Abstract: A composite sheet is disclosed. The composite sheet comprises an open random fibrous web having substantially vertical fibers near a top surface, a first binder resin and a second binder resin, wherein the first binder resin has a melting point lower than the melting point of the second binder resin, wherein the melting point of the second resin is lower than the melting point of the web, wherein the resins are activated in situ with the web fibers to form a resin-fiber rich region on the top surface and wherein the abrasion-resistant sheet can withstand at least about 3,000 cycles on the Wyzenbeek abrasion test using 80-grit abrasive paper. An abrasion-resistant sheet comprising a single binder resin and other abrasion-resistant sheets are also disclosed. Processes for making these abrasion-resistant sheets are further disclosed herein.

Abstract: A new adhesive coating composition, particularly for use on airbag fabrics, which is composed of a silicone polymer and an appreciable level of a copolymer of ethylene and a polar monomer, is provided. This coating provides excellent adhesive properties to the coated fabric and provides a synergistic effect such that lower gas permeability upon inflation may be obtained with this coating than might be achieved with the silicone polymer alone. Additionally, such a coating allows maximization of the adhesion characteristics on one-piece woven airbag fabric such that blistering upon high-pressure inflation can be reduced, while retaining a high degree of inflation gas retention. Fabric treated with this material in the manner described herein permits reduction in the cost of the coating itself (by reducing the use of expensive silicone polymers). Airbag fabrics and cushions, as well as methods of making and using such a novel airbag coating material are also encompassed within this invention.

Abstract: A polymeric fiber liner insulation includes of a resilient, insulation blanket core of randomly oriented entangled fibers with between 60% and 90% by weight of the fibers being standard polymeric fibers and/or flame retardant polymeric fibers and between 10% and 40% by weight of the fibers being polymeric lofting and bonding fibers. The first major surface the liner insulation has a low porosity or air and/or liquid impervious surface layer. The surface layer is formed by melting and consolidating fibers at and adjacent the first major surface of the blanket core or by coating the first major surface of the blanket core with a polymeric coating. The liner insulation exhibits a flame spread/smoke developed index of ≦25/50.