Overhead passenger airbag

• US 20050062262A1
• Filed: 09/23/2003
• Published: 03/24/2005
• Est. Priority Date: 09/23/2003
• Status: Active Grant

• Current Assignee: Autoliv ASP Incorporated (Autoliv Incorporated)
• Original Assignee: Autoliv ASP Incorporated (Autoliv Incorporated)
• Inventors: Williams, Jeffrey Daniel
• Granted Patent: US 7,331,597 B2
• Time in Patent Office: Days
• US Class Current: 280/728.200
• CPC Class Codes: B60R 2021/0004 Frontal collision
• CPC Class Codes: B60R 21/232 Curtain-type airbags deploying mainly in a vertical direction from their top edge
• CPC Class Codes: B60R 21/2346 Soft diffusers
• CPC Class Codes: B60R 21/237 characterised by the way they are folded
• CPC Class Codes: B60R 21/26 characterised by the inflation fluid source or means to control inflation fluid flow arrangement or mounting thereof to the vehicle B60R21/20; blasting cartridges for producing gas under pressure in general F42B3/04; initiators or igniters therefor F42B3/10
• CPC Class Codes: B60R 21/261 with means other than bag structure to diffuse or guide inflation fluid

Abstract

The application provides an overhead passenger airbag module for use in vehicles. The overhead passenger airbag module has a clamshell inflator housing configured to retain an airbag inflator. The inflator housing is also constructed to allow attachment of an airbag cushion to the airbag module. The overhead passenger airbag module also includes an airbag cushion having an airbag throat portion and a cushion portion. The invention also provides a method of folding the airbag cushions of the invention to aid proper deployment and help assure proper support and deceleration of a vehicle occupant during a collision event.

Claims

1. An airbag module for protecting a vehicle occupant comprising:

an airbag inflator;

an airbag cushion, the airbag cushion having a cushion throat, a windshield face, an occupant face, an inboard face, and an outboard face; and

a one-piece clamshell inflator housing, the inflator housing comprising an inflator sleeve and a diffuser sleeve, the inflator sleeve being configured to receive and close about the airbag inflator.

2. The airbag module of claim 1, wherein the cushion throat of the airbag cushion comprises a loop diffuser.

3. The airbag module of claim 2, wherein the loop diffuser comprises a secondary internal sleeve of the cushion throat having at least one diffuser orifice.

4. The airbag module of claim 1, wherein the cushion throat of the airbag cushion is configured to be coupled to the inflator housing.

5. The airbag module of claim 1, wherein the inflator housing further comprises cushion attachments.

6. The airbag module of claim 5, wherein the cushion attachments are attachment pegs.

7. The airbag module of claim 6, wherein the cushion throat comprises attachment rings for engaging the attachment pegs of the inflator housing.

8. The airbag module of claim 1, wherein the diffuser sleeve is formed by closing the clamshell inflator housing.

9. The overhead airbag module of claim 1, further comprising fasteners for maintaining the clamshell inflator housing in a closed position.

10. The overhead airbag module of claim 1, wherein the airbag cushion is folded using a method comprising the steps of:

flattening the windshield face and the occupant face of the airbag cushion;

tucking the inboard and outboard faces of the airbag cushion inwardly to produce at least one longitudinal pleat and a first folded end and a second folded end;

drawing the first and second folded ends of the airbag cushion toward each other to position them directly opposite the inflation orifice;

rolling the first folded end of the airbag cushion toward the inflation orifice to produce a first roll fold; and

rolling the second folded end of the airbag cushion toward the inflation orifice to produce a second roll fold, wherein the second roll fold encompasses the first roll fold.

11. An overhead airbag module for protecting a vehicle occupant comprising:

an airbag inflator;

an overhead airbag cushion, the airbag cushion having a cushion throat, a windshield face, an occupant face, an inboard face, and an outboard face; and

a one-piece clamshell inflator housing, the inflator housing comprising an inflator sleeve and a diffuser sleeve, the inflator sleeve being configured to receive and close about the airbag inflator.

12. The overhead airbag module of claim 11, wherein the cushion throat of the overhead airbag cushion comprises a loop diffuser.

13. The overhead airbag module of claim 12, wherein the loop diffuser comprises a secondary internal sleeve of the cushion throat having at least one diffuser orifice.

14. The overhead airbag module of claim 11, wherein the cushion throat of the overhead airbag cushion is configured to be coupled to the inflator housing.

15. The overhead airbag module of claim 11, wherein the inflator housing further comprises cushion attachments.

16. The overhead airbag module of claim 15, wherein the cushion attachments are attachment pegs.

17. The overhead airbag module of claim 16, wherein the cushion throat comprises attachment rings for engaging the attachment pegs of the inflator housing.

18. The overhead airbag module of claim 11, wherein the diffuser sleeve is formed by closing the clamshell inflator housing.

19. The overhead airbag module of claim 11, further comprising fasteners for maintaining the clamshell inflator housing in a closed position.

