Abstract:
An airbag bracket includes a self-fastening protrusion extending from a plate-like metallic base. The base includes a tongue onto which the protrusion is molded using a polymeric material. The base has at least one through-aperture onto which a fabric tail of an airbag unit may be wound. The base further includes a fastener aperture to receive there-through a fastener. The protrusion and fastener are mounted in respective holes or sockets in a body wall of a vehicle in order to mount the airbag system.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of Chinese Patent Application No. CN201510161149.2, filed Apr. 7, 2015, the entire contents thereof being incorporated herein by reference. 
       TECHNICAL FIELD 
       [0002]    The present invention relates to an airbag bracket and a vehicle airbag system including the same. 
       BACKGROUND OF THE INVENTION 
       [0003]    With increased attention for vehicle safety, enhanced safety measures such as side curtain airbags are equipped in certain vehicles, where such curtain airbags may be installed to vehicles through brackets. 
         [0004]    In one example, US2005/0046154A1 discloses a mounting bracket that may be used to mount an inflatable curtain airbag, where the mounting bracket includes a base bracket and a retaining clip attachable to the base bracket. 
       SUMMARY OF THE INVENTION 
       [0005]    In order to provide a robust mounting attachment and to protect against bracket rotation, the anchoring of an airbag bracket may preferably include two independent anchor points between the bracket and the underlying panel to which the bracket is attached. In addition, it is desirable for ease of installation for one of the anchor points to provide a self-fastening function so that a person performing the assembly operation is able to provide an initial placement and attachment of an airbag assembly (e.g., a side curtain airbag with brackets attached to it) to a vehicle wall (e.g., a roof panel) by simply aligning the assembly and pressing it in place, so that self-fastening pins extending from the brackets are captured in corresponding receptacles (e.g., holes) in the vehicle wall. Use of a self-fastening pin further enables the location of one of the anchor points to be behind (covered by) the main body of the airbag unit. After initial placement and engagement of the self-fastening pins, the assembler&#39;s hands are free to insert an additional fastener at each of the second anchor points of each bracket. 
         [0006]    In one or more embodiments of the invention, an airbag bracket includes a base including a fastener aperture to receive there-through a fastener and including a first material, and a protrusion supported on the base and including a second material different from the first material. The first material may include a metallic material and the second material may include a polymeric material. The base may include a tongue to be at least partially received within the protrusion. The base may define first and second through-apertures spaced apart from each other, the tongue extending from an edge of the first through-aperture. The second through-aperture may be longer in a width dimension than the first through-aperture. The first through-aperture may be positioned between the fastener aperture and the second through-aperture. The through-apertures provide a structure onto which the main body of the airbag unit may be attached (e.g., by a fabric tail of side curtain airbag being wound onto the base by threading and winding over the aperture(s). 
         [0007]    The protrusion may provide a self-fastening pin function, and may include a first segment with a first cross-section and a second segment with a second cross-section positioned between the base and the first segment. The first cross-section is different from the second cross-section in at least one of circumferential shape or perimeter dimension. The protrusion may include on its outer surface two or more ribs spaced apart from each other. The protrusion may include a transverse bar separating first and second cavities. 
         [0008]    The base may include a stepped area surrounding the fastener aperture. The fastener aperture is positioned in a first step, which is surrounded by a second step. When at an assembled position, the second step contacts a sidewall of the vehicle and the first stepping area is spaced apart from the sidewall of the vehicle. 
         [0009]    The airbag bracket may further include one or more supplemental apertures. 
         [0010]    In one or more embodiments, a vehicle airbag system includes an airbag unit together with an airbag bracket as detailed herein. The airbag bracket includes a base having a fastener aperture to receive there-through a fastener and including a first material, and a protrusion supported on the base and including a second material different from the first material. The base is connected to the airbag unit and the protrusion is to be engaged with a vehicle body portion. A flexible tail of the airbag may contact the protrusion. The flexible tail of the airbag may include an opening to receive there-through the protrusion such that the flexible tail of the airbag is between the bracket and an interior outer surface of the vehicle body portion in an assembled position. The flexible tail may also be wound over through-apertures in the base in addition to receiving the protrusion. 
