U.S. patent application number 13/286590 was filed with the patent office on 2012-05-03 for side airbag cushion and method of manufacture.
Invention is credited to William Abney, III, Michael F. Fink, Dayne B. Hassett, Ryan T. Pinsenschaum, Douglas S. Weston, Mark T. Winters.
Application Number | 20120104735 13/286590 |
Document ID | / |
Family ID | 38921743 |
Filed Date | 2012-05-03 |
United States Patent
Application |
20120104735 |
Kind Code |
A1 |
Abney, III; William ; et
al. |
May 3, 2012 |
SIDE AIRBAG CUSHION AND METHOD OF MANUFACTURE
Abstract
An inflatable having: an inflatable portion, the inflatable
portion partially surrounding an area when the inflatable portion
is inflated; a non-inflatable member secured to the inflatable
portion and positioned in the area; and a retentive pocket formed
by the non-inflatable member, the retentive pocket having a
periphery bounded on at least one side by the non-inflatable member
and a peripheral portion of the non-inflatable member being
configured to vary a length of the peripheral portion of the
non-inflatable member such that a recessed area is formed in the
retentive pocket.
Inventors: |
Abney, III; William;
(Richmond, IN) ; Hassett; Dayne B.; (Centerville,
OH) ; Pinsenschaum; Ryan T.; (Dayton, OH) ;
Weston; Douglas S.; (Tipp City, OH) ; Winters; Mark
T.; (Troy, OH) ; Fink; Michael F.; (Mesa,
AZ) |
Family ID: |
38921743 |
Appl. No.: |
13/286590 |
Filed: |
November 1, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12772653 |
May 3, 2010 |
8047566 |
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13286590 |
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11866992 |
Oct 3, 2007 |
7708308 |
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12772653 |
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60828765 |
Oct 9, 2006 |
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Current U.S.
Class: |
280/730.2 |
Current CPC
Class: |
B60R 21/233 20130101;
B60R 2021/0048 20130101; B60R 21/232 20130101; B60R 2021/23386
20130101; B60R 21/2338 20130101 |
Class at
Publication: |
280/730.2 |
International
Class: |
B60R 21/16 20060101
B60R021/16 |
Claims
1. An inflatable cushion for deployment along an interior side of a
vehicle, comprising: an inflatable portion, the inflatable portion
partially surrounding an area when the inflatable portion is
inflated; a non-inflatable member secured to the inflatable portion
and positioned in the area; and a retentive pocket formed by the
non-inflatable member, the retentive pocket having a periphery
bounded on at least one side by the non-inflatable member and a
peripheral portion of the non-inflatable member being configured to
vary a length of the peripheral portion of the non-inflatable
member such that a recessed area is formed in the retentive pocket,
the recessed area being disposed within the periphery of the
retentive pocket; and wherein the area is defined by a first
perimeter, the first perimeter being further defined by an edge of
the inflatable cushion and a gap defined by the edge of the
inflatable cushion defining a portion of the first perimeter; and a
tether is secured to the edge of the inflatable cushion defining
the portion of the first perimeter, the tether traversing the gap
and providing a limit to a size of the gap when the inflatable
cushion is inflated and the non-inflatable member has a second
perimeter, the second perimeter being larger than the first
perimeter, the second perimeter being further defined by a first
edge portion and a second edge portion, the first edge portion
traversing the gap and the second edge portion is secured to the
non-inflatable member such that the tether is at least partially
enclosed in the non-inflatable member.
2. The inflatable cushion as in claim 1, wherein at least a portion
of the second edge portion of the non-inflatable member is secured
to the edge of the inflatable cushion.
3. An inflatable cushion for deployment along an interior side of a
vehicle, comprising: an inflatable portion, the inflatable portion
surrounding an area, wherein no portion of the inflatable portion
is disposed in the area, the area being defined by a perimeter; a
non-inflatable member secured to the inflatable portion and
positioned in the area, the non-inflatable member being defined by
a perimeter and wherein the non-inflatable member does not have any
tear seams and wherein the perimeter of the non-inflatable member
is greater than the perimeter of the area; a retentive pocket
formed by the non-inflatable member and the inflatable cushion, the
retentive pocket having a periphery partially bounded by the
inflatable portion and the non-inflatable member being configured
such that a recessed area is formed in the retentive pocket, the
recessed area being disposed within the periphery of the retentive
pocket; and wherein the area is defined by a perimeter, the
perimeter having an edge portion bounded by a lower edge portion of
the inflatable portion, the lower edge portion of the inflatable
portion being constrained to limit a lateral expansion of the lower
edge portion of the inflatable portion.
