Airbag cushion with integrated inflator

• US 20060214400A1
• Filed: 03/22/2005
• Published: 09/28/2006
• Est. Priority Date: 03/22/2005
• Status: Active Grant

• Current Assignee: Autoliv ASP Incorporated (Autoliv Incorporated)
• Original Assignee: Autoliv ASP Incorporated (Autoliv Incorporated)
• Inventors: Cheal, Blake L., Jordan, Michael P., Smith, Bradley W., Enders, Mark L., Nelson, Earl H., Letendre, Guy R.
• Granted Patent: US 7,396,040 B2
• Time in Patent Office: Days
• US Class Current: 280/730.100
• CPC Class Codes: B60R 2021/23528 Metal
• CPC Class Codes: B60R 21/231 characterised by their shape, construction or spatial configuration

Abstract

An airbag module has a rigid cushion with an integrated inflator. The cushion has a rear cushion panel and the inflator may have a front inflator plate attached to the rear cushion panel. A rear inflator plate is optionally provided and may be positioned within the cushion or outside the cushion. A pyrotechnic may be disposed within the space between the front inflator plate and the rear cushion panel and/or the rear inflator plate. An initiator may be seated in the rear inflator plate and/or the rear cushion panel to initiate combustion of the pyrotechnic. Instead of the front inflator plate, the inflator may have an expanse of tape that secures the pyrotechnic and/or the initiator to the interior of the cushion. The pyrotechnic may be sealed by the tape or by a foil pouch. The initiator may be secured by the tape or by a rear inflator plate.

Claims

1. An airbag module for protecting an occupant of a vehicle from impact, the airbag module comprising:

a cushion comprising a front cushion panel and a rear cushion panel, each of which is constructed of a substantially rigid material, the cushion defining an expandable interior volume, wherein the front cushion panel defines a front plane and the rear cushion panel defines a rear plane; and

a pyrotechnic, at least a portion of which is disposed between the front and rear planes, wherein the pyrotechnic is combustible to produce a quantity of inflation gas sufficient to inflate the cushion to protect the occupant from impact, wherein the pyrotechnic is hermetically sealed to restrict moisture entry into the pyrotechnic from within the expandable interior volume.

2. The airbag module of claim 1, wherein the cushion is positioned to inflate proximate knees of the occupant to restrict forward motion of the knees during frontal impact.

3. The airbag module of claim 1, wherein the cushion is positioned to inflate underneath legs of the occupant to restrict forward motion of a pelvis of the occupant during frontal impact.

4. The airbag module of claim 1, wherein the cushion is positioned alongside a pelvis of the occupant to restrict lateral motion of the pelvis.

5. The airbag module of claim 1, wherein the cushion is constructed of a material selected from the group consisting of steel, aluminum, and plastic.

6. The airbag module of claim 5, wherein the cushion is constructed substantially of steel.

7. The airbag module of claim 6, wherein the steel of the cushion has a thickness ranging from about 0.010 inches to about 0.020 inches.

8. The airbag module of claim 1, further comprising an initiator disposed proximate the pyrotechnic to initiate combustion of the pyrotechnic in response to receipt of an electric activation signal by the initiator.

9. The airbag module of claim 8, wherein the initiator is disposed entirely within the expandable interior volume, wherein the cushion comprises an opening through which at least one wire passes to convey the electric activation signal to the initiator.

10. The airbag module of claim 8, wherein the initiator and the pyrotechnic are components of an inflator attached to an interior surface of the cushion by an attachment mechanism disposed entirely within the expandable interior volume.

11. The airbag module of claim 1, wherein the pyrotechnic is positioned outside the expandable interior volume, wherein the cushion comprises a frangible portion that forms the hermetic seal between the pyrotechnic and the expandable interior volume, wherein the frangible portion is positioned such that inflation gas formed by combustion of the pyrotechnic ruptures the frangible portion to enter the expandable interior volume through the frangible portion.

12. The airbag module of claim 1, wherein the pyrotechnic is positioned within the expandable interior volume, wherein the airbag module further comprises a sealing member positioned within the expandable interior volume to form the hermetic seal between the pyrotechnic and a remainder of the expandable interior volume.

13. The airbag module of claim 12, wherein the sealing member comprises a metal foil, the airbag module further comprising a front inflator plate attached to an inward facing surface of the rear cushion panel to enclose the pyrotechnic between the front inflator plate and the rear cushion panel, the front inflator plate comprising a plurality of orifices, wherein the metal foil is positioned to block the orifices to substantially prevent gas flow through the front inflator plate.

