Abstract:
A bracket for placement between the A-pillar and pillar garnish in an automobile, wherein the bracket includes a base and first and second mounting flanges for use in attaching the bracket to the A-pillar structure. The bracket also includes first and second handle flanges for use in attaching an occupant grab handle to the bracket. The bracket also includes a garnish mounting flange located between the base and handle flange. The garnish is secured to the bracket allowing the garnish to deflect slightly inwards and outwards, but not to such an extent that damage to the garnish occurs.

Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   This invention relates to brackets, more particularly to brackets used between an A-pillar and an associated pillar garnish on an automobile. 
   2. Description of Related Art 
   The most advanced modern vehicles are designed to meet industry requirements for minimizing injury to passenger&#39;s heads during an event such as an accident. Specifically, numerous target points on the vehicle&#39;s interior are tested using a passenger head simulator which impacts the target points during a simulated crash. Typical target points are on the vehicle roof, side rail, header and pillars. Materials such as garnishes that cover the structural member(s) of a pillar, etc. are designed to absorb a certain amount of force of the moving head simulator and, thus, cushion an impact. 
   In addition to garnish design, air bags play a significant role in protecting vehicle occupants during accidents. In a vehicle, a front pillar (commonly referred to as the “A-pillar”) may include an air bag that is placed between a pillar structural member and a protective/decorative cover garnish. When the air bag is deployed, the garnish is deflected slightly, thus, allowing the expanding air bag to enter the passenger compartment. 
   In addition to meeting head impact requirements, a pillar system that includes an air bag and garnish should also prevent damage to the garnish when the air bag is deployed or the garnish impacted (damage is most likely to occur when the temperature in the vehicle is low and the garnish less flexible), allow the air bag to be deployed quickly, and minimize space usage because an A-pillar is located within a driver and passenger&#39;s line of sight. Additionally, the pillar system should provide a suitable structure for mounting a grab handle that provides convenience for the vehicle passenger&#39;s entry and exit. 
   Some known pillar systems provide a bracket between the pillar structure and garnish to meet head impact requirements. What is desired is an improved bracket that, in addition to meeting head impact requirements, also minimizes visual obstruction, provides a mount for a grab handle and supports the garnish such that potential damage to the garnish is minimized both during deployment of an air bag (when the garnish moves outward) and during an impact event (when the garnish is contacted and moves inwards). Such a bracket is particularly required when a common vinyl-type garnish is used as opposed to a garnish that includes an outer fabric cushion. 
   BRIEF SUMMARY OF THE INVENTION 
   The present invention provides an improvement over the prior art by providing an improved pillar bracket that that is used in combination with a side curtain air bag on the A-pillar of an automobile. The bracket may be used on either the driver&#39;s side A-pillar, passenger side A-pillar, or both. The structure of the pillar bracket provides the strength required to be a suitable mount for a grab handle, if desired. Additionally, the structure of the pillar bracket and the ability of the bracket to attach to the garnish provides support for the garnish so the garnish meets head impact requirements, but is not damaged during air bag deployment. The structure of the bracket further allows the pillar system to be designed compactly so as not to be a significant visual obstruction. 
   The bracket includes a base and first and second mounting flanges for use in attaching the bracket to the A-pillar structure. The bracket also includes first and second handle flanges for use in attaching an occupant grab handle to the bracket. The bracket also includes a garnish mounting flange located between the base and handle flange. The garnish is secured to the bracket allowing the garnish to deflect slightly inwards and outwards, but not to such an extent that damage to the garnish occurs. 
   These and other aspects of the invention are herein described in particularized detail with reference to the accompanying figures. 

   
     BRIEF DESCRIPTION OF THE FIGURES 
       FIG. 1  is a perspective view of the bracket garnish and handle of the present invention, attached to a vehicle A-pillar; 
       FIG. 2  is a perspective view of the bracket and handle only, attached to the vehicle A-pillar; 
       FIG. 3  is a perspective view of the bracket attached to the vehicle A-pillar; 
       FIG. 4  is a rear view of the bracket handle and garnish without showing the A-pillar; 
       FIG. 5  is cross sectional view of the bracket, A-pillar, air bag, handle and garnish; and 
       FIG. 6  is a cross sectional view of the bracket. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Referring to the drawings, specifically  FIGS. 3-4 , a preferred pillar bracket  10  according to the present invention is illustrated. The bracket  10  is generally rectangular with sections along its length that are elevated with respect to a base section. The elevated sections include portions that are tilted with respect to the plane of the base. As described in more detail below, the bracket  10  includes as follows, from the bottom to the top of the bracket  10  (with respect to the vehicle when the bracket is mounted to the vehicle A-pillar): a first mounting flange  12 , a first handle flange  14 , a base  16 , a garnish flange  18 , a second handle flange  20  and a second mounting flange  22 , as well as various intervening walls. A sidewall  24  extends from approximately the first handle flange  14  to the second mounting flange  22 . Preferably, the bracket  10  is manufactured as a single piece from mild steel, via a stamping process. 