4. An inflatable cushion for deployment along an interior side of a
vehicle, comprising: an inflatable portion, the inflatable portion
surrounding an area, wherein no portion of the inflatable portion
is disposed in the area, the area being defined by a perimeter; a
non-inflatable member secured to the inflatable portion and
positioned in the area, the non-inflatable member being defined by
a perimeter and wherein the non-inflatable member does not have any
tear seams and wherein the perimeter of the non-inflatable member
is greater than the perimeter of the area; a retentive pocket
formed by the non-inflatable member and the inflatable cushion, the
retentive pocket having a periphery partially bounded by the
inflatable portion and the non-inflatable member being configured
such that a recessed area is formed in the retentive pocket, the
recessed area being disposed within the periphery of the retentive
pocket; and wherein the lower edge portion of the inflatable
portion is a tubular member and the tubular member has portions
stitched together in an alternating fashion to limit an expanded
size of the tubular member when the inflatable cushion is inflated.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application
Ser. No. 12/772,653 filed, May 3, 2010 which is a divisional of
U.S. patent application Ser. No. 11/866,992 filed Oct. 3, 2007 now
U.S. Pat. No. 7,708,308 which claims the benefit of U.S.
Provisional Patent Application Ser. No. 60/828,765 filed Oct. 9,
2006, the contents each of which are incorporated herein by
reference thereto.
BACKGROUND
[0002] The present invention relates to side airbag devices and
more particularly the present invention relates to an inflatable
cushion and method of manufacture.
[0003] Some vehicles are supplied with side airbag devices or side
airbag curtains. Generally the device is located along a side of
the vehicle and deploys an inflatable curtain in accordance with a
predetermined activation occurrence. The side impact airbags or
inflatable cushions are often mounted in close proximity to the
vehicle's roof rail, doorframe or center pillars, or in some
instances within the side door. Accordingly, the space or housing
for the un-inflated airbag is compact and extends or traverses
along the window area or frame, as the airbag cannot be installed
in the areas comprising the window. Moreover, it is also desirable
to have the inflatable cushion disposed behind a decorative trim
portion of the vehicle's interior. Thus, the presence of the side
airbag device is not observable to occupants when it is in its
un-deployed state.
[0004] When the airbag or inflatable cushion is mounted to the
vehicle the top edge portion is fixed and a lower edge portion,
which defines the bottom periphery of the airbag, deploys out of
the storage location positioned in close proximity to the roof
rail. Furthermore, and referring in particular to larger or longer
vehicles (e.g., sports utility vehicles, vans, mini-vans, station
wagons, etc.) a single side airbag or inflatable cushion that
extends from the A pillar to the D pillar, or further, of the
vehicle has to have an extended length to cover the side areas of
the vehicle. Accordingly, these extended inflatable cushions
require additional inflator output in order to inflate and maintain
the inflation of the cushion for a pre-determined period of
time.
[0005] In addition, and due to the location of deployment of these
cushions (e.g., vehicle side, A-D pillars) it is desirable to
provide these cushions with an extended period of inflation.
Moreover, and depending on the vehicle type other areas of the
cushion that traverse across the interior of the vehicle may not
require inflation. However, these areas still comprise a portion of
the inflatable cushion.
[0006] The required extended period of inflation may comprise up to
and exceed five seconds. These extended periods of inflation allow
the inflatable cushion to provide a retentive barrier across the
opening of the windows of the vehicle. In order to provide
inflation cushions which retain their inflation gases for extended
periods of time the cushion is in one configuration provided with
sealed seams in accordance with the teachings of U.S. Pat. No.
6,220,309, the contents of which are incorporated herein by
reference thereto. Alternatively, sealed cushions are provided by
disposing sealing material such as silicone between the edges of
two sheets of fabric members comprising the inflatable cushion. In
addition, these types of cushions (e.g., less permeable cushions or
cushions that retain inflation gases for extended periods of time)
are expensive to manufacture. Accordingly and as side impact
inflation cushions become larger in order to cover extended lengths
and areas their associated costs increase.
[0007] Alternatively, a plurality of cushions may be provided each
having a separate inflator and installation location, which will
result in additional costs. Moreover, usage of multiple cushions
with additional inflators will result the requirement of additional
space behind the interior trim as well as associated manufacturing
costs for multiple installation locations.
[0008] Accordingly, it is desirable to provide a cost-efficient
side airbag module wherein a plurality of separate inflatable
cushions are provided without the associated costs. In addition, it
is also desirable to provide an inflatable cushion for a side
airbag module wherein the same is configured to provide a portion
of a retentive barrier.
SUMMARY OF THE INVENTION
[0009] Exemplary embodiments of the present invention relate to a
side airbag and method for making. In an exemplary embodiment, an
inflatable cushion and method of making an inflatable cushion for
deployment along an interior side of a vehicle is disclosed.
