Apparatus and method for airbag cushion modularization

• US 6,631,922 B2
• Filed: 07/10/2001
• Issued: 10/14/2003
• Est. Priority Date: 07/10/2001
• Status: Active Grant

• Current Assignee: Autoliv ASP Incorporated (Autoliv Incorporated)
• Original Assignee: Autoliv ASP Incorporated (Autoliv Incorporated)
• Inventors: Hess, Travis B., Kottke, Kurt E.
• Primary Examiner(s): Dickson, Paul N.
• Assistant Examiner(s): Fleming, Faye M.
• Application Number:
  US09/902,175
• Publication Number:
  US 20030011175A1
• Time in Patent Office: 826 Days
• Field of Search: 280/730.2, 280/730.1, 280/743.2, 280/743.1, 280/733
• US Class Current: 280/730.2
• CPC Class Codes: B60R 2021/23107 the bag being integrated in a multi-bag system
• CPC Class Codes: B60R 2021/23386 External tether means
• CPC Class Codes: B60R 21/232 Curtain-type airbags deploying mainly in a vertical direction from their top edge
• CPC Class Codes: B60R 21/2338 Tethers
• CPC Class Codes: B60R 21/237 characterised by the way they are folded

Abstract

A system and method for enhancing the interchangeability, cost effectiveness, and protective capacity of side impact, inflatable curtains is disclosed. An inflatable curtain module may have multiple cushions attached together by a separately manufactured inflatable tension coupling. The tension coupling may be attached to the cushions prior to folding of the cushions by, for example, sewing one end of the tension coupling to each cushion. The tension coupling may also be attached to the cushions after the cushions have been folded. The cushions may each have one or more tabs positioned to extend inward toward the tension coupling; the tabs may protrude from the folded cushions so that the tension coupling can be attached to the tabs after the cushions have been folded. The tension coupling may have a plurality of expanses configured to be attached between the cushions parallel to each other, and a flexible central portion connecting a pair of expanses to provide a barrier against occupant excursion while still permitting compaction of the tension coupling. Several combinations of compaction methods may be used to compact the cushions and the tension coupling. The tension coupling may alternatively have an array of holes at each end configured to be aligned with an array of holes on each cushion, so that one or more attachment mechanisms such as laces can be inserted through the holes to provide attachment.

Claims

1. An inflatable curtain module for protecting one or more occupants of a vehicle from lateral impact, the inflatable curtain module comprising:

a first cushion having a protection zone;

a second cushion having a protection zone; and

a tension coupling having a first end attachable to the first cushion by a first attachment mechanism and a second end attachable to the second cushion by a second attachment mechanism, wherein the tension coupling is configured to transmit tension between the first cushion and the second cushion to keep the protection zones of the first and second cushions in a position suitable for protecting one or more occupants of the vehicle;

wherein the first cushion comprises holes configured to align with holes formed in the first end of the tension coupling, and wherein the second cushion comprises holes configured to align with holes formed in the second end of the tension coupling.

2. The inflatable curtain module of claim 1, wherein the first and second cushions each comprise a longitudinal edge, and wherein the tension coupling is sewn to the longitudinal edges of the first and second cushions.

3. The inflatable curtain module of claim 1, wherein the first cushion comprises a first tab extending outward from the protection zone of the first cushion, the second cushion comprising a second tab extending outward from the protection zone of the second cushion, wherein the first and second tabs are configured to receive the first and second attachment mechanisms, respectively.

4. The inflatable curtain module of claim 3, wherein the first and second attachment mechanisms each comprise a rigid mechanical fastener affixed to the tabs and to the tension coupling.

5. The inflatable curtain module of claim 4, wherein the first and second attachment mechanisms are selected from the group consisting of clamps, snaps, hooks, locking rings, screws, bolts, nuts, rivets, and tacks.

6. The inflatable curtain module of claim 3, wherein the first and second attachment mechanisms each comprise a sewn interface between the tabs and the tension coupling.

7. The inflatable curtain module of claim 3, wherein the first and second attachment mechanisms each comprise a welded interface between the tabs and the tension coupling.

