Abstract:
A module comprising a packaged airbag, wherein the airbag is configured to deploy on an interior side of a vehicle in a curtain arrangement; wherein the airbag is packaged so that the bottom of the airbag is folded then rolled in an outboard direction; and wherein the packaged airbag includes a folded portion located above the outboard rolled portion; and wherein the top portion is folded along a longitudinally extending crease to create a folded section located adjacent and outboard the rolled and folded sections. A module further comprising a Z-shaped folded portion above the outboard rolled portion, a second fold of the bottom portion in the outboard direction, a Z-shaped fold located between the bottom and top portions of the airbag, an inflator system, a plurality of mounting straps, and at least one tether on each of the fore and aft ends of the module.

Description:
BACKGROUND 
   The present disclosure relates generally to the field of vehicle airbags which provide occupant protection when deployed (e.g., during a dynamic vehicle impact). More particularly, the present disclosure relates to a method for packaging (i.e., folding and rolling) and storing a side curtain airbag in a vehicle for future deployment. 
   Airbags are located in vehicles to help protect occupants from injury during a dynamic vehicle impact event. A side curtain airbag can deploy and inflate, through the use of an inflator that provides gas for inflating the airbag. The inflator may use an explosive charge which causes gas to rapidly enter the inflatable regions of an airbag, to help protect at least one occupant from injury during a dynamic side-impact event. A side curtain airbag is generally stored within and deployed from the roof rail, which is the portion of a vehicle located just above the vehicle door frame and below the vehicle roof. Side curtain airbags are typically packaged through a process of folding and rolling to compact the airbag in order for it to fit within the small cross-section of the vehicle roof rail, and then after installation into the vehicle are hid behind a roof liner or headliner to improve the vehicle aesthetics. Side curtain airbags can be placed in any seat row (e.g., first, second, third) of a vehicle to deploy and to provide protection for any outboard vehicle occupant, and often a single side curtain airbag may protect multiple occupants in different seat rows. 
   It has been known to package side curtain airbags utilizing multiple step methods. One such method, first, folds the bottom portion of the airbag, in the inboard direction, onto itself (to form a closed U-shape); second, rolls the folded portion in the inboard direction; and third, pleats the top portion of the airbag with two Z-shaped folds. Another method, first, folds the bottom portion of the airbag, in the outboard direction, onto itself (to form a closed J-shaped fold); second, folds the J-shaped fold onto itself in the outboard direction, third rolls the airbag in the outboard direction; and fourth, pleats the top portion of the airbag with two Z-shaped folds. 
   These traditional airbag designs incorporate the same packaging method (i.e., the same steps of folding and rolling) along the entire length of the airbag. This means that the traditional airbag designs utilize the same packaging method to protect multiple occupants, although the interior compartment of each seat row is different. Conventional airbag designs deploy in a common trajectory for different occupants although the environment for each occupant may dictate the need to deploy along different trajectories to provide optimal protection to each occupant. Therefore it would be desirable to have a method to package an airbag which utilizes different methods for different sections of the airbag, to maximize the protection of each occupant. It would be desirable to design the deployment trajectory independently for each occupant to take into consideration the differences in the design of the window, door, pillar, and seat, as well as other vehicle components. 
   SUMMARY 
   One embodiment of the application relates to the packaging of a side curtain airbag module. The exemplary side curtain airbag module comprises a packaged airbag, so that the bottom of the airbag is folded then rolled in an outboard direction; and wherein the packaged airbag includes a folded portion located above the outboard rolled portion; and wherein the top portion is folded along a longitudinally extending crease to create a folded section located adjacent and outboard the rolled and folded sections. The first exemplary side curtain airbag module may further comprise a Z-shaped folded portion above the outboard rolled portion, a second fold of the bottom portion in the outboard direction, a Z-shaped fold located between the bottom and top portions of the airbag, an inflator system to provide the explosive charge of gas that fills and expands the airbag, a plurality of mounting straps to provide a method of attaching the module to a vehicle and at least one tether on each of the fore and aft ends of the module to provide stability during deployment of the airbag. 