   Beginning at the bottom end  25  of the bracket  10 , the first mounting flange  12  is provided and is generally square, oriented in the same plane as the base  16 , and extends across the width of the bracket  10 . The first mounting flange  12  includes narrow flaps  26  on each edge along the width of the bracket  10 , which extend toward the pillar structure  28  when the bracket  10  is mounted in place on the vehicle. The first mounting flange  12  defines an aperture  29  at its center for the passage of a mounting bolt that attaches the bracket  10  to the pillar structure  28 . 
   Moving up the bracket  10 , the first handle flange  14  is located adjacent to the first mounting flange  12 . The first handle flange  14  is elevated with respect to the first mounting flange  12  and the base  16 . Because the first handle flange  14  is elevated, a first transition wall  30  is provided between the first mounting flange  12  and the first handle flange  14 . The first transition wall  30  is perpendicular to the plane defined by the first mounting flange  12 . The first handle flange  14  is generally planer and defines a mounting aperture  32  in its center through which a bolt from the handle  100  passes. A notch section  33  is contoured to match a similar contour on a grab handle to guarantee that the handle is mounted with the correct orientation. A second transition wall  34  is located between the first handle flange  14  and the base  16 . The second transition wall  34  is perpendicular to the plane of the base  16 . A portion of the sidewall  24  horizontally aligned with the first handle flange  14  extends vertically from a height below the plane of the base  16  to the height of the first handle flange  14 . The first handle flange  14  is tilted such that a first edge  36  of the first handle flange  14 , intersects the sidewall  24 , and is lower than an opposite edge  37 . This opposite edge  37  is located closer to the lengthwise centerline of the bracket  10  than a corresponding edge  35  of the first mounting flange  12 . 
   The base  16  is located adjacent to the first handle flange  14 , specifically intersecting the second transition wall  34 , and has a generally rectangular shape. A portion of the sidewall  24  horizontally coincides with the full length of the base  16  and extends from the plane of the base  16  toward the pillar structure  28 . 
   The garnish mounting flange  18  is located on the opposite side of the base  16  from the first handle flange  14 . The garnish mounting flange  18  is also raised above the level of the base  16 . A third transition wall  38  is located between the base  16  and the garnish mounting flange  18 . The third transition wall  38  is perpendicular to the plane of the base  16 . The garnish mounting flange  18  is generally rectangular, generally parallel to the plane of the base  16 , and an aperture  39  is defined near the center of the garnish mounting flange  18 . The bracket sidewall  24  includes a portion horizontally aligned with the garnish mounting flange  18  that extends upward from below the plane of the base  16  to the level slightly above the garnish mounting flange  18 . A transverse junction section  40  extends from the top of this sidewall portion to a first edge directly above the garnish mounting flange  18  and tilts slightly, with an edge that intersects the sidewall  24  of the bracket  10 , being lower than the first edge. A fourth transition wall  43  extends from the first edge of the transverse junction section  40  to the garnish mounting flange. The transition wall  43  is generally perpendicular to the third transition wall  38  and generally perpendicular to the plane of the garnish mounting flange  18 . A fifth transition wall  41  is located between the garnish mounting flange  18  and the second handle flange  20 . The fourth transition wall  41  is also perpendicular to the plane of the base  16 . 
   The second handle flange  20  is located on the opposite side of the garnish mounting flange  18  from the base  16 . The second handle flange  20  is raised above the plane of the base  16 . The second handle flange  20  is generally planer and defines a mounting aperture  42  in its center through which a bolt from the handle  100  passes. A portion of the sidewall  24  horizontally aligned with the second handle flange  20  extends vertically from the height below the plane of the base  16  to the height of the second handle flange  20 . The second handle flange  20  is tilted such that an edge  44  of the second handle flange  20 , adjacent the sidewall  24 , is lower than an opposite edge  46 . 
   A sixth transition wall  48  is located between the second handle flange  20  and the second mounting flange  22 . The second mounting flange  22  is generally square and oriented in the same plane as the base  16 . The second mounting flange  22  does not extend across the full width of the bracket  10 . The second mounting flange  22  defines an aperture  49  at its center for the passage of a mounting bolt. 
   A portion of the sidewall  24  adjacent to the second mounting flange  22  extends upward from a level below the base  16  and merges into a cover section  50  that is generally cylindrically arched and is approximately equal in width to the second mounting flange  22 . 
   Referring to  FIGS. 1 ,  3  and  6 , the sidewall  24  has been previously described above in sections, but as a whole is generally perpendicular to the base  16  and extends away from the plane of the base  16  toward the pillar structure  28  at a generally equal distance along the length of the sidewall  24 , except in the vicinity of the first mounting flange where the sidewall  24  is replaced by the flaps  26  previously described. 
   When the bracket  10  is installed upon the pillar structure  28 , the first mounting flange  12  and second mounting flange  22  abut against pillar structure  28 . The bracket  10  as a whole has a slight curve that follows a contour that is present in the garnish  80 . 
