Coated airbag

1. A method for making a one-piece woven airbag, the method comprising:

(a) creating a one-piece woven fabric, the created fabric comprising a single fabric layer seam and a multiple fabric layer inflation chamber, the single fabric layer seam comprising odd-numbered woven baskets and even-numbered woven baskets;

(b) feeding the created fabric into a coating machine;

(c) preheating an initial outer surface of the fed fabric in the coating machine;

(d) extruding a polymeric material using the coating machine;

(e) coating the extruded polymeric material upon the preheated initial outer surface using the coating machine, the coated polymeric material being configured to operably reduce air permeability through the fabric if the inflation chamber is inflated, the preheated initial outer surface remaining hot during the coating, an entirety of a thickness of the coated polymeric material after solidification on the initial outer surface of the fabric being within the range of 1-6 thousandths of an inch and having a coverage area within the range of about 30-90 grams per square meter;

(f) compressing the fabric in the coating machine such that the coated polymeric material on the initial outer surface is substantially solidified;

(g) inverting the fabric coated on the initial outer surface such that an outer surface of the fabric that is opposite the coated initial outer surface is upwardly facing;

(h) feeding the inverted fabric into the coating machine;

(i) preheating the opposite outer surface of the fed inverted fabric in the coating machine; and

(j) coating the extruded polymeric material upon the preheated opposite outer surface of the inverted fabric using the coating machine,

wherein the coating of the extruded polymeric material upon the preheated initial outer surface and upon the preheated opposite outer surface comprises varying an amount of the extruded polymeric material such that a surface of the coated polymeric material is flat and independent of thickness variations of the created fabric.

2. The method of claim 1 , wherein the compressing of the fabric comprises cooling the coated polymeric material on the fabric.

3. The method of claim 1 , wherein the odd-numbered woven baskets are defined by 3×3 woven baskets, and

wherein the even-numbered woven baskets are defined by 2×2 woven baskets.

4. The method of claim 1 , wherein the one-piece woven fabric is made of nylon 6/6.

5. The method of claim 1 , wherein the one-piece woven fabric is made of polyester.

6. The method of claim 1 , wherein the one-piece woven fabric is woven on a programmable jacquard loom.

7. The method of claim 1 , wherein the coating machine comprises a coextruder having two or more extruder sections with corresponding feed hoppers, rotating screws located within heated barrels that correspond with the extruder sections, a combining block connected to the barrels, and an elongated die connected to the combining block, and

wherein the die has a laterally elongated exit slot downwardly facing toward the one-piece woven fabric during the coating.

8. The method of claim 1 , further comprising rolling up the one-piece woven fabric after the creation of the one-piece woven fabric,

wherein the one-piece woven fabric is unrolled during the feeding of the created fabric into the coating machine.

9. The method of claim 1 , wherein the one-piece woven fabric contacts against a lead-in roll after being fed into the coating machine and before being preheated.

10. The method of claim 1 , wherein the one-piece woven fabric moves through the coating machine at a speed with a range of about 0.3 msec-1.6 msec.

11. The method of claim 1 , wherein the compressing of the fabric comprises pressing against a backside of the one-piece woven fabric and a steel chill roll with a rubber roll.

12. The method of claim 1 , wherein the coating of the extruded polymeric material is a curtain-type coating that is performed essentially along a full width of the one-piece woven fabric.

13. The method of claim 1 , wherein a dwell time between the preheating of the initial outer surface to the coating of the material upon the preheated initial outer surface is 10 seconds or less.

14. The method of claim 1 , wherein the coated polymeric material is thermoplastic.

15. The method of claim 14 , wherein the thermoplastic material is applied to the one-piece woven fabric at a temperature within a range of about 200° C.-250° C.

16. The method of claim 1 , wherein the coated polymeric material comprises an inner adhesive material penetrating into and bonding with the one-piece woven fabric and an outer air impermeable and leak-resistant material bonded to the inner adhesive material.

17. The method of claim 16 , wherein the air impermeable material has a tensile strength within the range of 30 MPa-50 MPa.

18. The method of claim 16 , wherein, after solidification of the initial outer surface, approximately one half of the initial outer surface is the adhesive and approximately another half of the initial outer surface is the air-impermeable material.

19. The method of claim 16 , wherein the inner adhesive material is a thermoplastic material.

20. The method of claim 19 , wherein the thermoplastic material is an ethylene copolymer.

21. The method of claim 16 , wherein the air impermeable material is a thermoplastic polyurethane polymer.

22. The method of claim 21 , wherein the thermoplastic polyurethane polymer has a molecular weight within a range of 100,000-200,000.

23. The method of claim 16 , wherein the air impermeable material is polymeric and has an ultimate elongation percentage that is greater than 300%.

24. The method of claim 23 , wherein the ultimate elongation percentage of the air impermeable material is in a range of 500%-700%.

25. The method of claim 1 , wherein the preheating is performed by infrared heaters, and

wherein the initial outer surface of the one-piece woven fabric is preheated to a fabric temperature within a range of 100° C.-180° C.

26. The method of claim 25 , wherein the coating machine comprises an elongated die, and

wherein at least one of the infrared heaters is 3 meters or less from the die and 0.3 meters per second of fabric speed from the die.