U.S. patent application number 13/834822 was filed with the patent office on 2014-09-18 for air bag deployment restrictor.
This patent application is currently assigned to TRW Vehicle Safety Systems Inc.. The applicant listed for this patent is TRW VEHICLE SAFETY SYSTEMS INC.. Invention is credited to Robert W. Balsis, Kurt F. Fischer, Douglas M. Gould.
Application Number | 20140265269 13/834822 |
Document ID | / |
Family ID | 51418918 |
Filed Date | 2014-09-18 |
United States Patent
Application |
20140265269 |
Kind Code |
A1 |
Fischer; Kurt F. ; et
al. |
September 18, 2014 |
AIR BAG DEPLOYMENT RESTRICTOR
Abstract
An apparatus (10) for helping to protect an occupant of a
vehicle that has an instrument panel and a windshield includes an
air bag (14) packaged in an air bag module (30). The air bag (14)
is inflatable to a deployed position between the instrument panel
and a vehicle occupant. A deployment restrictor (100) is secured to
the air bag module (30). The deployment restrictor (100) includes a
deflector panel (102) secured to the air bag module (30) and having
a portion that is positioned between the packaged air bag (14) and
the windshield. The deflector panel (102) at least partially covers
the packaged air bag (14) so that the deflector panel moves with
the deploying air bag toward the windshield. The connection of the
deflector panel (102) to the air bag module (30) limits movement of
the deflector panel toward the windshield and thereby redirects the
air bag to deploy away from where it would otherwise impact the
windshield.
Inventors: |
Fischer; Kurt F.; (Leonard,
MI) ; Gould; Douglas M.; (Lake Orion, MI) ;
Balsis; Robert W.; (Imlay City, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
TRW VEHICLE SAFETY SYSTEMS INC. |
Washington |
MI |
US |
|
|
Assignee: |
TRW Vehicle Safety Systems
Inc.
Washington
MI
|
Family ID: |
51418918 |
Appl. No.: |
13/834822 |
Filed: |
March 15, 2013 |
Current U.S.
Class: |
280/730.1 |
Current CPC
Class: |
B60R 21/205 20130101;
B60R 21/2346 20130101; B60R 2021/23388 20130101; B60R 2021/23386
20130101; B60R 2021/161 20130101; B60R 21/201 20130101 |
Class at
Publication: |
280/730.1 |
International
Class: |
B60R 21/2334 20060101
B60R021/2334 |
Claims
1. An apparatus for helping to protect an occupant of a vehicle
that has an instrument panel and a windshield, the apparatus
comprising: an air bag packaged in an air bag module, the air bag
being inflatable to a deployed position between the instrument
panel and a vehicle occupant; and a deployment restrictor secured
to the air bag module, the deployment restrictor comprising a
deflector panel having a portion that is positioned between the
packaged air bag and the windshield and that at least partially
covers the packaged air bag so that the deflector panel moves with
the deploying air bag toward the windshield, the connection of the
deployment restrictor to the air bag module limiting movement of
the deflector panel toward the windshield and thereby redirecting
the air bag to deploy away from where it would otherwise impact the
windshield.
2. The apparatus recited in claim 1, wherein the deflector panel
comprises a front portion secured to the air bag module, and side
portions connected to the air bag module laterally of the packaged
air bag, the connections of the front portion and side portions to
the air bag module limiting movement of the deflector panel so that
the deflector panel directs the air bag to deploy away from where
it would otherwise impact the windshield.
3. The apparatus recited in claim 2, wherein the deployment
restrictor at least partially defines a deployment opening through
which the air bag deploys, the portions of the deployment
restrictor that define the deployment opening helping to direct the
air bag to deploy through the deployment opening.
4. The apparatus recited in claim 3, wherein the deflector panel
further comprises a rear portion secured to the air bag module, the
deployment restrictor comprising a rupturable portion for releasing
the connection of the rear portion to the air bag module in
response to deployment of the air bag to permit the air bag to
deploy through the deployment opening.
5. The apparatus recited in claim 2, wherein the deployment
restrictor comprises a multilayer strap that extends between the
connections of the side portions to the air bag module, the
multilayer strap being positioned to receive the initial force
generated by the deploying air bag.
6. The apparatus recited in claim 5, wherein the multilayer strap
at least partially defines a deployment opening through which the
air bag deploys, the strap helping to direct the air bag to deploy
through the deployment opening.
7. The apparatus recited in claim 5, further comprising brackets
that are fastened to the multilayer straps, the brackets
reinforcing the connection of the straps to the air bag module.
8. The apparatus recited in claim 2, wherein the deployment
restrictor further comprises deployment straps that connect the
side portions of the deflector panel to the air bag module.
9. The apparatus recited in claim 8, wherein the deployment straps
comprise narrow strip portions of the deflector panel that extend
from the side portions, the strips being doubled over onto
themselves to give the deployment straps a multilayer
construction.
10. The apparatus recited in claim 9, wherein the deployment
restrictor further comprises deployment strap reinforcing portions
comprising narrow strips of material positioned overlying the
narrow strip portions of the deflector panel, the deployment strap
reinforcing portions being doubled over along with the narrow strip
portions of the deflector panel and thereby forming additional
layers in the multilayer construction of the deployment straps.
11. The apparatus recited in claim 1, wherein the deployment
restrictor comprises a cowl-shaped fabric structure connected to
the air bag module, the deployment restrictor at least partially
defining a deployment opening through which the air bag
deploys.