8. The inflatable curtain module of claim 7, wherein the welded interface of the first and second attachment mechanisms are created through the application of ultrasonic energy.

9. The inflatable curtain module of claim 3, wherein the first cushion further comprises:

a top edge configured to be fastened to the vehicle;

a bottom edge configured to be moved toward the top edge by a compaction process selected from the group consisting of rolling and accordion style folding; and

a longitudinal edge extending between the top edge and the bottom edge, wherein the first tab is attached to the longitudinal edge such that the first tab will be exposed after compaction of the cushion to permit attachment of the first end of the coupling to the tab after compaction of the cushion.

10. The inflatable curtain module of claim 1, wherein the holes of the first cushion comprise a first array of cushion holes, the holes of the second cushion comprise a second array of cushion holes, the holes of the first end of the tension coupling comprise a first array of coupling holes, and the holes of the second end of the tension coupling comprise a second array of coupling holes, wherein the first array of cushion holes are configured to align with the first array of coupling holes and the second array of cushion holes is configured to align with the second array of coupling holes.

11. The inflatable curtain module of claim 10, wherein the first attachment mechanism comprises a first rigid mechanical fastener inserted through one or more of the first array of cushion holes and the first array of coupling holes, and wherein the second attachment mechanism comprises a second rigid mechanical fastener inserted through one or more of the second array of cushion holes and the second array of coupling holes.

12. The inflatable curtain module of claim 11, wherein the first and second attachment mechanisms are each selected from the group consisting of clamps, snaps, hooks, locking rings, screws, bolts, nuts, rivets, and tacks.

13. The inflatable curtain module of claim 10, wherein the first attachment mechanism comprises a first lace inserted in interlocking fashion through the first array of cushion holes and the first array of coupling holes, and wherein the second attachment mechanism comprises a second lace inserted in interlocking fashion through the second array of cushion holes and the second array of coupling holes.

14. The inflatable curtain module of claim 10, wherein the first cushion further comprises:

a top edge configured to be fastened to the vehicle;

a bottom edge configured to be moved toward the top edge by a compaction process selected from the group consisting of rolling and accordion style folding; and

a longitudinal edge extending between the top edge and the bottom edge, wherein the first array of cushion holes is arrayed along a length of the longitudinal edge.

15. The inflatable curtain module of claim 1, wherein the tension coupling further comprises:

a first expanse extending from the first end to the second end, wherein the first expanse is attachable to a first position in relation the longitudinal edge of the first cushion by the first attachment mechanism, and to a second position in relation to the longitudinal edge of the second cushion by the second attachment mechanism;

a second expanse offset from the first expanse, the second expanse extending from the first end to the second end, wherein the second expanse is attachable to a third position in relation to the longitudinal edge of the first cushion by a third attachment mechanism, and to a fourth position in relation to the longitudinal edge of the second cushion by a fourth attachment mechanism; and

a flexible central portion connecting the first and second expanses, wherein the flexible central portion is compactible to permit the first and third attachment mechanisms to be moved toward each other and the second and fourth attachment mechanisms to be moved toward each other so that the tension coupling can be connected to the first and second cushions after the first and second cushions are compacted.

16. A cushion for an inflatable curtain module for protecting one or more occupants of a vehicle from lateral impact, the cushion comprising:

a top edge configured to be attached to the vehicle;

a bottom edge configured to be drawn toward the top edge by a compaction process selected from the group consisting of rolling and accordion style folding;

a protection zone between the top edge and the bottom edge, the protection zone being configured to contain a pressurized gas;

an interior longitudinal edge extending between the top edge and the bottom edge; and

a first tab attached to the interior longitudinal edge to protrude away from the protection zone such that the first tab will be exposed after compaction of the cushion, wherein the first tab comprises an attachment structure for connecting the first tab to a complimentary attachment structure associated with a tension coupling disposed between the cushion and an adjacent cushion to transmit tension to the protection zone from the adjacent cushion and from the protection zone to the adjacent cushion.

