U.S. patent application number 13/440053 was filed with the patent office on 2012-09-27 for secured force concentrator in a vehicular bolster for airbag retention and deployment.
This patent application is currently assigned to LEAR CORPORATION. Invention is credited to Richard G. Dierl, Michael L. Tracht.
Application Number | 20120242123 13/440053 |
Document ID | / |
Family ID | 39277707 |
Filed Date | 2012-09-27 |
United States Patent
Application |
20120242123 |
Kind Code |
A1 |
Tracht; Michael L. ; et
al. |
September 27, 2012 |
SECURED FORCE CONCENTRATOR IN A VEHICULAR BOLSTER FOR AIRBAG
RETENTION AND DEPLOYMENT
Abstract
A vehicle seat assembly includes a frame for mounting the seat
to a vehicle. The seat assembly also includes a seat pad located
proximate the frame. A trim cover is disposed over the seat pad,
and includes a seam adjacent a side of the seat pad. An airbag
assembly, which includes an airbag and an inflator configured to
supply gas to the airbag, is also part of the seat assembly. A
force concentrator covers at least a portion of the seat pad for
protecting the pad during deployment of the airbag. The force
concentrator includes an inner panel attached to the airbag
assembly and an outer panel attached to the frame. The panels form
a deployment channel for the airbag, and thereby inhibit contact of
the airbag with the seat pad as the airbag deploys.
Inventors: |
Tracht; Michael L.;
(Ingolstadt, DE) ; Dierl; Richard G.;
(Sandersdoft, DE) |
Assignee: |
LEAR CORPORATION
Southfield
MI
|
Family ID: |
39277707 |
Appl. No.: |
13/440053 |
Filed: |
April 5, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11779594 |
Jul 18, 2007 |
8167333 |
|
|
13440053 |
|
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Current U.S.
Class: |
297/216.1 ;
29/428 |
Current CPC
Class: |
Y10T 29/49826 20150115;
B60R 21/207 20130101; B60R 2021/161 20130101 |
Class at
Publication: |
297/216.1 ;
29/428 |
International
Class: |
B60R 21/207 20060101
B60R021/207; B23P 11/00 20060101 B23P011/00 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 14, 2006 |
DE |
10 2006 053 601.0 |
Claims
1. A vehicle seat assembly, comprising: a frame for mounting the
seat assembly to a vehicle; a seat pad disposed proximate to the
frame with a portion or portions spaced apart from the frame; a
trim cover disposed over at least a part of the seat pad and
including a seam adjacent a side of the seat pad; an airbag
assembly securely attached to the frame so that rigid reaction
surfaces are provided against which forces of deployment may be
exerted, the airbag assembly including an airbag and an inflator
configured to supply gas to the airbag, the airbag assembly having
a clamshell housing at least partially surrounding the airbag, the
clamshell housing including a frangible split line proximate to the
seam to facilitate deployment of the airbag along an uninterrupted
deployment channel so that upon airbag deployment, the frangible
split line breaks and the clamshell housing opens and applies a
rupturing force at each side of and across the seam; a force
concentrator covering at least a portion of the seat pad for
protecting the seat pad during the deployment of the airbag, the
force concentrator including inner and outer panels and forming the
deployment channel therebetween for the airbag; the inner panel
extending substantially along an entire side of the clamshell
housing, the inner panel including a distal end secured to the
airbag assembly, the inner panel interfacing with the seat pad
along substantially all of the inner panel; and the outer panel
extending along a part of another side of the clamshell housing to
facilitate assembly, the outer panel having a distal end secured to
a portion of the frame, the outer panel interfacing with the seat
pad along substantially all of the outer panel.
2. The vehicle seat assembly of claim 1, wherein the deployment
channel is oriented to facilitate deployment of the airbag through
the seam in the trim cover.
3. The vehicle seat assembly of claim 1, wherein the inner and
outer panels of the force concentrator each include a proximal end
attached to the trim cover at the seam.
4. The vehicle seat assembly of claim 1, wherein the clamshell
housing at least partially surrounds the airbag, and the frangible
split line is offset from the seam.
5. The vehicle seat assembly of claim 4, wherein the panels
cooperate to form the deployment channel proximate a front of the
airbag housing.