14. The airbag module of claim 12, wherein the sealing member comprises a metal foil shaped to form a pouch that fully encloses the pyrotechnic.

15. The airbag module of claim 12, wherein the sealing member comprises an expanse of tape disposed within the expandable interior volume, the expanse of tape having an adhesive side secured to the cushion such that the pyrotechnic is disposed between the adhesive side and an interior surface of the cushion.

16. The airbag module of claim 15, further comprising a front inflator plate attached to an inward facing surface of the rear cushion panel such that the front inflator plate holds a portion of the expanse of tape against the rear cushion panel to secure the portion of the expanse of tape during combustion of the pyrotechnic.

17. The airbag module of claim 1, further comprising a filter positioned adjacent to a venting orifice such that inflation gas is able to exit the cushion by flowing through the filter and the venting orifice.

18. An airbag module for protecting an occupant of a vehicle from impact, the airbag module comprising:

a front cushion panel;

a rear cushion panel coupled to the front cushion panel to enclose an expandable interior volume;

a pyrotechnic configured to pressurize the interior volume upon receipt of an activation signal; and

a front inflator plate attached to an inward facing surface of the rear cushion panel to enclose the pyrotechnic between the front inflator plate and the rear cushion panel, wherein the front inflator plate is constructed of a substantially rigid material.

19. The airbag module of claim 18, wherein the front inflator plate and the front and rear cushion panels are constructed substantially of steel.

20. The airbag module of claim 18, further comprising an initiator positioned proximate the pyrotechnic, the rear cushion panel having an opening through which the activation signal is conveyed to the initiator to initiate combustion of the pyrotechnic.

21. The airbag module of claim 18, wherein the front inflator plate is attached to the rear cushion panel through the use of an attachment mechanism that operates independently of any rigid mechanical fasteners.

22. The airbag module of claim 21, wherein the attachment mechanism comprises a plurality of spot welds distributed about a perimeter of the front inflator plate and disposed between the front inflator plate and the rear cushion panel to attach the front inflator plate to the rear cushion panel.

23. The airbag module of claim 18, further comprising a rear inflator plate attached to the front inflator plate, wherein the rear inflator plate is disposed within the expandable interior portion, wherein the rear inflator plate is attached directly to the rear cushion panel and the front inflator plate is attached to the rear cushion panel via attachment to the rear inflator plate.

24. The airbag module of claim 18, further comprising a rear inflator plate attached to the front inflator plate, wherein the rear inflator plate is disposed outside the expandable interior portion, wherein the front inflator plate is attached to the rear inflator plate such that a portion of the rear cushion panel is disposed between the front and rear inflator plates.

25. The airbag module of claim 24, wherein the rear inflator plate comprises at least one mounting feature, independent of attachment of the rear inflator plate to the front inflator plate, that facilitates mounting of the rear inflator plate to the vehicle.

26. The airbag module of claim 24, wherein the front inflator plate is attached to the rear inflator plate through the use of a plurality of fasteners that extend through at least one opening in the rear cushion panel and through at least one opening in the rear inflator plate.

27. An airbag module for protecting an occupant of a vehicle from impact, the airbag module comprising:

a cushion defining an expandable interior volume;

an expanse of tape disposed within the expandable interior volume, the expanse of tape having an adhesive side secured to the cushion; and

a pyrotechnic retained between the adhesive side and the cushion, wherein the pyrotechnic is combustible to produce inflation gas.

28. The airbag module of claim 27, further comprising a pouch that fully encloses the pyrotechnic to form a hermetic seal between the pyrotechnic and a remainder of the expandable interior volume.

29. The airbag module of claim 27, wherein the expanse of tape forms a hermetic seal between the pyrotechnic and a remainder of the expandable interior volume.

30. The airbag module of claim 27, wherein the cushion is constructed of a substantially rigid material.

31. The airbag module of claim 27, further comprising an initiator disposed proximate a non-adhesive side of the expanse of tape to initiate combustion of the pyrotechnic in response to receipt of an electric activation signal by the initiator.

32. The airbag module of claim 27, further comprising an initiator retained between the adhesive side and the cushion to initiate combustion of the pyrotechnic in response to receipt of an electric activation signal by the initiator.