   A second embodiment of the application relates to the packaging of a side curtain airbag module. The exemplary side curtain airbag module comprises a packaged airbag, wherein the airbag has a first portion located aft of the vehicle B-pillar and a second portion located forward of a the B-pillar; wherein the first portion is packaged so that the bottom of the first portion airbag is folded then rolled in an outboard direction, and wherein the packaged first portion of the airbag includes a folded portion located above the outboard rolled portion; and wherein the second portion is packaged so that that the bottom of the second portion airbag is folded then rolled in an outboard direction and wherein the packaged second portion of the airbag includes a folded portion located above the outboard rolled portion; and wherein the top portion of the second portion is folded along a longitudinally extending crease to create a folded section located adjacent and outboard the folded and rolled sections. The second exemplary side curtain airbag module may further comprise of a Z-shaped folded portion above the outboard rolled portion of the first portion of the airbag, a Z-shaped folded portion above the outboard rolled portion of the second portion of the airbag, a second fold of the bottom portion in the outboard direction, a Z-shaped fold located between the bottom and top portions of the airbag, an inflator system, a plurality of mounting straps, and at least one tether on each of the fore and aft ends of the module. 
   This application also relates a method of packaging a side curtain airbag comprising the steps of; rolling the lower portion of the airbag in an outboard direction, and folding a portion of the airbag above the outboard roll to include an additional fold located adjacent and outboard the rolled section. This method of packaging a side curtain airbag may further comprise folding the bottom section of the airbag in the outboard direction to form a J-shape and a second fold of the bottom section of the airbag in the outboard direction to form a J-shape. 
   It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only, and are not restrictive of the invention as claimed. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1A  is a cross-car (side) view of the outboard side of an exemplary embodiment of a side curtain airbag in the unpackaged (unfolded and unrolled) state. 
       FIG. 1B  is a rear view of the side curtain airbag of  FIG. 1A  according to an exemplary embodiment. 
       FIG. 2A  is a cross-car (side) view the outboard side of an exemplary embodiment of a side curtain airbag showing an initial outboard J-shaped fold. 
       FIG. 2B  is a rear view of the side curtain airbag of  FIG. 2A  according to an exemplary embodiment. 
       FIG. 3A  is a cross-car (side) view of the outboard side of an exemplary embodiment of a side curtain airbag showing a first outboard J-shaped fold followed by a second outboard J-shaped fold. 
       FIG. 3B  is a rear view of the side curtain airbag of  FIG. 3A  according to an exemplary embodiment. 
       FIG. 4A  is a cross-car (side) view of the outboard side of an exemplary embodiment of a side curtain airbag showing a mid airbag Z-shaped fold. 
       FIG. 4B  is a rear view of the side curtain airbag of  FIG. 4A  according to an exemplary embodiment. 
       FIG. 5A  is a cross-car (side) view of the outboard side of an exemplary embodiment of a side curtain airbag showing an outboard roll. 
       FIG. 5B  is a rear view of the side curtain airbag of  FIG. 5A  according to an exemplary embodiment. 
       FIG. 6  is a cross-car (side) view of the outboard side of an exemplary embodiment of a side curtain airbag shown in the packaged state and ready for installation into a vehicle. 
       FIG. 7A  is a rear view along section A-A of the side curtain airbag of  FIG. 6  according to an exemplary embodiment. 
       FIG. 7B  is a rear view along section B-B of the side curtain airbag of  FIG. 6  according to an exemplary embodiment. 
       FIG. 7C  is a rear view along section C-C of the side curtain airbag of  FIG. 6  according to an exemplary embodiment. 
       FIG. 7D  is a rear view along section D-D of the side curtain airbag of  FIG. 6  according to an exemplary embodiment. 
       FIG. 7E  is a rear view along section E-E of the side curtain airbag of  FIG. 6  according to an exemplary embodiment. 
       FIG. 7F  is a rear view along section F-F of the side curtain airbag of  FIG. 6  according to an exemplary embodiment. 