[0010] In one exemplary embodiment, an inflatable cushion is
provided. Exemplary embodiments are directed to an inflatable
cushion for deployment along an interior side of a vehicle. In one
exemplary embodiment the inflatable cushion has: an inflatable
portion, the inflatable portion partially surrounding an area; a
non-inflatable member secured to the inflatable portion and
positioned in the area; and a retentive pocket formed by the
non-inflatable member and the inflatable cushion, the retentive
pocket having a periphery bounded on at least one side by the
non-inflatable member and the non-inflatable member being
configured such that a recessed area is formed in the retentive
pocket, the recessed area being disposed within the periphery of
the retentive pocket.
[0011] In another exemplary embodiment, an inflatable cushion for
deployment along an interior side of a vehicle is provided, the
inflatable cushion comprising: an inflatable portion, the
inflatable portion surrounding an area, wherein no portion of the
inflatable portion is disposed in the area; a non-inflatable member
secured to the inflatable portion and positioned in the area; and a
retentive pocket formed by the non-inflatable member and the
inflatable cushion, the retentive pocket having a periphery bounded
by the inflatable portion the non-inflatable member being
configured such that a recessed area is formed in the retentive
pocket, the recessed area being disposed within the periphery of
the retentive pocket.
[0012] In yet another exemplary embodiment, an inflatable cushion
is provided. The inflatable cushion having: a first inflatable
portion; a non-inflatable member depending away from the first
inflatable portion; and a retentive pocket formed on a portion of
the non-inflatable member.
[0013] In yet another exemplary embodiment, an inflatable cushion
is provided. The inflatable cushion having: an inflatable portion,
the inflatable portion surrounding an area, wherein no portion of
the inflatable portion is disposed in the area, the area being
defined by a perimeter; a non-inflatable member secured to the
inflatable portion and positioned in the area, the non-inflatable
member being defined by a perimeter and wherein the non-inflatable
member does not have any tear seams and wherein the perimeter of
the non-inflatable member is greater than the perimeter of the
area; a retentive pocket formed by the non-inflatable member and
the inflatable cushion, the retentive pocket having a periphery
partially bounded by the inflatable portion and the non-inflatable
member being configured such that a recessed area is formed in the
retentive pocket, the recessed area being disposed within the
periphery of the retentive pocket; and wherein the area is defined
by a perimeter, the perimeter having an edge portion bounded by a
lower edge portion of the inflatable portion, the lower edge
portion of the inflatable portion being constrained to limit a
lateral expansion of the lower edge portion of the inflatable
portion.
[0014] In yet another exemplary embodiment, an inflatable cushion
is provided. The inflatable cushion having: an inflatable portion,
the inflatable portion surrounding an area, wherein no portion of
the inflatable portion is disposed in the area, the area being
defined by a perimeter; a non-inflatable member secured to the
inflatable portion and positioned in the area, the non-inflatable
member being defined by a perimeter and wherein the non-inflatable
member does not have any tear seams and wherein the perimeter of
the non-inflatable member is greater than the perimeter of the
area; a retentive pocket formed by the non-inflatable member and
the inflatable cushion, the retentive pocket having a periphery
partially bounded by the inflatable portion and the non-inflatable
member being configured such that a recessed area is formed in the
retentive pocket, the recessed area being disposed within the
periphery of the retentive pocket; and wherein the lower edge
portion of the inflatable portion is a tubular member and the
tubular member has portions stitched together in an alternating
fashion to limit an expanded size of the tubular member when the
inflatable cushion is inflated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a side view of an inflatable cushion constructed
in accordance with an exemplary embodiment of the present
invention;
[0016] FIG. 2 is a side view of another inflatable cushion;
[0017] FIG. 3 is a side view of another inflatable cushion
constructed in accordance with an exemplary embodiment of the
present invention;
[0018] FIGS. 4 and 5 are views illustrating pleats on non-inflated
portions of an inflatable cushion constructed in accordance with an
exemplary embodiment of the present invention;
[0019] FIG. 6 is a view of a deployed inflatable cushion without a
pleat;
[0020] FIG. 7 is a view of a deployed inflatable cushion with a
pleat;
[0021] FIG. 8 is a view of a deployed inflatable cushion in
accordance with alternative exemplary embodiment of the present
invention;
[0022] FIG. 9 is a schematic illustration of another alternative
exemplary embodiment of the present invention;
[0023] FIGS. 10 and 11 are illustrations of still another
alternative exemplary embodiment of the present invention;
[0024] FIG. 12 is an illustration of an exemplary embodiment of the
present invention;
[0025] FIGS. 13A and 13B illustrate still another alternative
exemplary embodiment of the present invention; and
[0026] FIG. 14 is a schematic illustration of another alternative
exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0027] This disclosure in one embodiment relates to an inflatable
cushion and method of manufacture wherein the cushion has separate
cushion sections that are manufactured separately and assembled
together to provide an extended inflatable cushion, which is less
expensive to manufacture as areas not requiring inflation are not
covered by inflatable portions of the cushion, which typically add
to the related manufacturing costs. In accordance with an exemplary
embodiment, the non-inflated sections of the inflatable cushion are
provided with pleats or pleated areas to provide a desired
configuration to the non-inflated section as well as the inflatable
cushion. In one exemplary embodiment separate cushion sections are
manufactured for assembly into various configurations for use in
various vehicles having various sizes and configurations. In
another exemplary embodiment, the inflatable cushion comprises a
single inflatable portion with a single non-inflatable portion.
