Flexible heat shield with silicone elastomer and a topcoat for inflatable safety devices

1. A thermally resistant layered composite sheet for an inflatable vehicle safety device, the composite sheet comprising:

a first fabric layer having a top side and a bottom side; and

a thermal barrier layer comprising;

at least one silicone elastomer layer, and

one or more silicone topcoats different from the silicone elastomer layer;

the thermal barrier layer being located adjacent to one of the sides such that the silicone topcoat is spaced from the first fabric layer and the silicone elastomer layer is sandwiched between the first fabric layer and the silicone topcoat;

wherein the silicone elastomer layer is formed from a liquid silicone rubber (LSR) composition and exhibits a weight that is between about 100 g/m 2 to about 600 g/m 2 ;

wherein the silicone topcoat is formed from a different LSR composition and exhibits a weight that is between about 3 g/m 2 to about 50 g/m 2 ;

wherein the composite sheet has a thermal resistance value of six seconds or more at 725° C. with the thermal resistance imparted by the silicone topcoat being greater than the thermal resistance imparted by an equal amount by weight of the silicone elastomer layer; and

wherein the Young's modulus of elasticity of the silicone topcoat of the thermal barrier layer is greater than that of the silicone elastomer layer of the thermal barrier layer.

2. The composite sheet of claim 1 , wherein the first fabric layer comprises a fabric material and one or more silicone treatments located on the top side or bottom side, optionally wherein the silicone treatment of the first fabric layer is located on the top side or bottom side of the first fabric layer that is either adjacent to the thermal barrier layer or opposite the side that is adjacent to the thermal barrier layer.

3. The composite sheet of claim 1 , further comprising a second fabric layer having a top side and bottom side;

the second fabric layer being located either adjacent to the thermal barrier layer or on the side of the first fabric layer that is opposite to the thermal barrier layer; and

the second fabric layer including a fabric material and optionally one or more silicone treatments located on the top side or bottom side.

4. The composite sheet of claim 1 , having a thermal resistance value of 12 seconds or more at 725° C., alternatively 30 seconds or more at 725° C.

5. The composite sheet of claim 1 , wherein the first fabric layer comprises a fabric material and the fabric material of the first fabric layer is a woven fabric, a nonwoven fabric, or a polymeric film or composite selected from polypropylene, polyethylene, fiberglass, polyamides, poly(ethylene) terephthalate, and compositions or mixtures thereof.

6. The composite sheet of claim 5 , wherein the first fabric layer is:

i) a woven fabric having threads with a thickness that is equal to or greater than 20 dtex; or

ii) a nonwoven fabric or a polymeric film having a basis weight between about 40 g/m 2 and about 400 g/m 2 .

7. The composite sheet of claim 1 , wherein

the silicone elastomer layer exhibits a weight that is between about 150 g/m 2 to about 500 g/m 2 .

8. The composite sheet of claim 1 , wherein the hardness of the silicone topcoat of the thermal barrier layer is greater than that of the silicone elastomer layer of the thermal barrier layer.

9. The composite sheet of claim 3 , wherein the thermal barrier layer comprises at least two topcoats, with a first topcoat being located adjacent the silicone elastomer and a second topcoat separated from the first topcoat and silicone elastomer by the second fabric layer.

10. The composite sheet of claim 1 , wherein the LSR composition of the silicone topcoat comprises:

an organopolysiloxane having one or more silicon atom-bonded alkenyl groups on average in one molecule;

an organohydrogenpolysiloxane;

a hydrosilylation reaction catalyst present in any amount capable of curing the coating composition; and

optionally a filler material.

11. The composite sheet of claim 1 , wherein the silicone topcoat exhibits a weight between about 5 g/m 2 to about 30 g/m 2 .

12. The composite sheet of claim 1 , wherein the Young's modulus of elasticity of the silicone topcoat of the thermal barrier layer is at least 10% greater, alternatively is at least 20% greater, than that of the silicone elastomer layer of the thermal barrier layer.

13. The composite sheet of claim 12 , wherein the Young's modulus of elasticity of the silicone topcoat of the thermal barrier layer is greater than about 2 MPa, alternatively is greater than about 5 MPa.

14. The composite sheet of claim 8 , wherein the hardness of the silicone topcoat of the thermal barrier layer is greater than about 35 durometer (Shore A), alternatively is greater than about 40 durometer (Shore A).

15. The composite sheet of claim 7 , wherein the silicone topcoat exhibits a weight between about 5 g/m 2 to about 30 g/m 2 .

16. An inflatable vehicle safety device comprising:

an inflator capable of providing an inflation fluid;

a fluid compartment inflatable by the inflator; and

(i) an inflator wrap located adjacent to the inflator; and/or

(ii) a heat shield located within the fluid compartment;

wherein at least one of the inflator wrap and heat shield comprises a thermally resistant layered composite sheet; and

wherein the thermally resistant layered composite sheet is according to claim 1 .

17. The inflatable vehicle safety device of claim 16 , wherein the inflator wrap is present and comprises the thermally resistant layered composite sheet.

18. The inflatable vehicle safety device of claim 16 , wherein the heat shield is present and comprises the thermally resistant layered composite sheet.

19. The inflatable vehicle safety device of claim 16 , wherein the fluid compartment is selected from a front air bag, a side air bag, an air curtain, an H-sock, a Y-sock, a knee bag, and a belt bag.