         [0011]    One or more advantageous features as described herein will be readily apparent from the following detailed description of one or more embodiments when taken in connection with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    For a more complete understanding of one or more embodiments of the present invention, reference is now made to the one or more embodiments illustrated in greater detail in the accompanying drawings and described below wherein: 
           [0013]      FIG. 1A  illustratively depicts a perspective view of an airbag bracket for positioning a vehicle curtain airbag according to one or more embodiments of the present invention; 
           [0014]      FIG. 1B  illustratively depicts an enlarged sectional view of the curtain airbag referenced in  FIG. 1A ; 
           [0015]      FIG. 2A  illustratively depicts a front view of the airbag bracket referenced in  FIG. 1A  and  FIG. 1B ; 
           [0016]      FIG. 2B  illustratively depicts an enlarged perspective view of the airbag bracket referenced in  FIG. 2A ; 
           [0017]      FIG. 2C  illustratively depicts a cross-sectional view of the airbag bracket referenced in  FIG. 2A  in view of its assembled position relative to the curtain airbag; 
           [0018]      FIG. 3A  illustratively depicts an alternative view of the airbag bracket referenced in  FIG. 2A ; and 
           [0019]      FIG. 3B  illustrativley depicts a cross-sectional view of the airbag bracket referenced in  FIG. 3A . 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0020]    As referenced in the Figures, the same reference numerals may be used to refer to the same parameters and components or their similar modifications and alternatives. These specific parameters and components are included as examples and are not meant to be limiting. The drawings referenced herein are schematic and associated views thereof are not necessarily drawn to scale. 
         [0021]      FIG. 1A  illustratively dipicts a non-limiting example location of an airbag bracket  100  as employed for positioning a vehicle curtain airbag  104  according to one or more embodiments of the present invention. Curtain airbag  104  may be positioned at an interior upper portion of a vehicle  102 , where the curtain airbag  104  may be any suitable safety curtain airbag applicable in the vehicle  102 , and the curtain airbag  104  is installed via one or more airbag brackets  100 . In the event of a side impact, the certain airbag  104  may deploy to protect an occupant of the vehicle  102 . 
         [0022]      FIG. 1B  illustratively depicts an enlarged sectional view of the curtain airbag  104  shown in  FIG. 1A , wherein the curtain airbag  104  is generally located at the interior upper portion of a B-pillar  122  and a C-pillar  124  of the vehicle  102  and is connected to the vehicle  102  via one or more airbag brackets  100 . After a deployment, the curtain airbag  104  may space the occupant apart from any nearby windows, B-pillar  122 , and/or C-pillar  124  to protect the occupant from any resultant impact. The design of the airbag bracket  100  will be detailed herein. 
         [0023]    Without wanting to be limited to any particular theory, and as detailed herein in view of FIG. 2 A through  FIG. 2C , it is believed that to securely attach the curtain airbag  104  onto the vehicle  102 , and on a sidewall  110  thereof in particular, certain attachment strength is required between a base  200  and a protrusion  230  of the airbag bracket  100 , which in turn places certain requirement on the material(s) for the airbag bracket  100 . At the same time, a certain level of flexibility of protrusion  230  is needed to facilitate installation/assembly of curtain airbag  104  onto bracket  100  (e.g., to accommodate any misalignment between protrusion  230  and a receiving-hole in a body sheet metal panel to which bracket  100  is being mounted). Moreover, it is desirable that the curtain bracket  100  should facilitate a smooth deployment of the curtain airbag  104  without unnecessary damage to the curtain airbag  104 . By providing the airbag bracket  100  with different structural and/or material features, the present invention in one or more embodiments provides enhanced solutions for curtain airbag attachment in a vehicle. 
         [0024]      FIG. 2A  together with  FIG. 2B  and  FIG. 2C  illustratively depict airbag bracket  100  of curtain airbag  104  in one or more embodiments. Airbag bracket  100  includes base  200  and protrusion  230  supported on base  200 . Base  200  includes a fastener aperture  210  for receiving or connecting a fastener  280  so as for the base  200  to be attached to the side wall  110  of the vehicle  102 . The fastener  280  may include but is not limited to one or more pins, screws, bolts, or rivets. 
         [0025]    The present invention in one or more embodiments is advantageous in providing enhanced level of design and operation flexibility to the curtain bracket  100  by making the protrusion  230  materially independent from the base  200 . In particular, the protrusion  230  may differ in material from the base  200 . More particularly, the base  200  may include a material that is different from that of at least a portion of the protrusion  230 . The base  200  may include a material of a material strength higher than that of the protrusion  230 , or of a material with lower flexibility than that of the protrusion  230 . Accordingly, the protrusion  230  may be formed relatively more flexible and compressible in comparison to the base  200  such that the protrusion  230  facilitates its insertion into a hole or socket in the sidewall  110 , while the greater strength and relative rigidity of base  200  helps maintain the general shape and strength for supporting the curtain bag  104 . 