[0028] This application is related to U.S. patent application Ser.
No. 11/229,329, filed Sep. 16, 2005 and U.S. patent application
Ser. No. 10/914,884, filed Aug. 10, 2004 the contents each of which
are incorporated herein by reference thereto.
[0029] The fabric used for the inflatable cushion in airbag modules
is a significant portion of the total cost for the module. This is
especially true for curtain airbags due to the large size of the
cushion. It is further magnified on systems employing
low-permeability fabrics and sealed seams in order to provide
longer inflation periods without increasing the size of the
inflator to provide a longer duration output to overcome the loses
of the gases from the cushion. One piece woven constructions are
desired due to the retention capabilities. An example of such
construction is found in U.S. Pat. No. 6,220,309 the contents of
which are incorporated herein by reference thereto. However, for
very large cushions the cost is again increased because it can be
difficult to package several cushions side-by-side on the fabric
roll.
[0030] Often, the curtain cushions have large un-inflated regions.
These areas sometimes correspond to the areas between seats where
inflatable sections are not required however, the retentive
characteristics of the inflatable cushion may still be desired. In
order to minimize the cost of the cushion a composite construction
method may be employed. It being understood the composite and
non-composite constructions are within the scope of exemplary
embodiments of the present invention. The composite construction
allows the un-inflated regions to be made of a low-cost material
that could then be attached to the one-piece woven sections or more
expensive sections. The one-piece woven sections would be smaller
and therefore result in more efficient nesting of the patterns on
the sheets of material used for the inflatable cushions thus, less
material waste is caused by smaller cushion sizes as they provide
greater availability of orientations on a piece of material of a
given size. In other words by reducing the size of the cushion the
smaller cushions are able to be orientated in various positions on
a standard sheet (limited by manufacturing constraints) of the
material used for the inflatable cushion thus, the multiple
cushions may be placed on a single sheet in various orientations to
limit waste materials. A single inflator would be used and the gas
would be delivered to the inflatable, one-piece woven sections
using a diffuser tube.
[0031] In addition, and in accordance with an exemplary embodiment
a pleat is also positioned in the un-inflated portion or single
sheet to provide a desired deployment configuration of the
inflatable cushion. In one exemplary embodiment, the pleat forms a
containment area or retentive pocket on a portion of the single
sheet or non-inflated portion.
[0032] Referring now to FIG. 1, an airbag or inflatable cushion 10
constructed in accordance with exemplary embodiments of the present
invention is illustrated. As illustrated, inflatable cushion 10 is
manufactured and constructed in order to traverse from the A pillar
to a D pillar of a vehicle, as illustrated by the dashed lines in
FIG. 1. It is, of course, understood that inflatable cushion 10 is
configurable to cover other arrangements (e.g., A pillar to B
pillar, A pillar to C pillar and B pillar to C pillar etc.). In one
exemplary embodiment separate cushion sections are manufactured for
assembly into various configurations for use in various vehicles
having numerous size configurations. These sections comprise the
inflatable portions, which comprise the more expensive portions or
materials of the inflatable cushion.
[0033] As illustrated, inflatable cushion 10 comprises a first
forward section 12, a second section 14 and a third rear section
16. First section 12 comprises a forward leading edge 18, a
rearward edge 20, an upper portion 22 and a lower edge 24. In
accordance with an exemplary embodiment, the leading edge 18 is
configured to have an angled portion that traverses towards the
vehicle windshield. It is also noted that sections 14 and 16 may
also be configured to have angled sections or alternatively a pair
of sections 12 may be combined with section 14 thus angled portions
will be at either end of the cushion. These various configurations
allow the assembled cushion to be used with various vehicle
configurations. In an exemplary embodiment section 12 also
comprises inflatable portions 23 and un-inflatable portions 25. The
un-inflatable portions are positioned in areas not requiring
inflation thus, the inclusion of un-inflatable portions 25 will
reduce the inflator output required to inflate the section. In
addition, the un-inflatable portions may also be configured to
assist in deployment of the section or the inflatable cushion and a
particular direction.