6. The vehicle seat assembly of claim 5, wherein the inner panels
and the trim are sewn together by the airbag seam.
7. A vehicle seat assembly, comprising: a frame for mounting the
seat assembly to a vehicle; a seat pad disposed proximate the
frame; a trim cover disposed over at least a part of the seat pad
and including a seam adjacent to a side of the seat pad; an airbag
assembly, including an airbag and an inflator configured to supply
gas to the airbag, thereby facilitating deployment of the airbag;
and a force concentrator covering at least a portion of the seat
pad for protecting the seat pad during deployment of the airbag,
the force concentrator including an inner panel extending between
the seam and the airbag assembly and an outer panel extending
between the seam and the frame, the panels cooperating with each
other to form a deployment channel therebetween for the airbag such
that deployment of the airbag along the deployment channel moves a
portion of the seat pad away from the deploying airbag, while the
force concentrator inhibits contact between the seat pad and the
deploying airbag, the orientation of the deployment channel
facilitating deployment of the airbag through the seam in the trim
cover, so that deployment forces are substantially directed toward
the seam by the panels.
8. The vehicle seat assembly of claim 7, wherein the airbag
assembly includes a housing at least partially surrounding the
airbag, the housing including a frangible portion to facilitate
deployment of the airbag along the deployment channel.
9. The vehicle seat assembly of claim 8, wherein the inner and
outer panels of the force concentrator cooperate to form the
deployment channel proximate a front of the airbag housing.
10. The vehicle seat assembly of claim 9, wherein the inner panel
of the force concentrator includes a proximal seam end attached to
the trim cover at the seam, and a distal end attached to the airbag
assembly.
11. The airbag assembly of claim 9, wherein the outer panel has a
distal end secured to the frame.
12. A method of producing the vehicle seat assembly of claim 1,
comprising the steps of: A. locating a bolster, which includes a
wire frame with a deployment channel opening upwardly; B. placing a
trim material on the bolster, while aligning an airbag seam with
the opening of the deployment channel; C. feeding a force
concentrator having inner and outer panels, which are sewn to the
trim, into and through the deployment channel; D. affixing the trim
to the bolster; E. mounting the outer panel to the wire frame; F.
placing an airbag module adjacent the outer panel, and into the
cavity of the bolster; G. fastening the inner panel to the airbag
module; and H. securing the airbag housing to the wire frame,
thereby providing a rigid reaction surface against which the forces
of deployment may be exerted.
13. A method of producing the vehicle seat assembly of claim 1,
comprising the steps of: A. installing the seat pad, which includes
the frame and the deployment channel; B. placing the trim cover on
the seat pad, while aligning the airbag seam with the deployment
channel; C. feeding the force concentrator with its inner and outer
panels, which are sewn to the seam, into and through the deployment
channel; D. affixing the cover to the seat pad; E. affixing the
inner panel to the airbag assembly; F. placing the airbag assembly
between the inner and outer panels and into the seat pad, the
airbag assembly having the clamshell housing and the split line
adjacent the seam that opens against the inner and outer panels of
the force concentrator, so that the inner and outer panels
interface with the sides of the clamshell housing and directing
deployment along a deployment channel; G. fastening the outer panel
to a portion of the frame; and H. securing the airbag housing to
the frame, thereby providing a rigid reaction surface against which
the forces of deployment may be exerted to rupture the seam.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims foreign priority benefits under 35
U.S.C. .sctn.119(a)-(d) to DE 10 2006 053 601.0, filed Nov. 14,
2006, which is hereby incorporated by reference in its entirety.
This application also claims priority to and is a continuation of
U.S. Ser. No. 11/779,594 filed Jul. 18, 2007.
DESCRIPTIONS
[0002] 1. Field of the Invention
[0003] The invention relates to a vehicle seat assembly, and in
particular, a seat assembly with a secured force concentrator in a
bolster thereof for retaining and deploying a side airbag.
[0004] 2. Background Art
[0005] Vehicles today are often equipped with side airbags. They
may take the form of an airbag disposed within the seat back or
cushion of a vehicle seat assembly. One limitation of airbags that
are located within a seat assembly is that the airbag needs to
break through the seating material before it can fully deploy to
protect a vehicle occupant. During deployment, such an airbag may
encounter foam or other seat pad materials. It must then break
through a seat trim cover in order to escape from the seat
assembly.
