Mounting assembly for inflatable curtain

A novel mounting bracket for an inflatable curtain is described. The mounting bracket includes a pair of attachment plates for engaging respective sides of the inflatable curtain. One plate includes an opening through which a fastener may be positioned to secure the bracket and attached inflatable curtain to the interior of a vehicle. A bushing having an inner surface and an outer surface is positioned within the opening in the mounting plate. Flanges extending from an outer surface of the bushing maintain the bushing within the opening. The outer surface of the bushing is smaller than the opening which allows the bushing to rotate freely within the bracket when a fastener is used to secure the mounting bracket to the interior of a vehicle.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a system for mounting an inflatable curtain within a vehicle. More specifically, the present invention relates to a freely rotating mounting assembly for attaching an inflatable curtain to the interior side frame of a vehcle.

2. Technical Background

Inflatable safety restraint devices, or airbags, are mandatory on most new vehicles. Airbags are typically installed as part of a system with an airbag module in the steering wheel on the driver's side of car and in the dashboard on the passenger side of a car. In the event of an accident, a sensor within the vehicle measures abnormal deceleration and triggers the ignition of an explosive charge contained within an inflator. Expanding gases from the charge travel through conduits and fill the airbags, which immediately inflate in front of the driver and passenger to protect them from harmful impact with the interior of the car. Airbag systems have also been developed in response to the need for similar protection from lateral impacts between a passenger and the side of a vehicle's interior. This might occur when another vehicle collides with the side of the car, or in a rollover situation where the side of car is repeatedly impacting the ground.

Side impact airbag systems are designed to prevent the head of a vehicle occupant from emerging through the window opening or from colliding with the reaction surface at the side of the vehicle. Side impact airbags have a smaller area in which to deploy and must be configured to inflate efficiently and in the right direction. There is also less space in which to install side impact airbags. Side inflatable airbag curtains are typically attached to the roof rail of a car behind the head liner. The roof rail is the metal portion of the car frame which extends along the side of the car at the junction of the side doors and the roof. The head liner is an interior component which covers the roof rail at the door seal.

Side airbag modules typically include an inflatable curtain folded into a predetermined configuration and then placed in a covering, wrap, or housing. Most side airbag modules include an attachment means for securing the airbag module to the roof rail. When the airbag curtain is in a folded state, the airbag module is long, narrow, and flexible. The problem with most side impact air modules is that their long and narrow configuration makes them awkward and cumbersome to install. The folded airbag must be positioned next to the roof rail or other frame member to which it will be attached. Often times the installer needs both hands to align the somewhat flimsy folded airbag and module with the curved or twisted roof rail. This makes it extremely difficult if not impossible for the installer to operate the tool used to mount the airbag curtain to the vehicle. Sometimes this problem is overcome by using separate positioning equipment such as sophisticated mounting jigs, or using multiple people to hold the inflatable curtain in place during installation. Unfortunately, the use of additional equipment, tools, or human resources drives up the cost of installation.

Another problem with installing inflatable airbag curtains with existing mounting brackets is that the torque of the installation tools transfers to the mounting bracket and the airbag curtain causing it to twist and crimp which can negatively affect the folded configuration of the airbag curtain. Furthermore, an additional installer may be necessary to hold the airbag curtain to keep it from rotating while another installer secures the airbag curtain to the vehicle.

One attempt to solve these current problems is to configure the mounting brackets with hooks that can be placed into a special slot in the vehicle body. The hooks hold the inflatable curtain in place while installers bolt or otherwise secure that assembly to the vehicle. The hooks also help to keep the mounting brackets from rotating. However, these hooks suffer many disadvantages. The hooks require special notches in the vehicle to receive the hooks of the mounting bracket. Additionally, the hooks do not prevent the torque from transferring to the mounting bracket. Thus, the torque of the connection can transfer to the hooks making them susceptible to bending or twisting. This unwanted deformation can call into question the integrity of the mount. Further, the torque of the installation tool can cause the hook to disengage the slot. Still further, the use of mounting brackets with hooks involves multiple installation steps. The inflatable curtain must be hooked to the vehicle which requires alignment of the hooks within notches in the vehicle before the inflatable curtain can be secured to the vehicle. This drives up installation time and costs.

