Heat resistant coating for use in airbags and methods of their manufacture

1. A vehicle safety device, comprising:

an airbag comprising a base fabric and forming an interior space, wherein the airbag defines an aperture;

a pyrotechnic device positioned within working proximity to the aperture defined in the airbag, wherein the pyrotechnic device is configured to fill the interior space of the airbag with a gas upon ignition; and

a heat shield positioned within the interior of the airbag and proximate to the aperture, wherein the heat shield comprises:

a base substrate;

a heat resistant coating on the base substrate, wherein the heat resistant coating comprises particles of an organic material dispersed within a film-forming binder, wherein the organic material comprises vermiculite, mica, or a combination thereof; and

a first point-bonded sheet laminated to the heat resistant coating such that the first point-bonded sheet forms an outer surface of the heat shield with the heat resistant coating positioned between the first point-bonded sheet and the base substrate, and wherein the heat shield is positioned such that the first point-bonded sheet faces the interior space of the airbag.

2. The vehicle safety device as in claim 1 , wherein the heat shield further comprises:

a second point-bonded sheet laminated to the base substrate such that the second point-bonded sheet is positioned opposite to the first point-bonded sheet.

3. The vehicle safety device as in claim 1 , wherein the base substrate is a nonwoven fabric, a woven fabric, or a film.

4. The vehicle safety device as in claim 1 , wherein the film-forming binder comprises an acrylic resin, a styrene-butadiene rubber, a polyvinyl alcohol, an ethyl vinyl acetate resin, a phenolic resin, or a combination thereof.

5. The vehicle safety device as in claim 1 , wherein the particles have an average thickness of less than about 50 nm, and wherein the particles have a largest dimension of about 0.5 μm to about 50 μm.

6. The vehicle safety device as in claim 1 , wherein the particles have an aspect ratio of between about 500:1 to about 1000:1.

7. The vehicle safety device as in claim 1 , wherein the heat resistant coating further comprises a surfactant, a plasticizer, or a combination thereof.

8. The vehicle safety device as in claim 1 , wherein the inorganic material comprises about 50% by weight to about 95% by weight of the heat resistant coating upon drying.

9. The vehicle safety device as in claim 1 , wherein the heat resistant coating has an average thickness of about 10 μm to about 100 μm.

10. The vehicle safety device as in claim 1 , wherein the first point-bonded sheet comprises a point-bonded nonwoven web of thermoplastic and/or thermoset polymers.

11. The vehicle safety device as in claim 1 , wherein the heat shield defines a laminate having a total thickness of about 0.1 mm to about 1 mm.

12. The vehicle safety device as in claim 1 , wherein the base substrate comprises a plastic film having a thin metal coating.

13. The vehicle safety device as in claim 1 , wherein the thin metal coating comprises aluminum.

14. The vehicle safety device as in claim 1 , wherein the plastic film comprises a polyester.

15. The vehicle safety device as in claim 1 , wherein the heat resistant coating is directly adjacent to the thin metal film.

16. The vehicle safety device as in claim 1 , wherein the base substrate is point-bonded.

17. The vehicle safety device as in claim 1 , wherein the heat shield surrounds the aperture.