       FIG. 8  is a cross-car (side) view of the outboard side of an exemplary embodiment of a side curtain airbag in the unpackaged (unfolded and unrolled) in relation to an exemplary vehicle embodiment. 
   

   DESCRIPTION 
   Side curtain airbags are provided in vehicles to help protect an occupant from injury during a dynamic side-impact event. It is desirable for the side curtain airbag&#39;s trajectory during deployment to place the airbag cushion between the vehicle occupant and the vehicle&#39;s structure (which includes the window, the door frame and the pillars) to provide protection to the occupants during the impact event. The method of packaging (i.e., folding and rolling) the side curtain airbag for storage until deployment is critical to the trajectory path of the airbag during deployment. 
   Referring generally to the FIGURES, a side curtain airbag module  10  is shown according to an exemplary embodiment. Airbag module  10  remains packaged and stored in a portion of the vehicle, typically the roof rail, until deployment occurs. An airbag module  10  includes an inflator system  30  which provides inflation gas for the airbag. The inflator may use store gas or gas generant (or a combination) to provide inflation gas for the airbag. The inflator may include an explosive charge that causing the gas to rapidly enter and expand the inflatable regions of the airbag, causing the airbag to breach the surrounding flexible skin in order to deploy to protect the occupant. During deployment, airbag module  10  remains attached to the vehicle by a plurality of mounting straps  28  which protrude from the top edge  23  of airbag module  10 , causing airbag cushion  22  to expand in the downward and cross-car directions as the first and second portions  17  and  18 , respectively, are filled with gas. 
   Referring to  FIGS. 1A and 1B , an exemplary embodiment of a side-curtain airbag module  10  is shown in the unpackaged state, and includes an airbag cushion  22 , at least one seam  26 , a plurality of mounting straps  28 , an inflator system  30 , and at least one tether  32  on each end of the airbag module  10 , which attach directly to the vehicle. An exemplary airbag cushion  22  may include an inboard side  15 , which faces the passenger of the vehicle; coupled (through conventional means) to an outboard side  16 , which faces the door of the vehicle; which form a top edge  23  and a bottom edge  24 . An exemplary air bag cushion  22  also includes a first portion  17 , which when inflated, protects a rearward positioned occupant; and a second portion  18 , which when inflated, protects a forward positioned occupant. 
   Referring to  FIGS. 2A and 2B , a first exemplary embodiment of a side-curtain airbag module  10  is shown with the bottom edge  24  folded upward onto the outboard side  16  towards the top edge  23 , to form a J-shaped fold  38  with a crease  36  along the bottom. An alternative embodiment of airbag module  10  may fold the bottom edge  24  upward onto the inboard side  15  towards the top edge  23 . 
   Referring to  FIGS. 5A and 5B , a first exemplary airbag module  10  (from  FIGS. 2A and 2B ) is shown, where beginning with the crease  36  (of  FIG. 2A ) the fold  38  (of  FIG. 2B ) is rolled towards the top edge  23  on the outboard side, which forms roll  40 . An alternative embodiment of airbag module  10  may roll the fold  38  towards the top edge  23  on the inboard side. 
   Referring to  FIGS. 6  thru  7 F, a first exemplary airbag module  10  (from  FIGS. 2A and 2B ) is shown. The portion of airbag above the roll  40  of the second portion  18  of the first exemplary airbag module  10  is folded into a Z-shaped fold  54  which rests above roll  40  (as shown in  FIGS. 7D  thru  7 F). The remaining material of the second portion  18  of airbag module  10 , above the Z-shaped fold  54 , is folded along a longitudinally extending crease to create a folded section  56  located adjacent and outboard of the Z-shaped fold  54  and roll  40 . The portion of airbag above the roll  40  of the first portion  17  of the first exemplary airbag module  10  is folded into a first Z-shaped fold  54  which rests above roll  40  (as shown in  FIGS. 7A  thru  7 C). The remaining material of the first portion  17  of airbag module  10 , above the Z-shaped fold  54 , is folded into a second Z-shaped fold  54  which rests above the first Z-shaped fold  54 . 
