Driver airbag formed contact spring

• US 20040178611A1
• Filed: 03/12/2003
• Published: 09/16/2004
• Est. Priority Date: 03/12/2003
• Status: Active Grant

• Current Assignee: Autoliv Development AB (Autoliv Incorporated)
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Simpson, James J.
• Granted Patent: US 6,942,247 B2
• Time in Patent Office: Days
• US Class Current: 280/731
• CPC Class Codes: B60Q 5/003 mounted on the steering wheel
• CPC Class Codes: B60R 21/2037 the module or a major component thereof being yieldably mounted, e.g. for actuating the horn switch or for protecting the driver in a non-deployment situation horn switches integrated in steering wheel covers with tear lines B60R21/21658

Abstract

A method and apparatus for reducing gap variation between an airbag module and a steering wheel insert while acting as a horn switch for a horn. The apparatus includes a contact spring disposed between the airbag module and the steering wheel insert. The spring has at least two raised locations having one side of each raised location biasing the airbag module in a first direction while an opposite second side thereof electrically connects with a contact when the airbag module is biased in a second direction opposite said first direction to actuate the horn. An insulative spring retainer has one surface disposed on the steering wheel insert and an opposite surface configured to retain the contact spring. The retainer is further configured to operably couple with the steering wheel insert and includes at least one contact aligned with a corresponding raised location to actuate the horn upon electrical contact therebetween.

Claims

1. An apparatus for reducing gap variation between an airbag module and a steering wheel insert while acting as a horn switch for a horn comprising:

a contact spring disposed between the airbag module and the steering wheel insert, said contact spring configured having at least two raised locations having one side of each of said at least two raised locations biasing the airbag module in a first direction while an opposite second side thereof electrically connects with a contact when the airbag module is biased in a second direction opposite said first direction to actuate the horn; and

an insulative spring retainer having one surface disposed on the steering wheel insert and an opposite surface configured to retain said contact spring, said retainer configured having at least one said contact aligned with a corresponding said second side of said at least two raised locations, said retainer configured to operably couple with the steering wheel insert.

2. The apparatus as in claim 1, wherein a number of said at least one said contact corresponds to a number of said at least two raised locations.

3. The apparatus as in claim 1, wherein said retainer is configured to retain a portion of said contact spring intermediate each of said at least two raised portions.

4. The apparatus as in claim 1, wherein a height of said raised portions establishes an assembled height load of the driver airbag module from the steering wheel insert.

5. The apparatus as in claim 4, wherein said assembled height load is further controlled by features extending from said opposite surface of said retainer, said features limit at least one of travel and spring rate corresponding to the gap between the airbag module and the steering wheel insert when the airbag module is secured to the steering wheel insert.

6. The apparatus as in claim 5, wherein said features provide variable height adjustment of said contact spring relative to said one surface of said retainer.

7. The apparatus as in claim 5, wherein said features include retention tabs configured to retain and adjust the height of said contact spring relative to said one surface of said retainer.

8. The apparatus as in claim 5, wherein said features include a plurality of slots variously arranged in a flange disposed above said opposite surface of said retainer, said contact spring is aligned with corresponding slots to determine a height load of said contact spring relative to said one surface of said retainer.

9. The apparatus as in claim 1, wherein said retainer is configured with a corresponding aperture to receive a locking pin therethrough for slidable snap-fit engagement between the airbag module and the steering wheel insert.

10. The apparatus as in claim 1, wherein one end of said contact spring includes a terminal connected thereto and an electrical horn lead operably connected to a horn assembly.

11. The apparatus as in claim 10, wherein said electrical horn lead extends to a connector proximate a steering column associated with the SW insert.

12. The apparatus as in claim 10, wherein said retainer is configured with a terminal position assurance feature to secure said terminal to said contact spring with said terminal upon assembly with said retainer.

13. The apparatus as in claim 1, wherein said retainer insulates said contact spring from said SW insert.

14. The apparatus as in claim 1, wherein said retainer is made from molded plastic.

15. The apparatus as in claim 1, wherein said contact spring is made from an electrically conductive metal.

16. The apparatus as in claim 1, wherein said contact spring is made from at least one of stainless steel, plated steel, spring steel, CuBe, and including combinations of at least one of the foregoing.

17. The apparatus as in claim 9, wherein said retainer is configured having a snap-fit feature proximate said aperture for snap-fit engagement with a corresponding opening in said SW insert.

18. The apparatus as in claim 1, wherein at least one contact includes a portion of said SW insert extending through said insulative retainer aligned with at least one said raised locations to form the horn switch.

19. The apparatus as in claim 1 wherein said contact is one of a positive and a negative horn switch contact.

20. An apparatus for allowing a common horn mechanism for different DAB and SW insert configurations comprising:

a pair of a contact springs disposed between the airbag module and the steering wheel insert, each contact spring configured having at least two raised locations having one side of each of said at least two raised locations biasing the airbag module in a first direction while an opposite second side thereof electrically connects with a contact when the airbag module is biased in a second direction opposite said first direction to actuate the horn; and

a pair of insulative spring retainers, each retainer having one surface disposed on the steering wheel insert and an opposite surface configured to retain a corresponding contact spring of said pair of contact springs, said each retainer configured having at least one said contact aligned with a corresponding said second side of said at least two raised locations, said retainer configured to operably couple with the steering wheel insert.

21. A method for reducing gap variations between an airbag module and a steering wheel insert while providing a horn switch therebetween, the method comprising:

configuring a contact spring for disposal between the airbag module and the SW insert and having at least two raised locations having one side of each of said at least two raised locations biasing the airbag module in a first direction while an opposite second side thereof electrically connects with a contact when the airbag module is biased in a second direction opposite said first direction to actuate the horn;

securing the contact spring in an insulative spring retainer, said insulative retainer configured to isolate said contact spring form the SW insert, said insulative spring retainer having one surface disposed on the steering wheel insert and an opposite surface configured to retain said contact spring, said retainer configured having at least one said contact aligned with a corresponding said second side of said at least two raised locations; and

operably coupling said retainer to the steering wheel insert.

22. An air bag module and steering wheel assembly comprising:

an air bag module including

a base plate,

an air bag mounted on the base plate,

a container enclosing the air bag and connected to the base plate,

a plurality of elongated cylindrical mounting members affixed to the base plate for securing the module to a steering wheel insert;

the steering wheel insert attachable to a steering column and having a plurality of apertures receiving the mounting members;

a contact spring disposed between the airbag module and the steering wheel insert, the contact spring configured having at least two raised locations having one side of each of the at least two raised locations biasing the airbag module in a first direction while an opposite second side thereof electrically connects with a contact when the airbag module is biased in a second direction opposite the first direction to actuate the horn; and

an insulative spring retainer having one surface disposed on the steering wheel insert and an opposite surface configured to retain the contact spring, the retainer configured having at least one the contact aligned with a corresponding the second side of the at least two raised locations, the retainer configured to operably couple with the steering wheel insert, whereby a horn circuit connectable to a power source is closed through contact of the spring with the contact and the horn is activated when the container is depressed.