12. The apparatus recited in claim 1, wherein the deployment
restrictor comprises at least one strap having looped ends for
being secured to integral hooks formed on the air bag module.
13. The apparatus recited in claim 1, wherein the deflector panel
comprises a tear seam, the deployment restrictor comprising a strap
and connections connecting the strap to the deflector panel on
opposite sides of the tear seam, the tear seam maintaining a
portion of the strap between the connections in a slackened
condition.
14. The apparatus recited in claim 13, wherein the strap helps
define a deployment opening through which the air bag deploys, the
tear seam being adapted to rupture as the air bag deploys which
takes up the slackened portion of the strap to increase the size of
the deployment opening.
15. An apparatus for helping to protect an occupant of a vehicle
that has an instrument panel and a windshield, the apparatus
comprising: an air bag packaged in an air bag module, the air bag
being inflatable to a deployed position between the instrument
panel and a vehicle occupant; and a deployment restrictor
comprising a cowl-shaped fabric structure connected to the air bag
module, the deployment restrictor directing the air bag to deploy
through a deployment opening at least partially defined by the
deployment restrictor in a direction away from where the air bag
would otherwise deploy and impact the windshield.
16. The apparatus recited in claim 15, wherein the deployment
restrictor comprises a deflector panel having a cowl-shaped portion
that at least partially covers the air bag in the packaged,
pre-deployment condition, movement of the cowl-shaped portion with
the air bag upon deployment being limited by the connection of the
deployment restrictor to the air bag module so that the deflector
panel redirects the deploying air bag.
17. The apparatus recited in claim 16, wherein the deflector panel
comprises a front portion and opposite side portions that are
secured to the air bag module, the connections of the front portion
and side portions to the air bag module helping to maintain the
cowl-shaped configuration of the deflector panel so that the
deflector panel redirects the deploying air bag.
18. The apparatus recited in claim 17, wherein the deflector panel
further comprises a rear portion secured to the air bag module
through a rupturable connection that is releasable to permit the
deployment restrictor to assume its cowl-shaped configuration and
help define the deployment opening through which the air bag is
deployed.
19. The apparatus recited in claim 15, wherein the deployment
restrictor comprises a multilayer reinforced strap that extends
along the portion of the deployment opening defined by the
deployment restrictor.
20. The apparatus recited in claim 19, wherein the reinforced strap
is configured to receive and withstand the initial force generated
by the deploying air bag.
21. The apparatus recited in claim 19, further comprising brackets
that are fastened to opposite ends of the reinforced strap to help
reinforce the connection of the strap to the air bag module.
22. The apparatus recited in claim 15, wherein the deployment
restrictor comprises one or more straps having looped ends for
being secured to integral hooks formed on the air bag module.
23. The apparatus recited in claim 15, wherein the fabric structure
comprises a tear seam, the deployment restrictor comprising a strap
and connections connecting the strap to the fabric structure on
opposite sides of the tear seam, the tear seam maintaining a
portion of the strap between the connections in a slackened
condition.
24. The apparatus recited in claim 23, wherein the strap helps
define the deployment opening, the tear seam being adapted to
rupture after initial air bag deployment so that the slackened
portion of the strap is taken up to increase the size of the
deployment opening.
25. An apparatus for helping to protect an occupant of a vehicle
that has an instrument panel and a windshield, the apparatus
comprising: an air bag inflatable to a deployed position between
the instrument panel and a vehicle occupant; and a deployment
restrictor comprising a deflector panel having a portion that is
positioned between the packaged air bag and the windshield and that
at least partially covers the packaged air bag so that the
deflector panel moves with the deploying air bag toward the
windshield, the deployment restrictor comprising a cowl-shaped
fabric structure that directs the air bag to deploy through a
deployment opening at least partially defined by the deployment
restrictor in a direction away from where the air bag would
otherwise deploy and impact the windshield.
26. An apparatus for helping to protect an occupant of a vehicle
that has an instrument panel and a windshield, the apparatus
comprising: an air bag inflatable to a deployed position between
the instrument panel and a vehicle occupant; and a deployment
restrictor comprising a deflector panel having a portion that is
positioned between the packaged air bag and the windshield and that
at least partially covers the packaged air bag so that the
deflector panel moves with the deploying air bag toward the
windshield, the deployment restrictor further comprising a strap
connected to the deflector panel, the deployment restrictor helping
to define a deployment opening through which the air bag deploys,
the deployment restrictor being adapted to restrict initial air bag
deployment to avoid windshield breakage, the strap being adapted to
lengthen after initial air bag deployment to increase the size of
the deployment opening.
27. The apparatus recited in claim 26, wherein the deployment
restrictor comprises tear seam in the deflector panel that
maintains a portion of the strap in a slackened condition during
initial air bag deployment, the tear seam being adapted to rupture
after initial deployment, the slackened portion of the strap being
taken up in response to tear seam rupture.
28. The apparatus recited in claim 27, wherein the deployment
restrictor further comprises connections connecting the strap to
the deflector panel on opposite sides of the tear seam, the
slackened portion of the strap being located between the
connections.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to an apparatus for helping to
protect an occupant of a vehicle. More particularly, the present
invention relates to an air bag inflatable between an instrument
panel and a front seat occupant of a vehicle.