         [0026]    The base  200  may include a first material such as a metallic material while the protrusion  230  may include a second material such as a polymeric material which is different from the first material. Alternatively, the base  200  may be formed by non-metallic materials, such as carbon fiber enhanced polymeric material with good material strength. In a preferred embodiment, base  200  may comprise stainless steel and/or alluminum alloy, and protrusion  230  may include polyethylene, polypropylene, and/or polyvinyl chloride. 
         [0027]    Referring back to  FIG. 2A  and  FIG. 2B , base  200  includes a tongue  260  extending from an edge  226  of a first through-aperture  220 , with protrusion  230  being supported on tongue  260 . In one or more embodiments, the protrusion  230  is formed on the tongue  260  via molding (e.g., overmolding). Any suitable molding techniques may be used and are not reproduced herein for brievity. The tongue  260  provides and/or functions as a support for molding the protrusion  230  and may be of any suitable configurations and designs. For instance, the tongue  260  may curve away from or be at an angle relative to the plane that defines base  200 , and protrusion  230  may be formed onto the tongue  260  via injection molding. Moreover, tongue  260  may be a unitary and integral portion of the base  200  that is formed and defined during creation of the first through-aperture  220  via material removal. Moreover, tongue  260  may be readily configured in a manner that facilitates the injection molding process to form protrusion  230 . Because tongue  260  may be integrally extending from the base  200  and because a portion of the tongue  260  may be received within the protrusion  230  via injection molding, the protrusion  230  achieves enhanced support and attachment strength. 
         [0028]    In one or more embodiments, the tongue  260  and the protrusion  230  are generally positioned in or near a middle portion of the base  200 . In some instances, the tongue  260  and the protrusion  230  together with the fastener aperture  210  are located at or near a central (vertical) axis of the base  200 . As a result, the attachment or connection strength may be improved as force may be applied in an even manner. It should be appreciated that the tongue  260  and the protrusion  230  may be formed at other suitable locations within the vehicle  102  to function as an attachment locator for other types of curtain airbags. 
         [0029]    Referring back to  FIG. 2A  and  FIG. 2B , an end surface  238  of the protrusion  230  located further away from the base  200  has a perimeter dimension or profile different from that of an intervening cross-section of the protrusion  230 . In particular, the end surface  238  of the protrusion  230  may have the smallest perimeter/profile than any other segment along protusion  230 . Accordingly, protusion  230  be configured to provide tapered outer surfaces transitioning from a root portion where the protrusion  230  initially extends from the tongue  260  to the end surface  238 . In another embodiments, the end surface  238  of the protrusion  230  is of a circumference or circumferential shape different from that other segments along protrusion  230 . 
         [0030]    For instance, the shape of the end surface  238  may be circular while the other cross-sections may be rectangular. For instance and as illustratively depicted in  FIG. 2B , a first cross-section  292  of the protrusion  230  is positioned between the end surface  238  and a second cross-section  294  of the protrusion  230 , wherein the first and second cross-sections  292 ,  294  may differ from each other in size, dimension, and/or shape. In particular, and as illustratively depicted in  FIG. 2B , the first cross-section section  292  is smaller in its outer perimeter and/or its total profile area in comparison to the second cross-section  294 . 
         [0031]    Accordingly the end face  238  along with the cross-sections  292 ,  294  collectively define a sloped outside, the design of which is believed to make relatively easier to help the operator to locate a proper placement for inserting protrusion  230  into a corresponding hole in the vehicle wall. During installation, an operator may be able to locate where the attach with relatively enhanced ease and accuracy, and can readily achieve the required force to cause protrusion  230  to snap into the hole. Protrusion  230  may be of any suitable shapes, such as cylindrical, conical, cubical, or any combination thereof. 
         [0032]      FIG. 2B  illustratively depicts a perspective view of the airbag bracket  100  referenced in  FIG. 2A , where the protrusion  230  of the airbag bracket  100  defines a void space in the middle (i.e., has a hollow configuration). The hollow configuration is believed to bring about enhanced structural flexibility (i.e., for snapping into the receiving hole) and greater tolerance for deformation during pre-attachment positioning of the airbag bracket  100  to the vehicle  102 . Moreover, material cost as well as weight may accordingly be favorably reduced. Optionally, the void space of the protrusion  230  may be reduced in size or completely eliminated such that the protrusion  230  may be rendered relatively more solid and sturdy. 