[0006] A number of attempts have been made to facilitate deployment
of airbags from and through a vehicle seat assembly. One such
device is described in U.S. Pat. No. 5,816,610 issued to Higashiura
et al. on Oct. 6, 1998. Higashiura et al. describes a seat
structure having a side impact airbag apparatus. A side bolster pad
of the seat structure may be made from foam, in which case the
airbag apparatus is surrounded by a lining member. The lining
member has a perforation to facilitate its breaking when the airbag
deploys. The side bolster itself is covered with a surface layer
having a seam almost directly opposite the perforation in the
lining member. In this way, the airbag deploys through the
perforation in the lining member, breaks through the foam of the
seat pad, and exits the seat structure through the seam in the
surface layer. One limitation of the seat structure described in
Higashiura et al. is that the airbag must deploy through the seat
pad before exiting the seat structure. In particular, the airbag,
which may be moving with very high velocity, impacts the foam seat
pad as it exits the seat structure. This can cause pieces of the
seat pad to be expelled from the seat as the airbag exits the seat
cover. Therefore, a need exists for a seat assembly that includes
protection for the seat pad from the deploying airbag.
[0007] Another device is described in U.S. Pat. No. 6,045,151 which
issued to Wu on Apr. 4, 2000. Wu describes a seat assembly
including a side airbag with a force concentrator that surrounds
the airbag to concentrate and direct the force of the inflating
airbag by a pre-determined deployment seam so that the seam may
rupture and allow the airbag to deploy therethrough. Wu discloses
two embodiments of the force concentrator: (1) a layer of sheet
material joined to the inside of the trim cover; and (2) a sleeve
or pocket of sheet material which entirely surrounds the airbag
module. '151 Patent, col. 2, lines 51-65.
[0008] Other patents of interest include U.S. Pat. No. 5,816,610
which issued to Higashiura et al. on Oct. 6, 1998; U.S. Pat. No.
5,860,673 which issued to Hasegawa et al. on Jan. 19, 1999; U.S.
Pat. No. 5,927,749 which issued to Homier et al. on Jul. 27, 1999;
and U.S. Pat. No. 6,206,410 which issued to Brown on Mar. 27,
2001.
SUMMARY OF THE INVENTION
[0009] The prior art leaves at least partially unsolved the problem
of designing and assembling vehicle seats with a side airbag that
can be deployed consistently, regardless of the physical properties
of the seat trim cover and seat foam pad.
[0010] It would be useful to have a seat with a side airbag, the
deployment of which does not vary significantly over time,
regardless of the extent of wear and imperfection or damage
sustained by the trim cover.
[0011] The present invention provides a vehicle seat assembly
including a seat pad and a force concentrator configured to
facilitate the manufacturing process and protect the seat pad
during deployment of an airbag from within the side bolster.
[0012] The invention further provides a vehicle seat assembly
including a frame for mounting the seat to the vehicle. A seat pad
is disposed proximate the frame. A trim cover is disposed at least
partially over the seat pad, and includes a seam adjacent a side of
the seat pad. An airbag assembly is provided, which includes an
airbag and an inflator which is configured to supply gas to the
airbag, thereby facilitating its deployment. A force concentrator
covers at least a portion of the seat pad for protecting the seat
pad during deployment of the airbag. The force concentrator
includes multiple panels--preferably, inner and outer panels--that
form a deployment channel therebetween for the airbag, thereby
avoiding contact of the airbag with the seat pad during deployment
during expansion.
[0013] For added rigidity, in one embodiment, the inner panel has
one end secured to a frame member. The outer panel, in some
embodiments, fastens, for example, by a hook to the airbag module
itself.
