Method of making a flame resistant airbag suitable for use in aviation applications

A method of making a flame resistant aviation airbag suitable for use in aviation applications, said method comprising the steps of:

• providing a high tenacity continuous polyester filament yarn, said high tenacity continuous polyester filament yarn having a polyester fiber substrate and a phosphate-phosphonate compound;
• weaving said high tenacity continuous polyester filament yarn into a plain weave pattern fabric;
• said fabric comprising a plurality of high tenacity continuous polyester filament yarn woven into a plain weave pattern characterized by a count of 49-53 per inch by 49-53 per inch;
• heat setting said fabric to between 340 degrees Fahrenheit to 420 degrees Fahrenheit for a period of time of about 30 to 60 seconds;
• providing a coating composition onto said fabric and said coating composition comprising a flame retardant and a polyurethane;
• applying said coating composition to the fabric to achieve a coat weight of between 25-50 grams per square meter;
• and constructing an aviation airbag utilizing said fabric, whereby said aviation airbag exhibits a high pressure permeability resistance characterized as a pressure of not less than 198 kPa after five seconds from an initial inflation and pressurization to 200 kPa, as well as, vertical flammability performance, and adequately conforms pursuant to Federal Aviation Requirements 25.853 which is characterized as:
• being self-extinguishing when tested vertically in accordance with Federal Aviation Requirement 25.853, Appendix F, Part I (b)(4) or other equivalent means;
• having an average burn length not exceeding 8 inches when tested vertically in accordance with Federal Aviation Requirement 25.853, Appendix F, Part I (b)(4) or other equivalent means;
• having an average flame time after removal of the flame source not exceeding 15 seconds when tested vertically in accordance with Federal Aviation Requirement 25.853, Appendix F, Part I (b)(4) or other equivalent means;
• and
• having drippings that do not continue to flame for more than 5 seconds after falling when tested vertically in accordance with Federal Aviation Requirement 25.853, Appendix F, Part I (b)(4) or other equivalent means.