[0034] In order to provide first section 12 with inflation output
from an inflator, an inflation opening 26 is in fluid communication
with inflatable portions 23. An inflator 28, in accordance with
technologies known to those skilled in the art, provides an
inflation output to inflation opening 26 via one end of a fluid
dispersing conduit 30. In accordance with an exemplary embodiment,
fluid dispersing conduit 30 comprises tubing such as a plastic or
metal pipe or conduit, or woven tubing. Fluid dispersing conduit 30
comprises a fluid inlet 32 that provides fluid communication
between an outlet opening of the inflator 28 and fluid dispersing
conduit 30. It is, of course, understood and as applications may
vary, the positioning of the inflator may be located in other
positions than those illustrated in the drawings. For example, the
inflator may be located in a forward vehicle position. Thus, the
presented location is provided as an example and the present
invention is not intended to be limited by the same. In yet another
alternative, the inflator may be remotely located and a conduit or
other fluid providing means is used to supply the inflating gas
from the inflator to the inflatable cushion.
[0035] At another end of fluid dispersing conduit 30 a first
inflation opening 34 of a forward end 38 of second section 14 is in
fluid communication with fluid dispersing conduit 30. In the
embodiment of FIG. 1, second section 14 also comprises a rearward
edge 40, an upper edge 42 and a lower edge 44. Similar to first
section 12, second section 14 comprises inflatable portions 46 and
un-inflatable portions 48.
[0036] As illustrated in FIG. 1 an un-inflated single layer section
50 is disposed between rearward edge 20 of first section 12 and
forward edge 38 of second section 14. In accordance with an
exemplary embodiment section 50 may comprise a single layer of
fabric or alternatively, a layer of webbing or net that will
traverse the expanse between the two sections.
[0037] In an exemplary embodiment, un-inflated single layer section
50 comprises a portion of the inflatable cushion 10, which
traverses an area not requiring an inflatable cushion (e.g., the
area of the cushion which will traverse across the B pillar of the
vehicle or portion of the vehicle that is between the doors and
accordingly the seats of the vehicle). Of course, un-inflated
section 50 may traverse other areas of the vehicle not having
structural members associated therewith. Moreover and in accordance
with an exemplary embodiment, un-inflated section 50 may be located
in areas wherein the same is required for a retentive barrier.
[0038] Accordingly, and through the use of un-inflated section 50
the overall amount of material required for inflatable portions of
the inflatable cushion is reduced thereby reducing the overall cost
of the inflatable cushion. In addition, the configurations of first
section 12 and second section 14 allow the same to be manufactured
in separate manufacturing steps, which allows for modular
construction of the inflatable cushion wherein un-inflated section
50 and fluid dispersing conduit are secured to first section 12 and
second section 14 during separate manufacturing steps, which can be
performed at separate manufacturing facilities.
[0039] In addition, un-inflated single layer section 50 is provided
with a pleat 51 or a plurality of pleats. As used herein "pleat" is
intended to refer to a portion or area of the un-inflated single
layer section 50 that is configured to provide or form a retentive
pocket in the un-inflated section. For example, in one non-limiting
exemplary embodiment, the pleat comprises a portion of the
un-inflated layer that is folded upon itself and secured together
to vary the configuration of un-inflated single layer section
50.
[0040] In another exemplary embodiment, the retentive pocket is
formed by cutting a portion of the un-inflated section and
thereafter sewing or securing the edges together to provide the
retentive pocket. Thus, the pleat is formed by sewing or securing
the edges of an opening cut in the un-inflated section back
together (for example, see FIG. 1).
[0041] In yet another exemplary embodiment, the retentive pocket is
formed by configuring a lower edge of the un-inflated layer to have
a peripheral configuration such that when secured to the inflatable
portion or portions the retentive pocket is formed (for example see
FIGS. 10 and 11).
[0042] Referring back now to FIG. 1, pleat 51 comprises a portion
of the un-inflated section that is sewn upon itself to modify the
configuration of the un-inflated section to provide a desired
effect when the inflatable cushion is deployed and inflated. In one
exemplary embodiment, the "desired effect" is to provide a
retentive barrier in the area between the inflatable section of the
inflatable cushion (e.g., area 50 and other areas as will be
discussed herein). Another "desired effect" of the pleat or
exemplary embodiment of the present invention is to provide the
retentive barrier without the need of separately applying tension
along the entire lower edge or a portion of the lower edge of the
inflatable cushion when it is deployed and inflated. Non-limiting
examples of devices for providing tension along the lower edge of
the inflatable cushion include tethers, wherein a first tether is
secured to a forward edge of the inflatable cushion and a portion
of the vehicle frame and a second tether is secured to a rearward
edge of the inflatable cushion and a portion of the vehicle
frame.
[0043] In other words and by pleating a portion of the un-inflated
single layer a retentive pocket is formed in the un-inflated
portion, wherein the pleat forms an edge or peripheral portion of
the retentive pocket. Thus, the retentive pocket forms a retentive
barrier in the non-inflated portion of the inflatable cushion
without requiring the need to provide tension along the bottom edge
of the inflatable cushion.