BACKGROUND OF THE INVENTION
[0002] It is known to provide an inflatable vehicle occupant
protection device, such as an air bag, for helping to protect an
occupant of a vehicle. One particular type of air bag is a frontal
air bag inflatable between an occupant of a front seat of the
vehicle and an instrument panel of the vehicle. Such air bags may
be driver air bags or passenger air bags. When inflated, the driver
and passenger air bags help protect the occupant from impacts with
parts of the vehicle such as the instrument panel and/or a steering
wheel of the vehicle.
[0003] Passenger air bags are typically stored in a deflated
condition in a housing that is mounted to the vehicle instrument
panel. An air bag door is connectable with the housing and/or
instrument panel to help enclose and conceal the air bag in a
stored condition. Upon deployment of the passenger air bag, the air
bag door opens to permit the air bag to move to an inflated
position. The air bag door opens as a result of forces exerted on
the door by the inflating air bag.
[0004] Driver air bags are typically stored in a deflated condition
in a housing that is mounted on the vehicle steering wheel. An air
bag cover is connectable with the housing and/or steering wheel to
help enclose and conceal the air bag in a stored condition. Upon
deployment of the driver air bag, the air bag cover opens to permit
the air bag to move to an inflated position. The air bag cover
opens as a result of forces exerted on the cover by the inflating
driver air bag.
SUMMARY OF THE INVENTION
[0005] The present invention relates to an apparatus for helping to
protect an occupant of a vehicle that has an instrument panel and a
windshield. The apparatus includes an air bag packaged in an air
bag module. The air bag is inflatable to a deployed position
between the instrument panel and a vehicle occupant. A deployment
restrictor is secured to the air bag module. The deployment
restrictor includes a deflector panel having a portion that is
positioned between the packaged air bag and the windshield. The
deflector panel at least partially covers the packaged air bag so
that the deflector panel moves with the deploying air bag toward
the windshield. The connection of the deployment restrictor to the
air bag module limits movement of the deflector panel toward the
windshield and thereby redirects the air bag to deploy away from
where it would otherwise impact the windshield.
[0006] The present invention also relates to an apparatus for
helping to protect an occupant of a vehicle that has an instrument
panel and a windshield. The apparatus includes an air bag packaged
in an air bag module. The air bag is inflatable to a deployed
position between the instrument panel and a vehicle occupant. The
apparatus also includes a deployment restrictor that includes a
cowl-shaped fabric structure connected to the air bag module. The
deployment restrictor directs the air bag to deploy through a
deployment opening at least partially defined by the deployment
restrictor in a direction away from where the air bag would
otherwise deploy and impact the windshield.
[0007] The present invention also relates to an apparatus for
helping to protect an occupant of a vehicle that has an instrument
panel and a windshield. The apparatus includes an air bag
inflatable to a deployed position between the instrument panel and
a vehicle occupant. The apparatus also includes a deployment
restrictor that includes a deflector panel having a portion that is
positioned between the packaged air bag and the windshield and that
at least partially covers the packaged air bag so that the
deflector panel moves with the deploying air bag toward the
windshield. The deployment restrictor has a cowl-shaped fabric
structure that directs the air bag to deploy through a deployment
opening at least partially defined by the deployment restrictor in
a direction away from where the air bag would otherwise deploy and
impact the windshield.
[0008] The present invention further relates to an apparatus for
helping to protect an occupant of a vehicle that has an instrument
panel and a windshield. The apparatus includes an air bag
inflatable to a deployed position between the instrument panel and
a vehicle occupant and a deployment restrictor. The deployment
restrictor includes a deflector panel having a portion that is
positioned between the packaged air bag and the windshield and that
at least partially covers the packaged air bag so that the
deflector panel moves with the deploying air bag toward the
windshield. The deployment restrictor further includes a strap
connected to the deflector panel. The deployment restrictor helps
define a deployment opening through which the air bag deploys. The
deployment restrictor is adapted to restrict initial air bag
deployment to avoid windshield breakage, and the strap is adapted
to lengthen after initial air bag deployment to increase the size
of the deployment opening.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The foregoing and other features of the present invention
will become apparent to one skilled in the art to which the present
invention relates upon consideration of the following description
of the invention with reference to the accompanying drawings, in
which:
[0010] FIG. 1 is a schematic side view illustrating an apparatus
for helping to protect an occupant of a vehicle.
[0011] FIGS. 2 and 3 are schematic side views illustrating the
apparatus of FIG. 1 in different conditions.
[0012] FIG. 4 is a schematic plan view of a portion of the
apparatus, according to a first embodiment.
[0013] FIG. 5 is an exploded view illustrating components of the
portion of the apparatus illustrated in FIG. 4.
[0014] FIGS. 6A-6F illustrate the assembly of the components of
FIG. 5 to form the portion of the apparatus illustrated in FIG.
4.
[0015] FIG. 7 is a magnified view of a portion of the
apparatus.
[0016] FIGS. 8A-8B and 9A-9B are plan views illustrating a portion
of the apparatus at different stages of construction, according to
an embodiment of the invention.
[0017] FIG. 10 is an exploded perspective view of the apparatus of
FIGS. 8A-9B.
[0018] FIG. 11 is a perspective view of the apparatus of FIG. 10 in
an assembled condition.
[0019] FIGS. 12A and 12B are schematic views illustrating the
operation of the embodiment of FIGS. 8A-11.
DESCRIPTION
[0020] An apparatus 10 for helping to protect an occupant 20 of a
vehicle 12 includes an inflatable vehicle occupant protection
device 14 in the form of an air bag. In the embodiment illustrated
in FIG. 1, the air bag 14 is a passenger frontal air bag for
helping to protect an occupant 20 of a seat 22 on a passenger side
24 of the vehicle 12.
