Airbag chute assembly

An airbag chute assembly for a vehicle. The airbag chute assembly includes a chute portion, an inflator housing, and a coupling member that facilitates coupling and decoupling of the inflator housing.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to an airbag module for a motor vehicle and an airbag chute assembly.

SUMMARY OF THE INVENTION

In at least one embodiment of the present invention, an airbag chute assembly is provided. The airbag chute assembly includes a chute portion, an insert portion, an inflator housing, and a coupling member. The chute portion includes an airbag deployment opening and a first aperture. The insert portion is disposed proximate the chute portion and includes a door, a second aperture, and a slot having an open end. The inflator housing includes first and second retaining features. The first retaining feature engages at least one of the first and second apertures. The second retaining feature is disposed in the slot. The coupling member engages the second retaining feature to secure the inflator housing to the chute portion when the coupling member is coupled to the insert portion.

In at least one other embodiment of the present invention, an airbag chute assembly is provided that includes a chute portion, an inflator housing, and a coupling member. The chute portion includes an airbag deployment opening, an aperture, and a slot having an open end. The inflator housing includes first and second retaining features. The first retaining feature is disposed in the aperture. The second retaining feature is disposed in the slot. The coupling member engages the second retaining feature to secure the inflator housing to the chute portion when the coupling member is coupled to the chute portion.

DETAILED DESCRIPTION

Referring toFIG. 1, a side view of a vehicle10is shown. The vehicle10includes a seat assembly12that is adapted to receive an occupant14and an airbag module16. The airbag module16may have any suitable configuration. In at least one embodiment, the airbag module16includes an airbag20, an inflator22, and a chute assembly24.

The airbag module16may be disposed in any suitable location. For instance, the airbag module16may associated with a front occupant protection system or a side impact occupant protection system. In at least one embodiment, the airbag module16may be disposed proximate an interior trim panel26that may comprise a visible or “A” surface of a vehicle passenger compartment. InFIG. 1, the interior trim panel26is configured as an instrument panel. The interior trim panel26may help conceal the airbag module16and/or airbag20prior to inflation or deployment of the airbag20. Moreover, the interior trim panel26may include one or more doors that open to permit the airbag20to deploy into the vehicle passenger compartment.

The airbag20is configured to expand from a stored condition to an inflated or deployed condition when an inflation gas is provided with the inflator22. More specifically, the airbag20is deflated and disposed in the airbag module16when in the stored condition and is inflated and positioned between a vehicle occupant and an interior vehicle surface when in the inflated condition. InFIG. 1, the airbag20is shown in the stored condition in solid lines and is shown in the inflated condition in phantom.

The airbag20may have any suitable configuration and may be made of any suitable material. For example, the airbag20may be made of multiple panels that are assembled in any suitable manner, such as by stitching, bonding, or with an adhesive. Alternatively, the airbag20may be integrally formed. Optionally, the airbag20may include one or more tethers that control the shape of the airbag20upon deployment. The airbag20may be configured to cushion the head, thorax, and/or pelvis of an occupant when deployed.

The chute assembly24may be provided in various configurations. In at least one embodiment, such as that shown inFIGS. 2 and 3, the chute assembly24may include a chute portion30, a door insert portion32, an inflator housing34, and a coupling member36. The chute assembly24and its assorted components may be made of any suitable material or materials, such as one or more polymeric materials like a thermoplastic elastomer (TPE).

The chute portion30includes a plurality of panels that cooperate to define a passage through which the airbag20extends upon deployment. The chute portion30may have any suitable configuration. For example, the chute portion30may include a plurality of panels, such as a first panel40, a second panel42, a third panel44, a fourth panel46, and a fifth panel48.

The first panel40may be configured to be mounted to another component to secure the chute portion30to the vehicle10. For example, the first panel40may be disposed proximate the interior trim panel26and/or another suitable component and may be attached in any suitable manner, such as with one or more fasteners, an adhesive, or by vibration or sonic welding. The first panel40may include a deployment opening50. The deployment opening50may be at least partially concealed by one or more doors disposed proximate the interior trim panel26and/or the chute portion30to conceal the airbag20prior to deployment.

The second panel42may extend from the first panel40and may include one or more apertures52. The apertures52may be provided in any suitable quantity and may have any suitable configuration. In the embodiment shown inFIG. 2, a plurality of apertures are provided that are generally rectangular and are generally equally spaced. Of course, the present invention also contemplates embodiments in which one or more apertures have different shapes, spacing, and/or alignment as compared with another aperture. The apertures52may help secure the inflator housing34to the chute portion30as will be described in more detail below.

The third panel44may extend from the first panel40and may be spaced apart from the second panel42. The third panel44may extend from the first panel40by a same or different amount as another panel, such as the second42, fourth46, or fifth panels48. In the embodiment shown inFIG. 2, the third panel44is shorter than the second42, fourth46, and fifth panels48to provide additional clearance for the coupling member36when the coupling member36is installed as is best shown inFIG. 3.

The door insert portion32may be disposed proximate the chute portion30and may have any suitable configuration. For example, the chute portion30may include one or more doors60that are adapted to open in response to force exerted by the airbag20. In addition, the door insert portion32may include a first side wall62and a second side wall64.