[0014] The panels of the force concentrator cooperate with each
other such that deployment of the airbag along the deployment
channel moves a portion of the seat pad away from the deploying
airbag, while avoiding contact between the seat pad and the
deploying airbag. The orientation of the deployment channel
facilitates deployment of the airbag through the seam in the trim
cover so that substantially all of the deployment forces are
directed to the deployment channel, thereby increasing the speed at
which the airbag deploys.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a quartering perspective view of a portion of the
backrest of a seat assembly in accordance with the present
invention;
[0016] FIG. 2 is a sectional view of inner and outer panels of a
force concentrator located in the seat assembly shown in FIG. 1,
taken through the line A-A;
[0017] FIG. 3 is a quartering perspective view of the panels in
isolation from the view of FIG. 1 with the airbag and most of the
housing removed, in which the panels are attached to a structural
member of the seatback and to part of the housing; and
[0018] FIG. 4 resembles the view of FIG. 2, but illustrates an
embodiment in which the inner panel is affixed to the side airbag
module and the outer panel is secured to the vehicle frame.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0019] The invention relates to the integration of a multi-part,
preferably a two-part panel--the inner and the outer panel--in a
rear backrest or cushion of a seat that is mounted in a vehicle. As
used herein, the terms "inner" and "outer" respectively are used in
relation to proximity to the vehicle seat occupant and the vehicle
door.
[0020] FIG. 1 shows a portion--for example, a rear side bolster--of
a seat assembly 10 in accordance with the present invention. It
should be realized that although a rear side bolster is
illustrated, the invention is not so limited. The invention can
reside in any seatback or seat cushion. The seat assembly 10
includes a side bolster 12 and seat pad 16 that is at least
partially covered by a trim cover 18. The seat pad 16 preferably is
made from a molded polymeric material, such as a polyurethane foam.
The use of a polymeric foam material to construct the seat pad 16
is cost effective and provides the flexibility needed to change the
shape of the seat pad for different types of seat assemblies. Of
course, other types of polymeric materials may be molded to form
the seat pad 16.
[0021] Disposed within the side bolster 12 is an airbag assembly or
module 20. As shown in FIG. 2, the airbag assembly 20 includes an
airbag and an inflator 24, which is configured to supply gas to the
airbag 22, thereby facilitating deployment of the airbag 22. Also
shown in FIG. 2 is a portion of a seat frame 26 which can be used
for mounting the airbag assembly 20 to the seat assembly 10. The
seat pad 16 is disposed proximate the frame 26 and may be directly
attached to the frame 26 at various locations.
[0022] The trim cover 18 includes a seam 28 which is adjacent to a
side 30 or another side of the seat pad 16. It should be
appreciated that the seam 28 is a tear seam that could be located
on the trim in front of the module or at other locations that are
generally in the direction of deployment of the airbag from the
module. Covering at least a portion of the seat pad 16 is a force
concentrator 32 which protects the seat pad 16 during deployment of
the airbag 22. Inner (first) 34 and outer (second) 36 panels also
have the function of directing the force of the deploying airbag
directly into the tear seam. The forces of deployment are initially
directed against members by which the housing is secured in
relation to the frame of the seat. The deployment forces then are
exerted against the panels 34, 36, thereby focusing deployment
forces upon the seam 28 without significant diversion.
[0023] Comprising inner 34 and outer 36 panels, the force
concentrator 32 may be made from any material effective to protect
the seat pad 16 during deployment of the airbag 22. For example, a
woven or non-woven cloth material, which may include natural or
synthetic materials such as nylon. One material that is found to be
effective is a polyamide material, of the type from which the
airbag 22 may be manufactured. Regardless of the type of material
used to make the force concentrator 32, the use of the force
concentrator 32 can reduce friction on the airbag 22 as it deploys.
Although a polymer such as nylon may be particularly beneficial,
even a fleece material will help reduce the friction on the airbag
22. This is because the force concentrator 32 inhibits contact
between the deploying airbag 22 and the seat pad 16.
[0024] In the embodiment shown in FIG. 2, the force concentrator 32
effectively prohibits all contact between the deploying airbag 22
and the seat pad 16. This helps to prevent energy loss from the
airbag 22 by decreasing friction and protecting the seat pad 16
from damage. This, in turn, helps to reduce the deployment time of
the airbag 22.
[0025] As shown in FIG. 2, the force concentrator 32 includes inner
and outer panels 34, 36 which form a deployment channel 38 for the
airbag 22. As the airbag 22 deploys from the housing 40 through the
deployment channel 38, the force concentrator 32 inhibits contact
between the airbag 22 and the seat pad 16. Thus, portions of the
seat pad 16 are moved away from the airbag 22 as it deploys through
the deployment channel 38.