         [0033]    In one or more embodiments, the protrusion  230  may be formed as a hollow plastic member formed through injection molding. The hollow design may be more advantageous for the injection molding process wherein wall thickness as well as the general outer shape of the protrusion  230  may be under improved control and wherein issues with variable sizes and dimensions due to uneven shrinking associated with injection molding may be minimized. 
         [0034]    The term “hollow plastic member” may refer to the existence of one or more cavities defined in a cross-section of the protrusion  230  taken along line B-B. For instance and as illustratively depicted in  FIG. 2B , the protrusion  230  may include a traverse bar  250  positioned therein and the traverse bar  250  may vertically, horizontally or in any appropriate angle, extend across an interior cavity of protrusion  230 , thereby separating two cavities  272 ,  274  so as to present the prostrusion  230  as a hollow plastic member. The traverse bar  250  is believed to strengthen the protrusion  230  as a whole to reduce or prevent damages thereto during and/or after installation, while the existence of the cavities and its associated weight and cost benefits may be maintained. 
         [0035]    Referring back to  FIG. 2B , the protrusion  230  may include two or more spaced apart ribs  234  to provide better engagement for the attachment. The ribs  234  of the protrusion  230  may be of any suitable designs, such as in the form of one or more ribs, one or more protrusions, and ribs or protrusions with any shape or distribution. Ribs may be advantageously provided to guide an operator when the operator is pushing down the protrusion  230  during an installation operation. However, the outer surface of the protrusion  230  may be free of any textures such as ribs, lines, protrusions, or convex segments. In this configuration, the protrusion  230  may be simply be formed with one or more larger segments to ensure engagement into a relatively smaller aperture during installation. 
         [0036]    In view of  FIG. 2A , the base  200  of the airbag bracket  100  may further include the first through-aperture  220  and a second through-aperture  222  spaced from each other by a first bridge  240 . The first and second through-apertures  220 ,  222  may each independently be formed via material removal via any suitable cutting, knifing, or punching techniques, for example. The first through-aperture  220  and second through-aperture  222  may each have the shape of a trapezoid, a square, a rectangular, an oblong, or any other symmetrical or asymmetrical shapes or regular or irregular shapes. In a non-limiting example, the first through-aperture  220  may be a trapezoid in shape, and the second through-aperture  222  may be a rectangular in shape. In this configuration, the airbag bracket  100  may be greatly reduced in weight and the attachment of the curtain airbag  104  to the vehicle  102  may be better stabilized. 
         [0037]    In certain embodiments, as illustratively depicted in  FIG. 2A , the second through-aperture  222  is defined by a second linear dimension L 2  greater than a first linear dimension L 1  of the first through-aperture  220  along a width direction L. Curtain airbag unit  104  may be connected to the first bridge  240  via fabrics and may be wrapped onto the airbag bracket  100  via fabrics. Accordingly the second through-aperture  222  is positioned to receive therethrough relativley more fabrics extending from the curtain air bag  104  and hence greater attachment stability. 
         [0038]    In certain embodiments, and as illustratively depicted in  FIG. 2A , the second through-aperture  222  includes a second bridge  242  opposite to the first bridge  240 . The second bridge  242  is believed to be beneficial with its particular width and shape so as to accommodate and facilitate the attachment of the curtain airbag  104  into an elongated and rather narrow space in the interior upper portion of the vehicle  102  where the attachment is to occur. 
         [0039]    In one or more embodiments, the base  200  of the airbag bracket  100  may further include one or more supplemental apertures  282 . There does not need to be any no special restriction to the shape and distribution of the supplemental apertures  282 , provided that the connection strength of the airbag bracket  100  may be ensured and the total assembly weight may reduced as much as possible. Along these configurations mentioned herein, other suitable alternative designs for the supplemental apertures  282  may be reasonable within the scope of the present invention in one or more embodiments. 
