic fiber fabrics used to make air bags. Moreover, it is very coatable into thin films even without the use of a diluting solvent. Air bag base fabrics prepared by the application of the liquid silicone rubber coating composition of the instant invention are very flexible. Finally, the silicone rubber coating membrane is neither delaminated nor scorched by the severe abrasion that occurs between coated surfaces during inflation by the hot gas produced by the inflator.

Claims: Use of a liquid silicone rubber composition comprised of (A) an essentially straight-chain organopolysiloxane having at least two alkenyl groups in each molecule, (B) 5 to 80 weight parts per 100 weight parts of (A) of an organopolysiloxane resin comprised of (CH₃)₃SiO 1/2 units and SiO 4/2 units, (CH₃)₃SiO 1/2 units, (CH₂=CH)SiO 3/2 units and SiO 4/2 units; (CH₂=CH)(CH₃)₂SiO 1/2 units and SiO 4/2 units or (CH₂=CH)(CH₃)₂SiO 1/2 units, (CH₂=CH)SiO 3/2 units and SiO 4/2 units, (C) 5 to 100 weight parts per 100 weight parts of (A) of an inorganic filler, (D) an organohydrogenpolysiloxane having at least 2 silicon- bonded hydrogen atoms in each molecule, in a quantity sufficient for the ratio between the number of moles of silicon-bonded hydrogen atoms in the organohydrogenpolysiloxane and the number of moles of alkenyl groups in component (A) to have a value of 0.6:1 to 20:1, (E) a platinum group metal catalyst in a quantity providing 0.1 to 500 weight parts as platinum group metal per 1,000,000 weight parts component (A), and (F) 0,1 to 20 weight parts per 100 weight parts of (A) ot an epoxy group-containing organosilicon compound for application to airbags. Use as claimed in Claim 1 where the organopolysiloxane resin component (B) is a vinyl-containing organopolysiloxane resin. Use as claimed in Claim 1 where the inorganic filler component (C) is microparticulate silica having a specific surface area ≥ 50 m²/g. Use as claimed in Claim 1 wherein the platinum group metal catalyst component (E) is a chloroplatinic acid/divinyltetramethyl-disiloxane complex. Use as claimed in Claim 1 where the epoxy-containing organosilicon compound component (F) is an organosilicon compound that contains silicon-bonded alkoxy. Use as claimed in claim 1, wherein the liquid silicone rubber coating composition additionally contains (G) a compound selected from the group consisting of alkyne alcohols, ene-yne compounds, tetramethyltetrahexenylcyclotetrasiloxane, and benzotriazole.

Inventors: NAKAMURA AKITO, TSUJI KOICHI, NAKAMURA, AKITO, TSUJI, KOICHI, Nakamura, Akito, Main Office for R&amp;D Toray, Tsuji, Koichi, Main Office for R&amp;D Toray
Applicants: DOW CORNING TORAY SILICONE, DOW CORNING TORAY SILICONE COMPANY, LIMITED
Application year: 1993
Main classification: C09D183
IPC codes: C09D183, D06M15, B60R21, C08K3, C08L83, C08K5, C08G59, C09D163