[0021] The air bag 14 may be part of an air bag module 30 that
includes an inflator 32 and a support or housing 34 for the air bag
and inflator. The air bag 14 has a stored condition (shown in
dashed lines at 14' in FIG. 1 and at 14 in FIG. 2) in which the air
bag is folded and placed in the housing 34. The module 30 is
mounted to a dash or instrument panel 36 of the vehicle 12 adjacent
or near the intersection of the instrument panel and a windshield
38 of the vehicle. The housing 34 helps contain and support the air
bag 14 and inflator 32 in the instrument panel 36. The air bag is
inflatable from the stored condition to an inflated and deployed
condition, which is illustrated at 14 in FIGS. 1 and 3.
[0022] An air bag door 40 is releasably connected to the instrument
panel 36 and/or the housing 34. In a closed condition, the air bag
door (shown in dashed lines at 40' in FIG. 1) forms a cover for the
module 30 and helps enclose the air bag 14 in the stored condition
in the housing 34. The air bag door is movable to an opened
condition (shown in solid lines at 40 in FIG. 1) to uncover an
opening 44 through which the air bag 14 may be deployed from the
stored condition in the housing 34. The door 40 may be connected to
the vehicle 12, e.g., the instrument panel 36, either directly or
through the housing 34, by means (not shown), such as a plastic
hinge portion, a strap, or a tether.
[0023] The inflator 32 is actuatable to provide inflation fluid to
an inflatable volume 54 of the air bag 14 to deploy the air bag to
the inflated condition. The inflator 32 may be of any known type,
such as stored gas, solid propellant, augmented, or hybrid. The
apparatus 10 also includes a sensor/controller, illustrated
schematically at 50, for sensing an event for which inflation of
the air bag 14 is desired, such as a collision, and providing an
actuation signal to the apparatus 10 in response to the sensed
event. The inflator 32 is operatively connected to the
sensor/controller 50 via lead wires 52.
[0024] The air bag 14 can be constructed of any suitable material,
such as nylon (e.g., woven nylon 6-6 yarns), and may be constructed
in any suitable manner. For example, the air bag 14 may include one
or more pieces or panels of material. If more than one piece or
panel is used, the pieces or panels may be interconnected by known
means, such as stitching, ultrasonic welding, heat bonding, or
adhesives, to form the air bag. The air bag 14 may be uncoated,
coated with a material, such as a gas impermeable urethane, or
laminated with a material, such as a gas impermeable film. The air
bag 14 thus may have a gas-tight or substantially gas-tight
construction. Those skilled in the art will appreciate that
alternative materials, such as polyester yarn, and alternatives
coatings, such as silicone, may also be used to construct the air
bag 14.
[0025] Upon sensing the occurrence of an event for which inflation
of the air bag 14 is desired, such as a vehicle collision, the
sensor 50 provides a signal to the inflator 32 via the lead wires
52. Upon receiving the signal from the sensor 50, the inflator 32
is actuated and provides inflation fluid to the inflatable volume
54 of the air bag 14 in a known manner. The inflating air bag 14
exerts a force on the door 40, which moves the door to the opened
condition. The air bag 14 inflates from the stored condition in a
generally upward and rearward direction in the vehicle 12 to a
deployed condition, such as the fully inflated and deployed
condition illustrated in solid lines in FIG. 3. The air bag 14,
while inflated, helps protect the vehicle occupant 20 from impacts
with parts of the vehicle 12, such as the instrument panel 36.
[0026] The air bag 14 may have one or more actuatable features (not
shown) for helping to control or tailor inflation of the air bag in
response to vehicle conditions, occupant conditions, or both. These
features may be actuatable actively, for example, in response to
conditions determined via active sensors, or passively, for
example, having a configuration responsive to physical conditions
at the time of inflation and deployment. One example of an
actuatable feature that the apparatus 10 may include is one or more
adaptive tethers that can control or alter the shape or manner in
which the air bag 14 is deployed. Another example of an actuatable
feature that the apparatus 10 may include is one or more adaptive
vents for venting inflation fluid from the air bag 14.
[0027] The position and orientation of the air bag module 30 in the
instrument panel 36 can be limited or dictated by vehicle specific
configurations/architecture. Because of this, it may not be
possible to position and orient the air bag module 30 so that the
air bag 14 deploys along a direct trajectory to the inflated and
deployed condition. For example, in the configuration illustrated
in FIG. 2, the air bag module 30 is positioned and oriented in a
manner such that the air bag 14 would tend to deploy in a direction
indicated generally by the arrow A that is generally vertically
upward in the vehicle 12. As a result, the deploying air bag 14 may
strike the windshield 38 as it inflates and deploys. This can be
undesirable because the windshield 38 can act as a reaction surface
against which the air bag 14 rests as it absorbs impacts from the
occupant during use. It is therefore important that the windshield
38 remain as intact as possible, and not rupture or break during an
impact event in which the air bag 14 deploys.