20. The overhead airbag module of claim 11, wherein the airbag cushion is folded using a method comprising the steps of:

flattening the windshield face and the occupant face of the airbag cushion;

tucking the inboard and outboard faces of the airbag cushion inwardly to produce at least one longitudinal pleat and a first folded end and a second folded end;

drawing the first and second folded ends of the airbag cushion toward each other to position them directly opposite the inflation orifice;

rolling the first folded end of the airbag cushion toward the inflation orifice to produce a first roll fold; and

rolling the second folded end of the airbag cushion toward the inflation orifice to produce a second roll fold, wherein the second roll fold encompasses the first roll fold.

21. An airbag cushion having a throat portion and a cushion portion, the throat portion further comprising a loop diffuser.

22. The airbag cushion of claim 21, wherein the loop diffuser comprises an internal sleeve having at least one diffuser orifice to allow passage of an inflation gas between the throat portion and the cushion portion of the airbag cushion.

23. The airbag cushion of claim 22, wherein the internal sleeve of the loop diffuser has a windshield-facing panel and an occupant-facing panel, the panels being attached to form a closed sleeve.

24. The airbag cushion of claim 23, wherein the internal sleeve of the loop diffuser comprises at least one diffuser orifice on the occupant-facing panel.

25. The airbag cushion of claim 23, wherein the internal sleeve of the loop diffuser comprises at least one diffuser orifice on the windshield-facing panel.

26. The airbag cushion of claim 23, wherein the internal sleeve of the loop diffuser comprises at least one diffuser orifice on the occupant-facing panel and on the windshield-facing panel.

27. The airbag cushion of claim 21, wherein the airbag cushion is an overhead airbag cushion.

28. A folding method for an overhead airbag cushion comprising the steps of:

providing an airbag cushion having a windshield face, an occupant face, an inboard face, an outboard face, and an inflation orifice;

flattening the windshield face and the occupant face of the airbag cushion;

tucking the inboard and outboard faces of the airbag cushion inwardly to produce at least one longitudinal pleat and a first folded end and a second folded end;

drawing the first and second folded ends of the airbag cushion toward each other to position them directly opposite the inflation orifice;

rolling the first folded end of the airbag cushion toward the inflation orifice to produce a first roll fold; and

rolling the second folded end of the airbag cushion toward the inflation orifice to produce a second roll fold, wherein the second roll fold encompasses the first roll fold.

29. The folding method of claim 28, wherein the step of tucking the inboard and outboard faces of the airbag cushion inwardly to produce at least one longitudinal pleat is repeated to produce a plurality of longitudinal pleats.

30. The folding method of claim 29, wherein 2 longitudinal pleats are produced.

31. The folding method of claim 28, wherein the step of rolling the first folded end of the airbag cushion toward the inflation orifice comprises rolling the first folded end against the windshield face of the airbag cushion.

32. The folding method of claim 28, wherein the step of rolling the second folded end of the airbag cushion toward the inflation orifice comprises rolling the first folded end against the occupant face of the airbag cushion.

33. An airbag module comprising an airbag cushion folded according to the method of claim 28.

34. An overhead airbag module assembled according to a method comprising the steps of:

providing an airbag cushion having a windshield face, an occupant face, an inboard face, an outboard face, and a cushion throat with an inflation orifice;

providing an inflator housing for receiving and retaining an airbag inflator, the inflator housing including at least one cushion attachment;

attaching the cushion throat of the airbag cushion to the inflator housing;

flattening the windshield face and the occupant face of the airbag cushion;

tucking the inboard and outboard faces of the airbag cushion inwardly to produce at least one longitudinal pleat and a first folded end and a second folded end;

drawing the first and second folded ends of the airbag cushion toward each other to position them directly opposite the airbag inflator;

rolling the first folded end of the airbag cushion toward the airbag inflator to produce a first roll fold; and

rolling the second folded end of the airbag cushion toward the airbag inflator to produce a second roll fold, wherein the second roll fold encompasses the first roll fold.

35. The overhead airbag module of claim 34, wherein the step of attaching the cushion throat of the airbag cushion to the inflator housing comprises at least partially encompassing the inflator housing with the cushion throat and attaching the cushion throat to the cushion attachment of the inflator housing.

36. The overhead airbag module of claim 34, wherein the step of tucking the inboard and outboard faces of the airbag cushion inwardly to produce at least one longitudinal pleat is repeated to produce a plurality of longitudinal pleats.

37. The overhead airbag module of claim 36, wherein 2 longitudinal pleats are produced.

38. The overhead airbag module of claim 34, wherein the step of rolling the first folded end of the airbag cushion toward the inflation orifice comprises rolling the first folded end against the windshield face of the airbag cushion.

39. The overhead airbag module of claim 34, wherein the step of rolling the second folded end of the airbag cushion toward the inflation orifice comprises rolling the first folded end against the occupant face of the airbag cushion.