Another disadvantage of known airbag curtain mounting systems is that the attachment points for the airbag curtain are susceptible to slight rotations, even with the hooks. When these points of attachment are cinched tight with a slight rotation, the deployment of the airbag can be negatively affected. Specifically, the pressure or force caused by the inflating airbag may not be evenly distributed over all the points of attachment. Thus, the airbag may be susceptible to tearing at the point of attachment bearing an unequal amount of force.

Accordingly, it would be an advancement in the art to provide a mounting bracket for an inflatable curtain which allows the installer to secure the inflatable curtain to the interior of a vehicle without the need for extra tools, equipment, or human resources. It would also be an advancement to provide such an airbag curtain module that did not require the extra installation time of aligning the mounting bracket within a notch in the vehicle. It would further be an advancement to provide such a mounting bracket for an inflatable curtain that did not transfer the torque of the installation tool to the inflatable curtain. It would be yet another advancement to provide such a mounting bracket for an inflatable curtain that would evenly distribute the deployment forces caused by the inflating inflatable curtain. It would be yet another advancement to provide such a mounting bracket for an inflatable curtain that was less expensive and easier to install.

Such a mounting bracket for an airbag curtain is disclosed and claimed herein.

BRIEF SUMMARY OF THE INVENTION

The apparatus of the present invention has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available airbag curtain mounting brackets. Thus, it is an overall objective of the present invention to provide a freely rotatable mounting bracket.

To achieve the foregoing advancements, and in accordance with the invention as embodied and broadly described herein in the preferred embodiment, a mounting bracket for an inflatable curtain that allows free rotation of a fastener within the bracket is provided. The bracket includes an attachment plate for engaging the inflatable curtain. The attachment plate defines an opening in which a bushing is placed. A fastener may be positioned within the bushing to attach the mounting bracket and attached inflatable curtain to the interior of a vehicle.

In one embodiment, a pair of attachment plates are configured to engage respective opposing surfaces of the inflatable curtain. Each plate defines an opening. The openings are substantially aligned with each other to permit the positioning of a fastener through the aligned openings. A first attachment plate includes at least one, and in one embodiment, multiple locking tabs extending from an attachment surface of the first attachment plate. A second attachment plate is configured with receiving orifices for receiving the corresponding locking tabs. With the locking tabs positioned within the receiving orifices, the inflatable curtain is captured by the mounting bracket. Each attachment plate has a first edge at which the attachment plates are connected to each other. In one embodiment, the attachment plates are integral with each other and folded such that the attachment plates are adjacent to each other with the respective openings in each plate substantially aligned.

A bushing is in rotatable communication with the attachment plate adjacent the opening. The bushing may include an inner surface and an outer surface. Where the mounting bracket includes a pair of mounting pates, the bushing is positioned within the aligned openings of the attachment plates. The outer surface of the bushing comprises a diameter smaller than the opening of the attachment plate. Thus, the bushing may rotate freely within one or more attachment plates of the mounting bracket. Consequently, when a fastener such as a screw or bolt is positioned within the bushing to secure the mounting bracket and attached inflatable curtain to the interior of a vehicle, the torque applied to the fastener during installation does not transfer to the bracket or curtain. The bushing may also include flanges which help maintain the bushing within the attachment plate opening.

The bushing may be deformable to facilitate the positioning of the bushing within the attachment plate. In one embodiment, the bushing includes one or more protrusions positioned at the inner surface of the bushing. The protrusions facilitate the frictional engagement of a fastener with the bushing. Thus, the mounting bracket is easily and efficiently installed.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With particular reference toFIG. 1, a mounting bracket is generally designated at10. The mounting bracket10is particularly well-suited for engaging an inflatable curtain12to facilitate securing the curtain12to the interior of a vehicle. The mounting bracket10includes at least one attachment plate14. In one embodiment, a pair of attachment plates14are configured for engaging respective opposing surfaces16,18of the inflatable curtain12. Each attachment plate14may include a first edge20. In the embodiment illustrated inFIG. 1, the first edges20of the attachment plates14are integral with each other. In this configuration, the attachment plates14are formed from a unitary piece, folded at a single fold line22. In alternative embodiments, separate attachment plates14may be attached to each other in various ways, including, but not limited to welding, bonding, bolting, riveting, and the like.