[0026] The deployment channel 38 is oriented to facilitate
deployment of the airbag 22 through the seam 28 in the trim cover
18.
[0027] In particular, the airbag assembly 20 includes a housing 40
which at least partially surrounds the airbag 22 and the inflator
24. The housing 40 can resemble a clamshell cover with its split
line 39 oriented toward the tear seam 28. The housing 40 includes a
frangible portion which is broken by the airbag as it deploys. The
frangible portion 60 is disposed opposite the deployment channel 38
to facilitate deployment of the airbag along the channel 38 and out
from the seam 28.
[0028] Although the airbag housing 40 comprises a relatively rigid
material, in other embodiments, a thin sheet of material may be
used in place of a rigid housing. In such embodiments, the sheet
may contain a frangible portion, as its properties will be such
that it will tear as the airbag 22 deploys.
[0029] As shown in FIGS. 2-3, the inner and outer panels 34, 36 of
the force concentrator 32 respectively include ends 62, 64 that are
attached to the trim cover 18 at the seam 28. This configuration
helps to facilitate deployment of the airbag 22 through the seam
28. The deployment channel 38 opens as the airbag 22 is deployed,
thereby causing the panels 34, 36 to exert an outward force on the
trim cover 18 at the seam 28. This ruptures the seam 28 and
provides an exit path for the airbag 22.
[0030] The airbag seam 28 preferably is sewn through the edges of
ends 62 and 64 with both sides of the trim between them. It will
thus be appreciated that in most embodiments, the seam 28 extends
between all four layers.
[0031] As mentioned earlier, the force concentrator 32 includes two
separate panels 34, 36. In FIG. 3 the end 62 of the inner panel 34
of the force concentrator 32 is attached at the seam 28 (FIG. 2) of
the trim cover 18. A distal end 63 of the inner panel 34 of the
force concentrator 32 is attached to the seat frame 26. This
provides a convenient means for securely attaching the inner panel
34 of the force concentrator 32.
[0032] Similarly, the seam end 64 of the outer panel 36 of the
force concentrator 32 is attached at the seam 28 of the trim cover
18. A distal end 65 of the outer panel 36 of the force concentrator
32 may be attached to the side airbag module 20.
[0033] Thus, the force concentrator 32 not only provides a
deployment channel for the airbag 22, but also protects the seat
pad 16 from damage during high velocity deployment.
[0034] In FIG. 3, reference numerals 66, 67, respectively,
designate retainers, for example, one or more J-clamps, that
respectively affix the distal ends 63, 65 of the inner and outer
panels to the seat frame 26 and to the side airbag module 20. It
will be appreciated that the retainers 66, 67 have a shape that is
not limited to those depicted in FIG. 3.
[0035] It will also be appreciated that, as depicted in FIG. 4, if
desired, depending upon the application, the inner panel 34 may be
affixed to the side airbag module 20. Alternatively also, the outer
panel 36 may have a distal end 65 that is secured to a portion of
the seat frame 26.
[0036] One methodology by which the pad, trim, and airbag module
may be affixed to a side bolster is as follows:
[0037] A. Placing the bolster, which includes the wire frame that
preferably is molded in situ, with the deployment channel opening
upwardly;
[0038] B. Placing the trim on top of the bolster, while aligning
the airbag seam with the opening of the deployment channel;
[0039] C. Feeding the panels, which are sewn to the trim, into and
through the deployment channel;
[0040] D. Affixing the trim to the bolster (e.g., by retainers or
other fasteners);
[0041] E. Mounting the inner panel to the wire frame as shown in
FIGS. 2-3; F Fastening the outer panel to the side airbag module or
as shown in FIGS. 2-3;
[0042] G. Placing the airbag module between the inner and outer
panels, and into the cavity of the bolster; and
[0043] H. Feeding the threaded bolts through the holes of the
airbag housing.
[0044] While embodiments of the invention have been illustrated and
described, it is not intended that these embodiments illustrate and
describe all possible forms of the invention. Rather, the words
used in the specification are words of description rather than
limitation, and it is understood that various changes may be made
without departing from the spirit and scope of the invention.
* * * * *