33. The airbag module of claim 27, further comprising a screen positioned proximate the expanse of tape such that inflation gas formed by combustion of the pyrotechnic moves through the screen.

34. The airbag module of claim 33, wherein the expanse of tape comprises a burst region that at least partially covers the screen to restrict passage of inflation gas through the screen, wherein the burst region is removable from the screen in response to existence of a threshold pressure differential across the burst region.

35. The airbag module of claim 27, further comprising a front inflator plate attached to an inward facing surface of the cushion such that the front inflator plate holds a portion of the expanse of tape against the inward facing surface to secure the portion of the expanse of tape during combustion of the pyrotechnic.

36. An airbag module for protecting an occupant of a vehicle from impact, the airbag module comprising:

a cushion defining an expandable interior volume, the cushion having an opening;

an initiator disposed entirely within the expandable interior volume to initiate combustion in response to receipt of an electric activation signal; and

at least one wire extending through the opening and coupled to the initiator to convey the electric activation signal to the initiator.

37. The airbag module of claim 36, further comprising a pyrotechnic disposed within the expandable interior volume, wherein the pyrotechnic is combustible to produce a quantity of inflation gas sufficient to inflate the cushion to protect the occupant from impact.

38. The airbag module of claim 36, further comprising a connector coupled to an end of the wire, wherein the connector is attached to the initiator and is fully enclosed by the expandable interior volume.

39. The airbag module of claim 36, further comprising an expanse of tape having an adhesive side secured to the cushion and to the initiator to hold the initiator in place.

40. An airbag module comprising:

a cushion having an expandable interior volume bounded by an interior surface, wherein the cushion is constructed of a substantially rigid material;

an inflator disposed at least partially within the expandable interior volume to pressurize the expandable interior volume upon receipt of an activation signal; and

an attachment mechanism disposed entirely within the expandable interior volume to attach the inflator to the interior surface.

41. The airbag module of claim 40, wherein the cushion comprises a plurality of folds arranged to permit expansion of the cushion along at least two perpendicular directions.

42. The airbag module of claim 40, wherein the inflator comprises:

a front inflator plate attached directly to the interior surface to define an interior inflator volume; and

a pyrotechnic disposed within the interior inflator volume to produce inflation gas.

43. The airbag module of claim 40, wherein the inflator comprises:

a front inflator plate;

a rear inflator plate attached to the front inflator plate to define an interior inflator volume, wherein the rear inflator plate is attached directly to the interior surface; and

a pyrotechnic disposed within the interior inflator volume to produce inflation gas.

44. The airbag module of claim 40, wherein the attachment mechanism operates independently of any rigid mechanical fasteners.

45. The airbag module of claim 44, wherein the attachment mechanism comprises one or more items selected from the group consisting of line welds, spot welds, radio frequency welds, ultrasonic welds, frictional welds, laser welds, inertial welds, brazed interfaces, adhesives, and chemical bonds.

46. The airbag module of claim 45, wherein the inflator comprises an expanse of tape, wherein the attachment mechanism comprises an adhesive that attaches an adhesive side of the tape to the interior surface.

47. The airbag module of claim 45, wherein the attachment mechanism comprises a plurality of spot welds distributed about a perimeter of the inflator and disposed between the inflator and the interior surface to attach the inflator to the interior surface.

48. An airbag module for protecting an occupant of a vehicle from impact, the airbag module comprising:

a cushion comprising a frangible portion, the cushion defining an expandable interior volume;

an inflator positioned to provide inflation gas proximate the frangible portion in response to receipt of an activation signal such that the inflation gas ruptures the frangible portion to enter the expandable interior volume through the frangible portion.

49. The airbag module of claim 48, wherein the cushion is constructed of a substantially rigid material.

50. The airbag module of claim 49, wherein the cushion is constructed of a metal, wherein the frangible portion comprises at least one score along which the metal tears to permit entry of the inflation gas into the expandable interior volume.

51. The airbag module of claim 49, wherein the inflator is attached to the cushion, adjacent to the frangible portion.

52. The airbag module of claim 51, wherein the cushion comprises a depression in which the frangible portion is formed, wherein at least a portion of the inflator is positioned in the depression.