A first attachment plate24may include one or more locking tabs26extending from an attachment surface28of the first attachment plate24. A second attachment plate30may include one or more receiving orifices32configured within an attachment surface34of the second attachment plate30. Each receiving orifice32is configured to receive a corresponding locking tab26. The inflatable curtain12may also be configured with openings (not shown) through which the locking tabs26may be positioned. The locking tabs26, when positioned within the receiving orifices32, may be bent over to secure the inflatable curtain12within the mounting bracket10. It will be appreciated by those of skill in the art that the attachment plates14may be configured to capture the inflatable curtain12. The inflatable curtain12may also be secured to the mounting bracket10in a variety of ways, including, but not limited to latching, crimping, bonding, and the like. As will be discussed in greater detail below, the attachment plates14may include a variety of spaced indentations to facilitate the clamping of the attachment plates14onto the inflatable curtain12(see FIG.5).

At least one of the attachment plates14includes an opening38configured to receive a bushing40. The bushing40may include an inner surface42and an outer surface44. As will be discussed in greater detail below, the outer surface44of the bushing40loosely engages the opening38to allow free rotation of the bushing40within the mounting bracket10. In the illustrated embodiment, the opening38is configured within the first attachment plate24. The bushing40may include a flange46, which extends radially from the outer surface44of the bushing40. In one embodiment, a pair of flanges46extend radially outward from the outer surface44of the bushing40at a first end48and a second end50of the bushing40. The flanges46help to retain the bushing40within the opening38in the first attachment plate24. The bushing40may include one or more protrusions52which extend from the inner surface42of the bushing. In one embodiment, three protrusions52are spaced about the inner surface42, extending from the first end48of the bushing40to the second end50of the bushing40. The protrusions52provide a raised surface which may frictionally engage a fastener (FIG. 2) to help retain the fastener within the bushing40.

Referring now toFIG. 2, a cross section of the mounting bracket10, according to the teachings of the present invention is shown. The bushing40is in rotatable communication with the first attachment plate24adjacent the opening38. The diameter of the outer surface44of the bushing40is less than the diameter of the opening38. Accordingly, an annular gap54exists between the bushing40and the first attachment plate24. Thus, any torque applied to the bushing40during installation of the curtain12into a vehicle, will not transfer to the remainder of the bracket10.

The outer surface44, together with the flanges46form an annular channel56in which the first attachment plate24is seated. The diameter of each flange46is slightly greater than the diameter of the opening38which allows the bushing40to be retained within the first attachment plate24. In one embodiment, the bushing40is made of plastic and is deformable. In this configuration, the bushing40can be press fit into the opening38of the first attachment plate24.

The bushing40is configured to receive a fastener58. The fastener58may be configured with threads60to facilitate attachment of the fastener58to the interior of a vehicle. The fastener58includes a head62which is larger than the diameter of the inner surface42of the bushing40. This allows the fastener58to retain the mounting bracket10in close proximity to the interior of the vehicle. In one embodiment, the fastener58is affixed or attached to the inner surface42of the bushing40. This can be accomplished by press fitting, swage fitting, or other frictional coupling, or by bonding, welding or the like. In one embodiment, the fastener58and bushing40may be molded into one integral piece. It will be appreciated by those of skill in the art that a variety of fasteners58may be used to practice the teachings of this invention, including, but not limited to, bolts, screws, rivets, pins, and the like.

The bracket10may be made of sheet metal and should be of a thickness that provides strength, yet is bendable to allow the second attachment plate30to be folded over at the fold line22into a position opposite the first attachment plate24. The metal should also allow the locking tabs26to be folded over to capture the second attachment plate30after extending through a corresponding orifice32. In one alternative embodiment, the locking tab26of one locking plate14may extend through, or engage, a notch in an opposing locking plate14. The sheet metal allows the bracket10to be stamped out in one piece and then folded into the proper configuration, thus saving manufacturing costs.

Referring now toFIG. 3, an alternative embodiment of the bracket of the present invention is illustrated as110. The bracket110includes a pair of attachment plates114configured to engage opposing surfaces of an inflatable curtain (not shown). The attachment plates114are connected to each other to from a unitary piece folded at a single fold line122.