17. The cushion of claim 16, wherein the tab is formed integrally with the longitudinal edge from a fabric material.

18. The cushion of claim 16, wherein the tab is substantially formed of an ultrasonic weldable material.

19. The cushion of claim 16, wherein the tab is substantially coated with an ultrasonic weldable material.

20. The cushion of claim 16, wherein the tab comprises a hole configured to receive a rigid mechanical fastener.

21. The cushion of claim 16, wherein the longitudinal edge further comprises a second tab displaced along the longitudinal edge from the first tab.

22. A cushion for an inflatable curtain module for protecting one or more occupants of a vehicle from lateral impact, the cushion comprising:

a top edge configured to be attached to the vehicle;

a bottom edge configured to be drawn toward the top edge by a compaction process selected from the group consisting of rolling and accordion style folding;

a protection zone between the top edge and the bottom edge, the protection zone being configured to contain a pressurized gas; and

a longitudinal edge extending between the top edge and the bottom edge, the longitudinal edge having a plurality of cushion holes arrayed along a length of the longitudinal edge, wherein the holes are spaced apart to align with a plurality of coupling holes of a tension coupling such that an attachment mechanism can be inserted through the holes of the cushion and the tension coupling.

23. The cushion of claim 22, wherein the plurality of cushion holes are spaced apart such that accordion style folding of the cushion substantially aligns the plurality of cushion holes with each other so that the attachment mechanism can be inserted through all of the plurality of cushion holes by moving the attachment mechanism in a single direction.

24. The cushion of claim 22, wherein the plurality of cushion holes are substantially sealed from the protection zone to avoid escape of pressurized gas through the plurality of cushion holes.

25. A tension coupling having a first end configured to be attached to a longitudinal edge of a first cushion and a second end configured to be attached to a longitudinal edge of a second cushion to transmit tension between the first and second cushions, the tension coupling comprising:

a first expanse extending from the first end to the second end, wherein the first expanse is configured to be attached to a first position in relation to the longitudinal edge of the first cushion and to a second position in relation to the longitudinal edge of the second cushion;

a second expanse offset from the first expanse, the second expanse extending from the first end to the second end, wherein the second expanse is configured to be attached to a third position in relation to the longitudinal edge of the first cushion and to a fourth position in relation to the longitudinal edge of the second cushion; and

a flexible central portion connecting the first and second expanses to permit the first and second expanses to move compactly toward each other so that the tension coupling can be connected to the first and second cushions after the first and second cushions are compacted.

26. The tension coupling of claim 25, wherein the flexible central portion is configured to be rolled.

27. The tension coupling of claim 26, wherein the flexible central portion is configured to be rolled with a number of rolls equal to a number of rolls between the first and third positions of the first cushion and between the second and fourth positions of the second cushion.

28. The tension coupling of claim 25, wherein the flexible central portion is configured to be accordion folded.

29. The tension coupling of claim 28, wherein the flexible central portion is configured to be accordion folded with a number of folds equal to a number of folds between the first and third positions of the first cushion and between the second and fourth positions of the second cushion.

30. The tension coupling of claim 25, wherein the first and second expanses are configured to be attached to first, second, third, and fourth tabs positioned at the first, second, third, and fourth positions, respectively.

31. The tension coupling of claim 25, further comprising:

a first array of coupling holes configured to be held in alignment with a first array of cushion holes formed in the longitudinal edge of the first cushion by a first attachment mechanism; and

a second array of coupling holes configured to be held in alignment with a second array of cushion holes formed in the longitudinal edge of the second cushion by a second attachment mechanism.

32. An inflatable curtain module for protecting one or more occupants of a vehicle from lateral impact, the inflatable curtain module comprising:

a first cushion having a protection zone;

a second cushion having a protection zone; and

a tension coupling having a first end attachable to the first cushion by a first attachment mechanism and a second end attachable to the second cushion by a second attachment mechanism, wherein the tension coupling is configures to transmit tension between the first cushion and the second cushion to keep the protection zones of the first and second cushions in a position suitable for protecting one or more occupants of the vehicle;

wherein the first cushion comprises a first tab extending outward from the protection zone of the first cushion, the second cushion comprising a second tab extending outward from the protection zone of the second cushion, wherein the first and second tabs are configured to receive the first and second attachment mechanisms, respectively.