[0028] The apparatus 10 includes a deployment restrictor 100 that
helps control deployment of the air bag 14. As shown in FIG. 2, the
restrictor 100 can also serve as a protective cover for the air bag
14 when in the stored condition. As shown in FIG. 3, the restrictor
100 has a base that is anchored to the air bag module 30. In use,
the restrictor 100 has a generally hood shaped or cowl shaped
configuration that helps define a deployment opening 46. The
deployment restrictor 100 guides/directs the inflating and
deploying air bag 14 from the air bag module 30 through the
deployment opening 46 in a manner so as to avoid the deployment
door 40 impacting the windshield 38 with a magnitude sufficient to
cause its breakage. The restrictor 100, directing the air bag 14 to
deploy through the deployment opening 46, directs the air bag 14 to
deploy away from the direction A and toward the direction indicated
generally by the arrow B, which is both upward and rearward in the
vehicle 12. By doing so, the restrictor 100 helps to prevent the
initial force of the deploying air bag 14 from being absorbed by
the windshield 38 through an impact with the deployment door
40.
[0029] The restrictor 100 does not necessarily prevent all contact
between the air bag 14 and the windshield 38. To the contrary, the
windshield 38 can necessarily support the air bag 14 against forces
applied to the air bag 14 by an impacting and penetrating occupant.
To provide the desired ride down effect, the air bag 14 requires a
reaction surface to resist the tendency of the air bag to move with
the impacting and penetrating occupant instead of absorbing the
occupant forces and cushioning the occupant through a controlled
deceleration/ride down. Without the windshield 38 acting as a
reaction surface, the air bag 14 may not provide the desired ride
down effect. In preventing the air bag 14 and deployment door 40
from damaging the windshield 38, the deployment restrictor 100
helps to ensure that the windshield can perform its function as a
reaction surface for the air bag.
[0030] The deployment restrictor 100 can be constructed of any
suitable material, such as nylon (e.g., woven nylon 6-6 yarns), and
may be constructed in any suitable manner. For example, the
restrictor 100 may include one or more pieces or panels of
material. If more than one piece or panel is used, the pieces or
panels may be interconnected by known means, such as stitching,
ultrasonic welding, heat bonding, or adhesives, to form the
restrictor. The deployment restrictor 100 may be coated, uncoated,
or laminated. Those skilled in the art will appreciate that
alternative materials, such as polyester yarn, and alternatives
coatings, such as silicone, may also be used to construct the
restrictor 100.
[0031] A first embodiment of the deployment restrictor 100 is
illustrated in FIG. 4 (plan view) and FIG. 5 (exploded view). The
deployment restrictor 100 includes a deflector panel 102 that is
configured to assume the hood/cowl shape of the restrictor. The
deflector panel 102 includes a rear portion 104 secured to the air
bag module 30, a front portion 106 secured to the air bag module,
and a central portion 108 that extends between the front and front
portions. The deflector panel 102 also includes opposite side
portions 110 that are connected to the air bag module 30. The
deflector panel 102, primarily the central portion 108, covers and
protects the air bag 14 in the deflated and stored condition of
FIG. 2. When the air bag 14 inflates and deploys (FIG. 3), the
deflector panel 102 moves with the deploying air bag, assumes its
hood/cowl shaped configuration, and deflects the air bag away from
the windshield 38, causing the air bag to deploy in the direction
B.
[0032] The assembled deployment restrictor 100 is illustrated in
detail in FIG. 4. Referring to FIG. 4, the deployment restrictor
100 includes deployment straps 120 for connecting the side portions
110 to the air bag module 30. The deployment straps 120 extend
laterally from the central portion 108 at a position adjacent or
near the rear portion 104. The deployment restrictor also includes
release straps 140 for connecting the rear portion 104 to the air
bag module 30. For facilitating the connection between the
deployment straps 120 and the air bag module 30, the deployment
restrictor 100 may be outfitted with reinforcing brackets 150.
[0033] The deployment restrictor 100 is configured with features
that help to facilitate a mating connection with the air bag module
30. More particularly, these features are configured to facilitate
a mating connection with the inflator 32. The inflator 32 can, for
example, have a cylindrical configuration with a relatively short
height as measured along its central axis 60. The inflator 32
includes studs 62 that can help secure the inflator, air bag 14,
restrictor 100 and housing 34 to the vehicle 12. The connection
between the inflator 32, air bag 14, and restrictor 100 facilitated
by the studs 62 is illustrated schematically in the figures for the
purpose of simplicity. This connection is completed with threaded
fasteners 64, such as nuts.
[0034] As best shown in FIG. 4, the deflector panel 102 has a
generally trapezoidal configuration, the rear portion 104 being
wider than the front portion 106 with the central portion 108
tapering therebetween. The front portion 106 has a tapered
configuration and includes a semi-circular cutout portion 112
formed along its terminal end. The cutout portion 112 mates with
the round contour of the inflator 32 and fastening apertures 114
through which the studs can pass to connect the front portion to
the air bag module 30.
[0035] The release straps 140 extend from the rear portion 104 and
have terminal end portions that include circular cutout portions
142 for mating with the round contour of the inflator 32 and
fastening apertures 144 through which the studs 62 can pass to
connect the release straps and the rear portion to the air bag
module 30. The release straps 140 also include rupturable portions
146 that are positioned adjacent a leading or front edge 116 of the
deflector panel 102. The rupturable portions 146 may, for example,
comprise perforations in the fabric material of the release straps
140 that weaken the release straps in that area.
[0036] The deployment straps 120 extend laterally from the
deflector panel 102 and have a curved end portion 122 that includes
an aperture 124 for securing the deployment straps to the air bag
module 30. The curve of the end portion 122 positions the aperture
24 to receive the studs 62 and connect the deployment straps to the
air bag module 30. The reinforcing brackets 150 bolster the
strength and reliability of this connection of the deployment
straps 120 to the air bag module 30.