[0044] Although, the embodiment of FIG. 1 illustrates the
non-inflatable portion as comprising a single layer it is
understood that exemplary embodiments of the present invention
contemplate numerous configurations wherein the inflatable sections
and non-inflatable sections may comprise a single layer or multiple
layers, a single cushion or segmented cushion secured together and
combinations thereof wherein a retentive pocket is formed in the
non-inflatable portion and wherein the retentive pocket is formed
without providing tension along an entire lower edge or a portion
of a lower edge of the inflatable cushion.
[0045] In order to provide a robust securement about fluid
dispersing conduit 30 a securement means 52 is provided to secure a
portion of the inflatable sections about fluid dispersing conduit
30. A non-limiting example of securement means 52 is a band clamp.
Other contemplated means include adhesives and/or welding
techniques.
[0046] In a similar fashion a fluid dispersing conduit 30 provides
fluid communication between second inflation opening 36 and an
inflation opening 54 of rear section 16. Similarly to the other
sections, rear section 16 has a forward leading edge 56, a rearward
edge 58, an upper edge 60 and a lower edge 62. Section 16 also
comprises inflatable portions or chambers 64 and non-inflatable
portions 66. In accordance with an exemplary embodiment rearward
edge 58 is configured to match a profile of a rearward portion of
the vehicle. An un-inflated single layer section 68 is disposed
between rearward edge 40 of second section 14 and forward edge 56
of third section 16.
[0047] In an exemplary embodiment, un-inflated single layer section
68 comprises a portion of the inflatable cushion 10, which
traverses an area not requiring an inflatable cushion, e.g., the
area of the cushion, which will traverse across the C pillar of the
vehicle and correspond to a location not adjacent to a seat of the
vehicle thus, an area not requiring an inflatable section.
Un-inflated single layer section 68 is secured to rearward edge 40
of second section 14 and forward edge 56 of third section 16 via
stitching or welding or other equivalent securement means during an
assembly step when cushion 10 is assembled.
[0048] Again, un-inflated section 68 is also provided with a pleat
71 to provide a desired deployment configuration of the inflatable
cushion. In one exemplary embodiment, the pleat provides a
containment area on a portion of the single sheet or non-inflated
portion.
[0049] It is also understood that the configuration of the
inflatable cushion may vary and the illustrations of the sections
in the Figures are provided as examples and the present invention
is not intended to be limited to the specific configurations
provided in the figures, as they are considered ancillary to the
present invention. For example, the un-inflated sections may
traverse other areas of the vehicle, which may or may not
correspond to the location of the pillars of the vehicle frame.
[0050] Moreover, the present invention is contemplated for use with
numerous other vehicle configurations. For example, the vehicle may
include three rows of seats; such vehicles include but are not
limited to sports utility vehicles, station wagons, vans or
minivans. Conversely, the vehicle may comprise only a single row of
seats such vehicles include but are not limited to sports
coupes.
[0051] Prior to deployment, the inflatable cushion is stored in a
compartment mounted to the roof rail or proximate to the roof rail.
In order to store the airbag into the compartment the un-inflated
airbag is folded into a configuration which allows it to occupy a
small discrete area within the vehicle interior. In accordance with
exemplary embodiments of the present invention, the inflatable
cushion is folded by a machine in order to provide the
configurations disclosed herein. It is also possible to fold the
inflatable cushion by hand.
[0052] When a predetermined activation event or occurrence is
detected, the inflatable cushion is inflated by gas from the
inflator. In general, the inflator will receive an inflation or
deployment signal that causes the inflator to generate an inflation
gas or inflation output for inflating the inflatable cushion. In an
exemplary embodiment, the deployment signal is generated by a
controller, such as a microcontroller of a sensing and diagnostic
module configured for use with the airbag module. The sensing and
diagnostic module receives a plurality of signals from appropriate
sensing devices (e.g., door mounted accelerometers), and will
generate a deployment signal if a predetermined activation event
has been sensed.
[0053] Referring now to FIGS. 2 and 3, another exemplary embodiment
of the present invention is illustrated. Here an inflatable cushion
110 is illustrated without a pleat (FIG. 2) and with a pleat (FIG.
3). In this embodiment cushion 110 has a slightly different
configuration than the inflatable cushion illustrated in FIG. 1.
Here a first inflatable section 112 is fluidly connected to another
inflatable section 114 via a connecting section 115 of the
inflatable cushion. In one exemplary embodiment, inflatable section
115 is integrally formed with inflatable sections 112 and 114 and
the inflatable sections/members and non-inflatable sections
comprise multiple layers of fabric. In other words, at least two
layers of fabric are sewn and sealed together to form cushion 110,
wherein the inflatable chambers and non-inflatable sections are
formed by the sealing of the two layers together. It is also
understood that cushion 110 may be formed from multiple layers
comprising more than three layers. In addition and in yet another
embodiment, the inflatable sections are formed from two layers and
the non-inflatable sections are formed from a single layer or two
or more layers. As illustrated, at least three non-inflated
sections 149, 150 and 168 are provided. In this embodiment, a pleat
151 is positioned on non-inflated section 150, creating a retentive
pocket 161.