   Referring to  FIGS. 2 and 4 , an adapter plate  60  that is formed separately from the bracket  10  and includes first and second clasps  62  and  64  and a tang  66  is shown. The adapter plate  60  is generally rectangular and the tang  66  is at a first end  68  of the plate  60 . The tang  66  is bent toward the pillar structure  28 . At the opposite end  70  of the adapter plate  60 , an aperture  72  is defined. A central aperture  74  is also defined in the adapter plate  60 . The first and second clasps  62  and  64  are located at approximately the mid point of the length of the adapter plate  60  and are on opposite sides of the adapter plate  60 , extending outwardly therefrom. The clasps  62  and  64  can be folded over without breaking. The adapter plate  60  fits between the first mounting flange  12  of the bracket  10  and the pillar structure  28 . 
   Referring to  FIGS. 3 and 4 , a typical vehicle A-pillar  28  is shown with a bracket  10  of the present invention attached thereto. Additionally, a side curtain air bag (SCAB)  90  is shown between the bracket  10  and the A-pillar structure  28 . Referring to  FIG. 5 , a cut-away section of garnish  80  is shown covering the bracket  10 . 
   Referring to  FIGS. 1-4 , assembly of the bracket  10 , garnish  80 , air bag  90  and A-pillar structure  28  is shown. First, the adapter plate  60  of the bracket  10  is placed on the A-pillar structure  28 . The tang  66  fits into an aperture of the A-pillar structure  28 . The air bag  90  and bracket  10  are then placed as an assembly on the A-Pillar structure  28  and fastened thereto. The air bag  90  and bracket  10  are installed simultaneously as part of a module. A cord portion  92  of the air bag  90  fits within the aperture  72  in the adapter plate  60  and is held therein. The bracket  10 , in place over the air bag  90 , is then bolted to the A-pillar structure  28 . The clasps  62  and  64  on the adapter plate  60  fit into or around slots on the first mounting flange  12  and are folded over in order to secure the adapter plate  60  to the bracket  10 . The cover section  50  covers a portion of the air bag  92  that extends out from the bracket  10  and toward the top of the vehicle. A bolt passing through the first mounting flange  12  of the bracket  10  also passes through the central aperture  74  in the adapter plate  20 . 
   The garnish  80  is placed over the bracket  10  and the remainder of the A-pillar  28 . Referring to  FIG. 5 , a clip  82  protruding from the back side  84  of the garnish  80  fits into the aperture  49  within the garnish mounting flange  18 . The clip  82  includes a spacer  86  and a nipple  88 . The nipple  88  passes through the aperture  49  and snappingly engages the garnish mounting flange  18 . The garnish  80  can be detached from the bracket  10  without breaking the clip  82 . The handle  100  is then attached to the bracket handle flanges  14  and  20  by extending bolts through the garnish  80 . Preferably, the handle is only installed on the passenger side of the vehicle. 
   Referring to  FIGS. 1 ,  3  and  5 , when the vehicle is involved in a collision, the air bag  90  inflates and extends through a gap  110  between the A-pillar structure  28  and the bracket  10  and garnish  80  combination. 
   Because the bracket  10  is placed between the garnish  80  and air bag  90 , when the air bag  90  inflates and expands, the garnish  80  is not deflected as much as if the bracket  10  were not present. Thus, the risk of damage to the garnish  80  during outward expansion is reduced. The shape of the bracket  10  acts as a housing that keeps the air bag  90  in position before it is deployed and protects the air bag  90  from damage. The shape of the first handle flange  14  and the second handle flange  20  of the bracket  10  provide the rigidity in the bracket required such that the handle does not need to be mounted to the pillar structure  28  directly. Additionally, the shape of the handle mounting flanges  14  and  20  provides significant column strength and provides a large strength to deflection ratio. 
   Because the garnish  80  is clipped directly to the bracket  10 , the garnish  80  is able to meet head impact requirements and not deflect significantly during inward expansion. The spacing of the bracket  10  from the garnish  80  caused by the spacer portion  86  of the clip  82  allows for slight, but not significant deflection upon impact. 
   Because the bracket  10  is formed from steel, a high level of strength is provided using a relatively small bracket  10 . As a result, the garnish  80  that covers the bracket  10  and A-pillar  28  fits closely to the A-pillar  28  and minimizes visual obstruction. 
   The bracket is a significant improvement over the prior art because the garnish is not damaged due to significant deflection when the air bag is deployed or garnish impacted. However, the bracket does not slow down the speed of air bag deployment significantly. 
   Also, the bracket acts as a mount for a grab handle, the handle not having to be attached directly to the pillar. The bracket further provides an attachment point for the vehicle garnish that is close to the surface of the garnish, thus the garnish deflects less when the vehicle occupant impacts the garnish. This is especially important in multiple rollover instances of the vehicle where there remains the potential for the vehicle occupant to contact the A-pillar after the air bag has already deployed. 
   Preferably, the garnish is a simple vinyl type and does not include a fabric applied to its outer surface, but alternatively may be other types of known garnishes. The bracket may also include fold and/or bead reinforcement in desired positions to provide additional strength. Bolted connections may be replaced by other fasteners such as clips. 
   Although the invention has been shown and described with reference to certain preferred and alternate embodiments, the invention is not limited to these specific embodiments. Minor variations and insubstantial differences in the various combinations of materials and methods of application may occur to those of ordinary skill in the art while remaining within the scope of the invention as claimed and equivalents.