[0037] According to the first embodiment, the deployment restrictor
100 is constructed to withstand the force of the inflating air bag
14 while directing the air bag to deploy in the desired direction.
The deployment restrictor 100 also helps prevent the air bag door
40 from breaking the windshield 38. To achieve this high degree of
strength, the deployment restrictor 100 has a multi-piece, modular
configuration in which several components are assembled to provide
the required strength in the areas of the restrictor. These
components are illustrated in FIG. 5.
[0038] Referring to FIG. 5, the deployment restrictor 100 includes
a first or left deflector panel piece 200 and a second or right
deflector panel piece 202. The deflector panel pieces 200, 202
include respective deflector panel portions 204, 206 and deployment
strap portions 208, 210. The deployment strap portions 208, 210
include respective reinforcing bracket apertures 212, 214. The
deployment strap portions 204, 206 extend laterally away from their
respective deflector panel pieces 200, 202 and include upwardly
curved portions at or about the location of the reinforcing bracket
apertures 212, 214. The deflector panel pieces 200, 202 also
include their respective cutout portions 112 and fastening
apertures 116.
[0039] The deployment restrictor 100 also includes a first or left
deployment strap reinforcing piece 216 and a second or right
deployment strap reinforcing piece 218. The deployment strap
reinforcing pieces 216, 218 include respective reinforcing bracket
apertures 220, 222. The deployment strap reinforcing pieces 216,
218 include upwardly curved portions at or about the location of
the reinforcing bracket apertures 222, 224. The configurations of
the deployment strap reinforcing pieces 216, 218 is similar or
identical to the corresponding deployment strap portions 208,
210.
[0040] The deployment restrictor 100 also includes a release panel
230. The release panel 230 includes a deflector reinforcing portion
232 that has a generally rectangular configuration. The release
panel 230 includes the release straps 140, which extend from a
front edge of the deflector reinforcing portion 232. The release
panel 230 therefore also includes the cutout portions 142 and
fastening apertures 144 as portions of the release straps.
[0041] The deployment restrictor 100 also includes the reinforcing
brackets 150, which are illustrated in greater detail in FIG. 7.
The brackets 150 are constructed at least partially of a material,
such as metal, that can be formed or bent as described herein to
achieve the desired reinforcing performance. As shown in FIG. 7,
each reinforcing bracket 150 includes a first bracket part 152 and
a second bracket part 154, each of which have a generally
rectangular overall configuration. The first bracket part 152 has a
central aperture 156 and a pair of tabs 158 that are defined by
slots 160 that cut into a longitudinal upper edge of the first
bracket part 152, as viewed in FIG. 7. The second bracket part 154
has a central aperture 162 and a pair of slots 164 that cut into
opposite edges spaced apart along the length of the second bracket
part, as viewed in FIG. 7.
[0042] Assembly of the deployment restrictor 100 is illustrated in
FIGS. 6A-6F. Referring to FIG. 6A, the components of the deployment
restrictor 100 are assembled by initially positioning the left
deployment strap reinforcing piece 216 overlying the deployment
strap portion 208 of the left deflector panel piece 200. The right
deployment strap reinforcing piece 218 is positioned overlying the
deployment strap portion 210 of the right deflector panel piece
202. As shown in FIG. 6A, the deployment strap reinforcing pieces
216, 218 are configured to completely cover the deployment strap
portions 208, 210 and to extend across the deflector panel portions
204, 206 to inside edges thereof. The components are positioned
such that the reinforcing bracket apertures 220, 222 of the
reinforcing pieces 216, 218 are aligned with the reinforcing
bracket apertures 212, 214 of the deflector panel pieces 200,
202.
[0043] Referring to FIGS. 6B and 6C, the next step in assembling
the deployment restrictor 100 is to assemble a reinforcing bracket
150 onto the left deflector panel piece 200 and its overlying
reinforcing piece 216 and to assemble a reinforcing bracket 150
onto the right deflector panel piece 202 and its overlying
reinforcing piece 218. To prepare the reinforcing brackets 150, the
tabs 158 of the first bracket parts 152 are bent to extend
transverse, e.g., to about 90 degrees, to the remainder of the
first bracket part.
[0044] One of the first bracket parts 152 is then maneuvered from
beneath the overlying components so that the tabs 158 extend
through corresponding ones of the aligned reinforcing bracket
apertures 212, 220 on the overlying left deployment strap
reinforcing piece 216 and deployment strap portion 208. In doing
so, the aperture 156 of the first bracket part 152 becomes aligned
with the corresponding ones of the aligned reinforcing bracket
apertures 212, 220 on the overlying left deployment strap
reinforcing piece 216 and deployment strap portion 208. The second
bracket part 154 is then positioned onto the overlying components
such that the tabs 158 extend through the slots 164 and such that
the aperture 162 overlies the corresponding ones of the apertures
212, 220 and the aperture 156. The tabs 158 are then bent over onto
portions of the second bracket part 154 adjacent the slots 164 to
thereby connect the bracket 150 to the assemblage.