[0054] Non-limiting examples of the construction of the retentive
pocket are illustrated in FIGS. 11-14. Although a single pleat is
shown, exemplary embodiments of the present invention contemplate a
single pleat, a plurality of pleats, each of which may be disposed
along a lower edge of the non-inflated section or in another
portion of the non-inflated section as long as the desired effect
is achieved. FIG. 6 illustrates the inflation or deployment of an
inflatable cushion without a retentive pocket while FIG. 7
illustrates the inflation or deployment of an inflatable cushion
with a retentive pocket. As illustrated, a lower edge 157 of
un-inflated section 150 of the inflatable cushion of FIG. 6 is
longer than a lower edge 159 of un-inflated section 150 of the
inflatable cushion of FIG. 7.
[0055] FIG. 8 illustrates an inflated or deployed inflatable
cushion having un-inflated sections comprising a single sheet of
fabric with a pleated section to provide the desired deployment
configuration of the un-inflated section as well as the inflatable
cushion as a whole.
[0056] Referring now to FIG. 9 yet another exemplary embodiment of
the present invention is illustrated. Here inflatable cushion 210
is formed via a pair of sheets of fabric sewn together wherein an
inflatable portion 212 is in fluid communication with another
inflatable portion 214 and the non-inflated member 250 comprises at
least two sheets of fabric sewn together and the pleat is located
on the non-inflated member, wherein at least one or both of the
sheets of the non-inflatable member are folded and secured together
to form the pleat and the non-inflated member provides the
retentive pocket on the inflatable cushion.
[0057] In accordance with exemplary embodiments of the present
invention although a pleat is shown as a means for providing the
retentive pocket other means for providing a retentive pocket in
the non-inflatable section of the inflatable cushion are
contemplated to be within the scope of the present invention.
[0058] Referring now to FIGS. 10 and 11 an alternative exemplary
embodiment of the present invention is illustrated. Here a portion
of an inflatable cushion 310 for deployment along an interior side
of a vehicle is illustrated. The inflatable cushion has an
inflatable portion 312. As illustrated, the inflatable portion
partially surrounds an area 313 when the inflatable portion is
inflated. Area 313 corresponds to an area not comprising inflatable
portions of the inflatable cushion. The inflatable cushion further
comprises a non-inflatable member 350 secured to the inflatable
portion and positioned in the area. The non-inflatable member and
the inflatable cushion forms a retentive pocket 355 for receiving a
portion of an occupant therein when the inflatable cushion is
inflated. The retentive pocket has a periphery 357 bounded on at
least one side 359 by an edge of the non-inflatable member and the
non-inflatable member is configured such that a recessed area 361
is formed in the retentive pocket. The recessed area being disposed
within the periphery of the retentive pocket that is defined by the
non-inflatable member and the edges of the inflatable member.
[0059] In one exemplary embodiment, the recessed area of the
retentive pocket is centrally located within the non-inflatable
member. Of course, the recessed area may be disposed anywhere in
the area or non-inflatable member.
[0060] In another alternative embodiment and as illustrated in FIG.
12, the periphery of the retentive pocket bounded by the
non-inflatable member further comprises a pleat 351. In one
non-limiting exemplary embodiment, the pleat comprises a portion of
the non-inflatable member that is folded and secured together.
Furthermore, and as illustrated in FIG. 12 the pleat is located on
a lower edge of the inflatable cushion. Of course, other locations
are contemplated to be within the scope of exemplary embodiments of
the present invention.
[0061] In one non-limiting exemplary embodiment, the non-inflatable
member is a single layer of fabric and the inflatable portion
further comprises a plurality of inflatable cells 363.
[0062] As illustrated in FIGS. 10 and 11, the non-inflatable member
comprises an oversized shaped panel, wherein a lower portion
controls a distance between edges of the inflatable cushion. Here a
periphery of an upper portion of the non-inflatable member is
larger than the periphery it is secured to thus and when the
non-inflatable member is sewn in place slack is built therein to
form the retentive pocket.
[0063] As illustrated in FIGS. 10 and 11, the area 313 is defined
by a first perimeter, the first perimeter being further defined by
an edge 315 of the inflatable cushion and a gap 371 between the
edge of the inflatable cushion defining a portion of the first
perimeter. Furthermore, the non-inflatable member has a second
perimeter, the second perimeter being larger than the first
perimeter, the second perimeter being further defined by a first
edge portion and a second edge portion, the first edge portion
traversing the gap defined by the edge of the inflatable cushion
defining a portion of the first perimeter and the first edge
portion has a distance less than a length of the gap when the
inflatable cushion is inflated and when the non-inflatable member
is not secured to the inflatable cushion.