53. A method for protecting an occupant of a vehicle from impact through the use of an airbag module comprising a cushion comprising a front cushion panel defining a front plane and a rear cushion panel defining a rear plane, wherein the front and rear cushion panels cooperate to define an expandable interior volume, and a pyrotechnic, hermetically sealed to restrict moisture entry into the pyrotechnic from within the expandable interior volume, the method comprising:

initiating combustion of the pyrotechnic, wherein at least a portion of the pyrotechnic is disposed between the front and rear planes;

breaking the hermetic seal in response to the combustion, thereby enabling inflation gas from the pyrotechnic to inflate the cushion; and

producing a sufficient quantity of inflation gas via combustion of the pyrotechnic to inflate the cushion to protect the occupant from impact, wherein the cushion is constructed of a substantially rigid material.

54. The method of claim 53, wherein inflating the cushion comprises positioning the cushion to restrict forward motion of knees of the occupant during frontal impact.

55. The method of claim 53, wherein the cushion is positioned underneath legs of the occupant, wherein inflating the cushion comprises restricting forward motion of a pelvis of the occupant during frontal impact.

56. The method of claim 53, wherein the cushion is positioned alongside a pelvis of the occupant, wherein inflating the cushion comprises restricting lateral motion of the pelvis.

57. The method of claim 53, wherein the airbag module further comprises an initiator disposed proximate the pyrotechnic, wherein initiating combustion of the pyrotechnic comprises initiating combustion of the initiator in response to receipt of an electric activation signal by the initiator.

58. The method of claim 53, wherein the pyrotechnic is positioned outside the expandable interior volume, wherein the cushion comprises a frangible portion that forms the hermetic seal between the pyrotechnic and the expandable interior volume, wherein breaking the hermetic seal comprises rupturing the frangible portion.

59. The method of claim 53, wherein the pyrotechnic is positioned within the expandable interior volume, wherein the airbag module further comprises a sealing member positioned within the expandable interior volume to form the hermetic seal, wherein breaking the hermetic seal comprises moving at least a portion of the sealing member.

60. The method of claim 59, wherein the sealing member comprises a metal foil, the airbag module further comprising a front inflator plate attached to an inward facing surface of the rear cushion panel to enclose the pyrotechnic between the front inflator plate and the rear cushion panel, the front inflator plate comprising a plurality of orifices, wherein the metal foil is positioned to block the orifices to substantially prevent gas flow through the front inflator plate, wherein moving at least a portion of the sealing member comprises rupturing the metal foil to unblock the orifices.

61. The method of claim 59, wherein the sealing member comprises a metal foil shaped to form a pouch that fully encloses the pyrotechnic, wherein moving at least a portion of the sealing member comprises rupturing the pouch.

62. The method of claim 59, wherein the sealing member comprises an expanse of tape disposed within the expandable interior volume, the expanse of tape having an adhesive side secured to the cushion such that the pyrotechnic is disposed between the adhesive side and an interior surface of the cushion, wherein moving at least portion of the sealing member comprises rupturing the expanse of tape.

63. The method of claim 62, wherein the airbag module further comprises a front inflator plate attached to an inward facing surface of the rear cushion panel, the method further comprising holding a portion of the expanse of tape against the rear cushion panel with the front inflator plate to secure the portion of the expanse of tape during combustion of the pyrotechnic.

64. The method of claim 53, wherein the airbag module further comprises a filter positioned adjacent to a venting orifice, the method further comprising permitting inflation gas to exit the cushion by flowing through the filter and the venting orifice.

65. A method for manufacturing an airbag module, the method comprising:

forming a front cushion panel and a rear cushion panel;

forming a front inflator plate of a substantially rigid material;

coupling the front inflator plate to an inward facing surface of the rear cushion panel to define an interior inflator volume; and

coupling the front cushion panel to the rear cushion panel to define an expandable interior volume that contains the front inflator plate.

66. The method of claim 65, wherein coupling the front inflator plate to the rear cushion panel comprises attaching the front inflator plate directly to the rear cushion panel.

67. The method of claim 65, further comprising:

forming a rear inflator plate; and

attaching the rear inflator plate directly to the rear cushion panel;

wherein coupling the front inflator plate to the rear cushion panel comprises attaching the front inflator plate directly to the rear inflator plate such that the front inflator plate is attached to the rear cushion panel via attachment to the rear inflator plate.

68. The method of claim 65, further comprising:

forming a rear inflator plate;

disposing the rear inflator plate outside the expandable interior portion; and

attaching the rear inflator plate to the front inflator plate such that a portion of the rear cushion panel is disposed between the front and rear inflator plates.