[0045] The other of the first bracket parts 152 is then maneuvered
from beneath the overlying components so that the tabs 158 extend
through corresponding ones of the aligned reinforcing bracket
apertures 214, 222 on the overlying right deployment strap
reinforcing piece 218 and deployment strap portion 210. In doing
so, the aperture 156 of the first bracket part 152 becomes aligned
with the corresponding ones of the aligned reinforcing bracket
apertures 214, 222 on the overlying right deployment strap
reinforcing piece 218 and deployment strap portion 210. The second
bracket part 154 is then positioned onto the overlying components
such that the tabs 158 extend through the slots 164 and such that
the aperture 162 overlies the corresponding ones of the apertures
214, 222 and the aperture 156. The tabs 158 are then bent over onto
portions of the second bracket part 154 adjacent the slots 164 to
thereby connect the bracket 150 to the assemblage.
[0046] Next, the assemblage of the deflector panel pieces 200, 202,
the reinforcing pieces 216, 218, and the brackets 150 are flipped
over, as shown in FIG. 6D. The overlying left deployment strap
reinforcing piece 216 and deployment strap portion 208 are folded
over along the dashed line A shown in FIG. 6B to the position shown
in FIG. 6D. In doing so, the folded over strap reinforcing piece
216 and deployment strap portion 208 assume a four layer
construction. Also, in doing so, the fastener receiving apertures
162, 212, and 220 are brought into alignment with each other. The
components are maintained in this folded over condition by
stitching 240, such as a double needle lock stitch.
[0047] Next, the overlying left deployment strap reinforcing piece
218 and deployment strap portion 210 are folded over along the
dashed line B shown in FIG. 6B to the position shown in FIG. 6D. In
doing so, the folded over strap reinforcing piece 218 and
deployment strap portion 210 assume a four layer construction.
Also, in doing so, the fastener receiving apertures 162, 214, and
222 are brought into alignment with each other. The components are
maintained in this folded over condition by stitching 242, such as
a double needle lock stitch.
[0048] Next, the left and right deflector panel pieces 200 and 202
are aligned with abutting edges as shown in FIG. 6E. The release
panel 230 is positioned with the reinforcing portion 232 overlying
the deflector panel pieces 200, 202 and the attached deployment
strap reinforcing pieces 216, 218, as shown in FIGS. 6E and 6F. The
deflector panel pieces 200, 202, reinforcing pieces 216, 218, and
release panel 230 are interconnected by stitching identified
generally at 244 to interconnect those components and thereby form
the assembled deployment restrictor 100. In one example the
stitching 244 may comprise linear double needle stitching
[0049] Next, as shown in FIGS. 6E and 6F, the assembled deployment
restrictor 100 is positioned overlying the main panel 26 of the air
bag 14. The deployment restrictor 100 is secured to the main panel
26 by stitching identified generally at 246 and 248 to interconnect
the deployment restrictor and the air bag 14. The stitching 246,
248 extends through and interconnects the deflector panel pieces
200, 202, the reinforcing pieces 216, 218, the release panel 230,
and the main panel 26 of the air bag 14. The stitching 246, 248
thus interconnects the multilayer portion of the deployment panel
102 of the to the main panel 26 of the air bag 14. In one example,
the stitching 246 may comprise rectangular double needle stitching
and the stitching 248 may comprise zigzag stitching.
[0050] To assemble the deployment restrictor 100 onto the air bag
module 30, the central portion 108 of the deflector panel 102 is
positioned over the folded air bag 14 as shown in FIG. 2. The
apertures 114 of the front portion 106 are positioned over the
corresponding studs 62 of the inflator 32. The apertures 144 of the
release straps 120 are positioned over the corresponding studs 62
of the inflator. The aligned apertures of the deployment straps
120, i.e., the aligned apertures of the deployment strap
reinforcing pieces 216, 218, the deployment strap portions 210, 212
of the deflector panel pieces 200, 202, and the reinforcing
brackets 150, are positioned over the corresponding studs 62 of the
inflator 32. The deployment restrictor 100 is secured onto the air
bag module 30 via the fasteners 64.
[0051] The inflation and deployment of the air bag 14 can generate
tremendous forces that the deployment restrictor 100 needs to
withstand in order to function as intended to direct the inflating
air bag away from impacting the windshield 38. Accordingly, the
deployment restrictor 100 is configured to withstand these high
forces. The components of the deployment restrictor 100, assembled
as described herein, is reinforced in the areas where deployment
forces are focused--along a band 250 (see FIGS. 6E and 6F)
extending along the deployment straps 120 and across the deflector
panel 102. Along this band 250, the deployment restrictor 100 has a
construction that is at four layers thick along the deployment
straps 120 and five layers thick in the area of the deflector panel
102. The band 250 essentially extends along the periphery of the
deployment restrictor 100 that defines deployment opening 46, and
therefore strengthens and reinforces the deployment restrictor in
this important area. Additionally, the reinforcing brackets 150
help improve further the strength of the deployment straps 120 at
the connection with the air bag module 30, where air bag deployment
forces are concentrated.
[0052] Additionally, as shown in FIG. 5, the weave directions,
i.e., warp and weft directions, of the fabric components are
indicated by directional cross-arrows 130. The components of FIG.
5, when assembled as described herein to form the deployment
restrictor 100 shown in FIG. 4, are arranged so that the weave
directions of the components are maintained so that the warp and
weft directions of the components extend parallel to each other
when assembled. The weave directions 130 illustrated in FIG. 4 thus
applies to all of the portions of the deployment restrictor 100
(La, the deflector panel 102, the deployment straps 120, and the
release straps 140), as well as all of the individual components of
the restrictor (i.e., the deflector panel pieces 200, 202, the
deployment strap reinforcing pieces 216, 218, and the release panel
230). Thus, when deployment forces act along the length of the band
250, they are acting along, i.e., parallel to either the warp or
weft direction in each layer of the band. Thus, the deployment
forces act primarily in tension along the yarns of each layer in
the band 250. This minimizes the amount of shear acting on the band
250 and thus helps to further prevent rupture.