[0064] An upper edge portion or second edge portion of the
non-inflatable member is at least partially secured to the edge of
the inflatable cushion defining a portion of the first
perimeter.
[0065] Referring now to FIGS. 13A and 13B, an alternative exemplary
embodiment is disclosed. Again, the area is defined by a first
perimeter, the first perimeter being further defined by an edge 315
of the inflatable cushion and a gap between the edge of the
inflatable cushion defining a portion of the first perimeter. In
this embodiment, a tether 373 is secured to the edge of the
inflatable cushion defining the portion of the first perimeter and
also defining the gap, the tether traversing the gap and providing
a limit to a size of the gap when the inflatable cushion is
inflated. The non-inflatable member has a second perimeter, the
second perimeter being larger than the first perimeter, the second
perimeter is further defined by a first edge portion and a second
edge portion, the first edge portion traversing the gap and second
edge portion is secured to the edge of the inflatable cushion
defining the area. The second edge portion has a greater length or
distance than the edge of the inflatable cushion defining the area
such that a portion of the non-inflatable member extends past the
gap and then the first edge portion is secured (e.g., stitching,
adhesives, welding, etc.) to the non-inflatable member such that
the tether is at least partially enclosed in the non-inflatable
member.
[0066] In another alternative exemplary embodiment and referring
now to FIG. 14, the inflatable portion surrounds the area 313 and
no portion of the inflatable portion is disposed in the area. The
non-inflatable member is disposed in the area and is secured to the
inflatable portion and the retentive pocket formed by the
non-inflatable member and an edge of the inflatable portion, the
edge bounding a periphery of the non-inflatable member. In this
embodiment, the non-inflatable member is configured such that a
recessed area is formed in the retentive pocket, the recessed area
being disposed within the periphery of the retentive pocket.
[0067] Here the perimeter of the area is bounded by a lower edge
portion 379 of the inflatable portion. In accordance with an
exemplary embodiment of the present invention, the lower edge
portion of the inflatable portion is constrained to limit a lateral
expansion (e.g., in the direction of arrows 381) of the lower edge
portion of the inflatable portion.
[0068] In one exemplary embodiment, the lower edge portion of the
inflatable portion is a tubular member and the tubular member has
portions 383 stitched together in an alternating fashion to limit
an expanded size of the tubular member when the inflatable cushion
is inflated. Portions 383 are configured to allow inflation gases
to pass therethough and therein to allow for inflation of the
tubular member.
[0069] In one non-limiting exemplary embodiment, the non-inflatable
member is a single layer of fabric and the inflatable portion
further comprises a plurality of inflatable cells and the recessed
area of the retentive pocket is centrally located in the
non-inflatable member. Of course, other configurations are
contemplated to be within the scope of exemplary embodiments of the
present invention.
[0070] In accordance with exemplary embodiments of the present
invention the inflatable cushion is configured to provide a
retentive pocket when the same is inflated in accordance with a
predetermined activation event. In some embodiments, a
non-inflatable member provides the retentive pocket wherein a lower
edge of the non-inflatable member is provided with little or no
tension along the lower edge prior to interaction with an occupant
and after interaction with the occupant the lower edge of the
non-inflatable member is provided with tension and the retentive
pocket contains a portion of the occupant therein. In one exemplary
embodiment, the pleat provides the tension along the lower edge
after an occupant interacts with the retentive pocket. Moreover,
and during occupant interaction of the inflatable cushion a
vertical tension is created to portions of the inflatable cushion.
The vertical tension being created due to occupant interaction and
tension being applied along the lower edge of the pocket and/or
cushion from the interaction. As referred to herein, vertical
tension is shown by arrows 390 while horizontal or tension along
the lower edge is shown by arrows 392 in FIG. 12. It being
understood, that the vertical tension may be angularly positioned
with respect to the horizontal or tension along the lower edge and
that the tension along the lower edge may be at any angle.
Furthermore, the horizontal and vertical tension may be found in
any of the embodiments of the present invention although not
specifically illustrated by arrows 390 and 392. It is, of course,
understood that vertical tension and horizontal tension ultimately
depends on the cushion configuration and the occupant
interaction.
[0071] While the invention has been described with reference to an
exemplary embodiment, it will be understood by those skilled in the
art that various changes may be made and equivalents may be
substituted for elements thereof without departing from the scope
of the invention. In addition, many modifications may be made to
adapt a particular situation or material to the teachings of the
invention without departing from the essential scope thereof.
Therefore, it is intended that the invention not be limited to the
particular embodiment disclosed as the best mode contemplated for
carrying out this invention, but that the invention will include
all embodiments falling within the scope of the present
application.
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