         [0040]    Additionally, in one or more embodiments, the fastener aperture  210  of the base  200  may adopt a stepwise design. For instance, and as illustratively depicted in  FIG. 2B  in view of  FIG. 2C , the fastener aperture  210  is defined by stepped areas  212 ,  214  of the base  200 , which together define a cavity  216  facing side wall  110 . The cavity  216  may be configured and/or sized to receive there-through a pre-formed boss or raised surface surrounding a receiving-hole (not shown) formed on the side wall  110 . In this manner, the above mentioned stepwise design of the fastener aperture  210  may engage a convex boss portion on the vehicle body such that the base  200  of the airbag bracket  100  may closely engage the body of the vehicle  102 , which as a result is to increase the contact area and the connection strength there-between. 
         [0041]    The protrusion  230  may be configured to extend from the plane that defines the base  200 . For instance, the airbag bracket  100  has generally a flat sheet shape, with a circumference to thickness ratio of the base  200  being greater than 2:1, or 10:1. 
         [0042]    In certain other embodiments, and as illustratively depicted in  FIG. 3A  and  FIG. 3B , the first through-aperture  220  may be configured as two spaced-apart through-apertures  220   a,    220   b  separated from each other via a third bridge  362  of the base  200 . The third bridge  362  defines opposing edges  364   a,    364   b,  upon which two opposing ribs  360   a,    360   b  may be respectively located to support the protrusion  230 . Similarly, the ribs  360   a,    360   b  may be a unitary and integral extension from the third bridge  362  as a result of the formation of the through-apertures  220   a,    220   b  via material removal. 
         [0043]    Variable methods may be employed to install the airbag bracket  100 . The curtain airbag  104  may be connected to the airbag bracket  100  via a flexible tail  204  extending from the curtain airbag  104  with non-limiting example of material thereof including a natural or synthetic fabric or polymer, wherein the flexible tail  204  may be sewn onto the first bridge  240  of the airbag bracket  100 , and then wrapped onto the second bridge  242  of the airbag bracket  100 . The remaining part of the flexible tail  204  after the wrapping may be returned onto the protrusion  230  via a hole defined on the flexible tail  204 . Thereafter, the protrusion  230  is pushed into the vehicle body along with the flexible tail  204  of the curtain airbag  104 . In this manner, the protrusion  230  not only functions to pre-position for the attachment, but also serves to facilitate the attachment of the airbag  104  without necessarily having to use other connectors or hooks otherwise required in certain existing designs. 
         [0044]    With this design, the curtain airbag  104  may be beneficially devoid of issues in the prior art associated with excess use of metal hooks and other rigid connectors, and hence the attachment of the curtain airbag  104  is provided with less scratches and greater operational ease. The curtain airbag  104  may thus be pre-positioned at its predetermined locations with various airbag brackets  100 , and such an assembly may then readily be installed onto the interior upper portion of the vehicle  102  in an optionally one-step procedure. Specifically, the operator may push the protrusion  230  of the airbag bracket  100  into a receiving portion on the vehicle  102  to realize both the positioning and the attachment. Subsequently, the attachment may be finalized and secured by applying one or more fasteners such as bolts or pins into the fastener aperture of the airbag bracket  100 . 
         [0045]    As mentioned herein elsewhere, the second bridge  242  helps secure and maintain the flexible connector on and around the bracket assembly  100  and hence the curtain airbag  104  onto the vehicle  102 . More particularly, because of its particular width-to-height dimension or L/H ratio with relatively elongated presence along the direction “L”, the second bridge  242  of the airbag bracket  100  is better positioned to maintain a predetermined width and shape of the airbag  104 . 
         [0046]    Referring back to  FIG. 1A  and  FIG. 1B , the curtain airbag  104  may be attached onto a vehicle body via a number of airbag brackets  100 . The distance between any two adjacent airbag brackets  100  may be no less than 2.5 centimeters (cm), 5 cm, 7.5 cm, or 10 cm, and no greater than 50 cm, 40 cm, 30 cm or 20 cm. In certain embodiments, the distance between any two adjacent airbag brackets  100  may be 15 cm to 20 cm to accommodate a need for a sturdy attachment and a need for fewest number of brackets possible. The total number of brackets  100  may suitably be varied dependent upon a particular airbag installation project at hand, while total assembly weight and cost may also be carried into consideration. 
         [0047]    In one or more embodiments, the present invention as set forth herein is believed to have overcome certain challenges associated with vehicle curtain airbag attachment and installation. However, one skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims that various changes, modifications and variations can be made therein without departing from the true spirit and fair scope of the invention as defined by the following claims.