69. The method of claim 68, wherein forming the rear inflator plate comprises providing at least one mounting feature of the rear inflator plate, independent of attachment of the rear inflator plate to the front inflator plate, to facilitate mounting of the rear inflator plate to the vehicle.

70. The method of claim 68, wherein attaching the rear inflator plate to the front inflator plate comprises extending a plurality of fasteners through at least one opening in the rear cushion panel and through at least one opening in the rear inflator plate.

71. The method of claim 65, further comprising:

forming an opening in the rear cushion panel; and

installing the initiator retainer in the opening.

72. The method of claim 71, further comprising positioning a pyrotechnic proximate the initiator, wherein coupling the front inflator plate to the rear cushion panel comprises enclosing the pyrotechnic between the front inflator plate and the rear cushion panel.

73. The method of claim 65, wherein forming the front cushion panel, the rear cushion panel, and the front inflator plate each comprise stamping a metal sheet into a desired shape.

74. The method of claim 65, wherein coupling the front inflator plate to the rear cushion panel comprises applying an attachment mechanism that operates independently of any rigid mechanical fasteners.

75. The method of claim 74, wherein coupling the front inflator plate to the rear cushion panel comprises applying a plurality of spot welds about a perimeter of the front inflator plate, between the front inflator plate and the rear cushion panel to attach the front inflator plate to the rear cushion panel.

76. A method for manufacturing an airbag module, through the use of a front cushion panel, a rear cushion panel, an expanse of tape, the method comprising:

attaching the front and rear cushion panels together to form a cushion having an expandable interior volume between the front and rear cushion panels;

positioning the pyrotechnic adjacent to the cushion, wherein the pyrotechnic is combustible to produce inflation gas; and

attaching the expanse of tape directly to the cushion such that the pyrotechnic is disposed between the expanse of tape and the cushion, such that the expanse of tape and the cushion are both disposed within the expandable interior volume.

77. The method of claim 76, further comprising fully enclosing the pyrotechnic in a pouch to form a hermetic seal between the pyrotechnic and a remainder of the expandable interior volume.

78. The method of claim 76, wherein attaching the expanse of tape directly to the cushion comprises forming a hermetic seal between the pyrotechnic and a remainder of the expandable interior volume.

79. The method of claim 76, further comprising positioning an initiator proximate a non-adhesive side of the expanse of tape to initiate combustion of the pyrotechnic in response to receipt of an electric activation signal by the initiator.

80. The method of claim 76, further comprising positioning an initiator such that the initiator is retained between the adhesive side and the cushion to initiate combustion of the pyrotechnic in response to receipt of an electric activation signal by the initiator.

81. The method of claim 76, further comprising positioning a screen such that the screen is positioned adjacent to the expanse of tape such that inflation gas formed by combustion of the pyrotechnic moves through the screen.

82. The method of claim 81, wherein the expanse of tape comprises a burst region, the method further comprising positioning the burst region to at least partially cover the screen to restrict passage of inflation gas through the screen, such that the burst region is removable from the screen in response to existence of a threshold pressure differential across the burst region.

83. The method of claim 76, wherein the airbag module further comprises a front inflator plate, the method further comprising attaching the front inflator plate to an inward facing surface of the rear cushion panel such that the front inflator plate holds a portion of the expanse of tape against the rear cushion panel to secure the portion of the expanse of tape during combustion of the pyrotechnic.

84. A method for protecting an occupant of a vehicle through the use of an airbag module comprising a cushion comprising a frangible portion, the cushion defining an expandable interior volume, and an inflator, the method comprising:

producing inflation gas proximate the frangible portion in response to receipt of an activation signal by the inflator;

rupturing the frangible portion in response to production of the inflation gas; and

moving the inflation gas into the expandable interior volume through the frangible portion to inflate the cushion.

85. The method of claim 84, wherein the cushion is constructed of a substantially rigid material, wherein inflating the cushion comprises plastically deforming the cushion.

86. The method of claim 85, wherein the cushion is constructed of a metal, wherein the frangible portion comprises at least one score, wherein rupturing the frangible portion comprises tearing the metal along the score to permit entry of the inflation gas into the expandable interior volume.

87. The method of claim 85, wherein the cushion comprises a depression in which the frangible portion is formed, wherein the inflator is attached to the cushion, adjacent to the frangible portion such that at least a portion of the inflator is positioned in the depression, wherein rupturing the frangible portion comprises moving the inflation gas through at least a portion of the depression to reach the frangible portion.