[0053] According to a second embodiment, the deployment restrictor
300 is constructed to withstand the force of the inflating air bag
14 while directing the air bag to deploy in the desired direction.
The deployment restrictor 300 also helps prevent the air bag door
40 from breaking the windshield 38. To achieve this high degree of
strength, the deployment restrictor 300 has a configuration in
which components are assembled to provide the required strength in
the areas of the restrictor. These components are illustrated in
FIGS. 8A-8B.
[0054] Referring to FIGS. 8A and 8B, the deployment restrictor 300
includes a deflector panel 302 and a deployment strap 304. The
deflector panel 300 has a generally rectangular/trapezoidal
configuration and includes an inflator receiving portion 310. The
inflator receiving portion 310 is shaped and configured to have a
portion 312 for receiving the inflator, and a portion 314 for
receiving fasteners that are used to assemble the air bag module.
As shown in FIG. 8A, the deflector panel 302 may be constructed of
two identically configured layers that are interconnected, e.g., by
stitching, to give the panel a two-ply construction. The deflector
panel 302 also includes a central opening 316 and a tear seam 318
that extends from the opening to an upper edge of the panel.
[0055] The deployment strap 304 has opposite ends that are folded
over and connected by means 320, such as stitching, to form loops
322 at opposite ends of the strap. A central portion of the
deployment strap 304 is pushed through the tear seam 318 adjacent
the upper edge to form a slackened portion in the form of a loop
324 of strap material on a rear side of the deflector panel 302.
The deployment strap 304 is secured to the deflector panel 302 by
connections 326, such as stitching, on opposite sides of the tear
seam 318. The connections 326 maintain the loop 324 in the strap
304.
[0056] Referring to FIGS. 9A and 9B, the deflector panel 302 is
folded over onto itself, which locates the deployment strap 304
more centrally on the panel, i.e., near the inflator receiving
portion 310. The folded over portions of the deflector panel 302
are interconnected by means 330, such as stitching, to help
maintain the panel in the folded-over condition.
[0057] Referring to the exploded view of FIG. 10, to assemble the
air bag module 40 with the deployment restrictor 300, the
restrictor is initially positioned with studs 352 of the air bag
retainer 350 extending through the apertures 312 (see FIGS. 8A and
9A) in the restrictor and through apertures (not shown) in the air
bag 14. The air bag 14 is then folded and the deployment restrictor
300 is then wrapped around the folded air bag to form a package 360
with the strap 304 extending from opposite sides thereof. The
package 360 along with the retainer 350 are positioned in an air
bag housing 370 along with the inflator 32 so that the studs 352
protrude through corresponding openings in the housing. A mounting
bracket 380 is positioned over a protruding pair of the studs 352
and the assemblage is fastened together with threaded fasteners,
such as nuts 382. The loops 322 at the opposite ends of the strap
304 are slid through slits 390 in the housing 370 and slid over
corresponding hooks 392 to connect the strap to the housing.
[0058] The deployment restrictor 300 is configured to withstand the
high forces generated by the inflating air bag 14. Along the strap
304, the deployment restrictor 300 has a construction that is three
layers thick along, including the thickness of the strap and the
two-ply deflector panel 302. Thus, when the air bag 14 deploys, the
deployment restrictor 300 helps restrict the deployment door 40
from impacting and breaking the windshield 38.
[0059] Referring to FIGS. 12A and 12B the restrictor 300 is
configured to restrict initial deployment of the air bag 14. This
helps prevent rapid acceleration of the deployment door 40 (see
FIG. 1) during initial air bag deployment so as to avoid damaging
the windshield 38. Referring to FIG. 12A, the tear stitching 318 is
maintained intact during the initial phases of air bag deployment.
This maintains the loop 324 in the strap 304, thus giving the strap
a shortened configuration during the initial stages of air bag
deployment. Since the length of the strap 304 helps determine the
size of the deployment opening 46, the size of the opening is
restricted during these initial stages of deployment.
[0060] As the air bag 14 continues to inflate and deploy, the tear
stitching 318 eventually breaks, as shown in FIG. 12B. As a result,
the loop 324 is released and the strap 304 extends, taking up the
slack of the loop and thus giving the strap a lengthened
configuration throughout the remainder of air bag 14 deployment.
This increase in strap 304 length increases the size of the
deployment opening 46, thus reducing the restrictive effects of the
restrictor 300 and permitting the air bag 14 to inflate and deploy.
The restrictor 300 thus allows the air bag 14 to deploy more
rapidly after the risk of windshield breakage is eliminated. The
restrictor 300 thus initially restricts air bag 14 deployment to
avoid rupturing the windshield 38 by the deployment door 40, and
then expands to lessen or remove the restriction on the air bag
deployment further inflation and deployment.
[0061] From the above description of the invention, those skilled
in the art will perceive improvements, changes and modifications.
For example, certain ones of the components that are assembled to
form the deployment restrictor 100 (see FIG. 5) may be combined to
form a single component. For instance, the deflector panel pieces
200, 202 could be combined as a single component, or the deployment
strap reinforcing pieces 216, 218 could be combined as a single
component. These and other such improvements, changes and
modifications within the skill of the art are intended to be
covered by the appended claims.
* * * * *