   Also referring to  FIGS. 6  thru  7 F, a first exemplary airbag module  10  is wrapped in a skin  60 , which is both flexible and non-structural, as it maintains the packaged shape of airbag module  10 . During deployment, airbag module  10  breaches the skin  60  while expanding to take its design intent inflated shape. The plurality of mounting straps  28  protrude through the skin  60 , to provide a means of attaching airbag module  10  to the vehicle, as shown in  FIGS. 7A and 7F . 
   Referring to  FIGS. 3A and 3B , a second exemplary embodiment of a side curtain air bag module  10  is shown with the bottom edge  24  folded upward onto the outboard side  16  towards the top edge  23 , to form a J-shaped fold  38  with a crease  36  on the bottom. The J-shaped fold  38  is then folded upwards toward the top edge  23 , to form a second J-shaped fold  38  and a second crease  36  along the now bottom edge of the second exemplary airbag module  10 . The second crease  36  of the second J-shaped fold  38  of the second exemplary airbag module  10  is rolled towards the top edge  23  on the outboard side, which forms roll  40 , as shown in  FIGS. 5A and 5B . The second portion  18  of the second exemplary airbag module  10  is folded into a Z-shaped fold  54 , which rests above roll  40 , then the remaining material is folded along a longitudinally extending crease to create a folded section  56  located adjacent and outboard of the Z-shaped fold  54  and roll  40 , as shown in  FIGS. 7D  thru  7 F. The first portion  17  of the second exemplary airbag module  10  is folded into a first and second Z-shaped fold  54 , which rests above roll  40 , as shown in  FIGS. 7A  thru  7 C. 
   Also referring to  FIGS. 3A and 3B , an alternative embodiment of the second exemplary embodiment of airbag module  10  may involve the first and second folds  38  being folded onto the inboard side  15 , towards the top edge  23 . Another alternative embodiment of the second exemplary embodiment of the airbag module  10  may involve rolling the first and second folds  38  towards the top edge  23  on the inboard side, which forms roll  40 . 
   Referring to  FIGS. 4A and 4B , a third exemplary embodiment of a side curtain air bag module  10  is shown. In between the bottom edge  24  and the top edge  23 , a section of the airbag module  10  is folded into a Z-shaped fold  54 . The bottom edge  24  of the second exemplary airbag module  10  is rolled towards the top edge  23  on the outboard side, which forms roll  40 , as shown in  FIGS. 5A and 5B . The second portion  18  of the second exemplary airbag module  10  is folded into a Z-shaped fold  54 , which rests above roll  40 , then the remaining material is folded along a longitudinally extending crease to create a folded section  56  located adjacent and outboard of the Z-shaped fold  54  and roll  40 , as shown in  FIGS. 7D  thru  7 F. The first portion  17  of the second exemplary airbag module  10  is folded into a first and second Z-shaped fold  54 , which rests above roll  40 , as shown in  FIGS. 7A  thru  7 C. 
   Also referring to  FIGS. 4A and 4B , an alternative embodiment of the third exemplary embodiment may include adding a J-shaped fold  38  (as shown in  FIGS. 2A and 2B ) to the bottom of the airbag module  10 . The airbag module  10  may then be rolled beginning with the crease  36  through the Z-shaped fold. 
   Referring to  FIG. 8 , an exemplary embodiment of a side-curtain airbag module  10  is shown in relation to an exemplary embodiment of a vehicle  70 , which includes an A-pillar  72 , a B-pillar,  74 , a C-pillar  76 , and a roof rail  78 . A roof rail  78  spans between the A-pillar  72  and the C-pillar  76 , and is where an exemplary side curtain airbag  10  is stored when packaged until deployment. A side curtain airbag  10  may be attached to a roof rail  78  through the use of the mounting straps  28 . 
   It is important to note that the construction and arrangement of the side curtain airbag folding method as shown in the various exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the description. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of the elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the exemplary embodiments.