The one or more doors60may be at least partially defined by a seam portion66that is adapted to break, tear, sever, unsnap or otherwise disengage in response to force exerted by the airbag20when the airbag20is inflated. The seam portion66may have any suitable configuration. For instance, the seam portion66may be configured as a tear seam that is disposed on or more surfaces of the door insert portion32as shown inFIG. 2. Alternatively, the seam portion66may be configured with male and female portions that unsnap or disengage from each other in response to force exerted by a deploying airbag.

The first side wall62may include one or more apertures68, each of which may be generally aligned with the one or more apertures52disposed on the chute portion30. In the embodiment shown inFIG. 2, each aperture68on the first side wall62is generally aligned with an aperture52on the chute portion30when assembled. Alternatively, each aperture68may be associated with more than one aperture52of the chute portion30or vice versa. In at least one embodiment, the first side wall62may be eliminated or shortened so that it does not overlap the apertures52in the chute portion30. In such embodiments, the apertures68may be deleted.

The second side wall64may include one or more open ended slots70and one or more coupling engagement features72. The open ended slots70may be provided in any suitable quantity, shape, spacing, or configuration. In the embodiment shown, the open ended slots70are generally rectangular and have an open end that faces toward the inflator housing34. A coupling engagement feature72may be provided proximate the open end of one or more open ended slots70. In the embodiment shown, a coupling engagement feature72is provided adjacent to two sides of each slot70. Alternatively, one or more slots70may not have a coupling engagement feature72disposed adjacent or proximate to its sides. The coupling engagement feature72may have any suitable configuration. In the embodiment shown, the coupling engagement feature72is configured as a hook having a generally J-shaped cross section. Alternatively, the coupling engagement feature72may be a protrusion and may be generally L-shaped. Differently configured coupling engagement features72may also be provided in any suitable combinations.

The second wall64may also include one or more holes74. Each hole74may receive a fastener that may be provided to secure the coupling member36to the door insert portion32. Optionally, the door insert portion32may also include one or more tabs76that facilitate alignment of the door insert portion32with the chute portion30.

The inflator housing34may include a cavity80that is adapted to receive at least a portion of the inflator22. In addition, the inflator housing34may include a plurality of retaining features82. In the embodiment shown, the inflator housing34includes a first set84of retaining features disposed on a first side86of the inflator housing34and a second set88of retaining features disposed on a second side90of the inflator housing34. The retaining features82may have any suitable configuration. In the embodiment shown, the retaining features82are configured as hooks that extend toward the coupling engagement features72on the door insert portion32when assembled. Each member of the first set84may be configured to be disposed in an associated aperture, such as aperture52on the chute portion30and/or aperture68on the door insert portion32. Similarly, each member of the second set88may be configured to be disposed in an associated open ended slot70.

The coupling member36helps secure the inflator housing34to the chute portion30and/or door insert portion32. The coupling member36may have any suitable configuration. In the embodiment shown, the coupling member36is generally planar and includes a first surface92and a second surface94disposed opposite the first surface92. The first surface92may be disposed proximate at least one member of the second set88of retaining features. The second surface94may be disposed proximate the coupling engagement features72of the door insert portion32. As such, the coupling member36inhibits at least one member of the second set88of retaining features82from sliding out of the open end of an associated slot70when the coupling member36is disposed between the coupling engagement features72and a member of the second set88as shown inFIG. 3.

The coupling member36may include one or more enlarged ends that may help prevent the coupling member36from being inadvertently removed. In addition, the coupling member36may include one or more holes96. Each hole96may align with a hole74on the door insert portion32for receiving an optional fastener98. If a fastener is provided, it may be removed to permit the coupling member36to be moved to decouple at least a portion of the inflator housing34from the door insert portion32and/or chute portion30.

Removing the coupling member36(i.e., such that it is not disposed between the coupling engagement features72and at least one member of the second set88of retaining features) allows the second set88of retaining features82to slide through the open end of their associated slots70. Moreover, the inflator housing34may then pivot about the first set84of retaining features to permit access to the contents of the inflator housing34and the chute assembly24and/or the complete removal of the inflator housing34. As such, the present invention simplifies the disassembly and reassembly of an airbag module16before or after installation into a vehicle. Moreover, the present invention permits an inflator22or other airbag module components to be serviced without prying against “live” components or otherwise deforming, damaging, or loosening the airbag module16or its components.

Referring toFIG. 4, another embodiment of a chute assembly24′ is shown. In the embodiment shown, the chute assembly24′ includes a chute portion30′ as well as an inflator housing34and a coupling member36as previously described. A door insert portion is not provided.

The chute portion30′ may include one or more apertures, like aperture52described above. In addition, the chute portion30′ may include one or more doors60′, one or more open ended slots70′, and one or more coupling engagement features72′.

The doors60′ may be configured to at least partially conceal a deployment opening. The doors60′ may be integrally formed with the chute portion30′ and may be at least partially defined by a seam portion that is adapted to break, tear, sever, unsnap or otherwise disengage as previously described.

The open ended slots70′ and coupling engagement features72′ may be similar to slots70and coupling engagement features72, respectively. In the embodiment shown inFIG. 4, one or more open ended slots70′ may be provided on or integrally formed with the third wall44′. One or more coupling engagement features72′ may be provided proximate the open end of one or more open ended slots70′ as previously described. As such, the coupling engagement features72′ may cooperate with the retaining features82on the inflator housing34to receive the coupling member36to help secure the inflator housing34to the chute portion30′.