As with the embodiment described above, a first attachment plate124may include one or more locking tabs126which may extend through corresponding receiving orifices132configured within the second attachment plate130. The locking tabs126, when positioned within the receiving orifices132or notches (not shown), may be bent to secure an inflatable curtain within the mounting bracket110. It will be appreciated by those of skill in the art that the attachment plates114may be configured to capture the inflatable curtain in a variety of ways, including, but not limited to latching, crimping, bonding, and the like.

The first and second locking plates124,130each define a respective opening138,139. The openings138,139may be substantially aligned to facilitate receiving a fastener (not shown) through the aligned openings138,139. At least one of the openings138,139may be configured to receive a bushing140. In one embodiment, the openings138,139may be substantially the same size to allow the bushing140to engage both openings138,139.

The bushing may include an inner surface142, an outer surface144, and a pair of flanges146, which extend radially from the outer surface144of the bushing140. In the illustrated embodiment, the bushing140is a snap having a male member148and a female member150. The male member148snaps within the female member150about the opening138and is retained there by the flanges146which are positioned on opposite sides of the opening138in the first attachment plate124. It will be appreciated that in this embodiment, the bushing140need not be deformable to be press fit into position within the opening138.

The outer surface144of the coupled bushing140is configured on the female member150. The diameter of the outer surface144is smaller than the diameter of the opening138which allows the bushing140to freely rotate with the attachment plate124. In another embodiment, the male member148may be freely rotatable within the female member150. In this embodiment, the female member150may engage or be attached to one or more attachment plates124,130while still allowing free rotation of a fastener positioned adjacent the inner surface142which is configured on the male member148of the snap. In both of these embodiments, torque from a fastener is prevented from transferring to the bracket110.

As in the embodiment discussed above, the male member148may include one or more protrusions149which extend from the inner surface142to facilitate the attachment of a fastener to the bushing140.

It will be appreciated by those of skill in the art that various snap configurations may be used to allow free rotation of a fastener within the bracket110while the fastener cinches the bracket110and the accompanying inflatable curtain onto an interior surface of a vehicle. Additionally the bushing140may include a first piece rotatably engaged to a second piece without the two pieces snapping together. For example, an annular or ring ball bearing system may be used to allow a first piece to freely rotate relative to a second piece. In this embodiment, free rotation of a fastener relative to the bracket110may be accomplished because the bushing140freely rotates within the bracket110. Free rotation may also be achieved because of the rotational relationship of the multiple bushing pieces which allows one piece to be attached to the bracket110and another piece to be attached to a fastener.

Referring now toFIG. 4an inflatable curtain or airbag device200is shown. The device includes an inflator202with an initiator device204, such as a lead wire, attached at a first end206of the inflator202. A second end208of the inflator202is in communication with an inflatable curtain210in a folded state. Brackets212may secure the inflator202to the interior of a vehicle. Mounting brackets211of the kind discussed previously may secure the inflatable curtain210to the interior of a vehicle. The mounting brackets211allow the inflatable curtain210to be secured to the vehicle by a fastener positioned within the brackets211while significantly reducing any torque exerted on the fastener during installation to be transferred to the brackets211or inflatable curtain210.

Referring now toFIG. 5, the airbag device200may include an inflatable curtain210having a first edge213and opposing surfaces216and218. A pair of attachment plates224and230are configured to engage the opposing surfaces216and218of the inflatable curtain210. In the illustrated embodiment, the attachment plates224,230are configured with indentations231to facilitate the capture of the inflatable curtain210between the plates224,230.

The first and second locking plates224,230each define a respective opening238,239that may be substantially aligned to facilitate receiving a fastener258. The inflatable curtain may also include an orifice which is aligned with the openings238,239to receive the fastener258therethrough. At least one of the openings238,239may be configured to receive a bushing240. The bushing240may have an inner surface242and an outer surface244. The bushing240is configured to be positioned within the opening238and in rotatable communication with at least one of the attachment plates224,230. As discussed in conjunction with the embodiments described above, the bushing240may include one or more flanges246extending radially from the outer surface244of the bushing240to facilitate retention of the bushing240within the opening238in the attachment plate.

The bushing240may be configured to receive the fastener258. The fastener258may be configured with threads260to facilitate attachment of the inflatable curtain device200to the interior of a vehicle. The fastener258includes a head262which is larger than the diameter of the inner surface242of the bushing240. This allows the fastener258to retain mounting bracket211in close proximity to the interior of the vehicle.

As discussed above, various embodiments of the attachment plates224,230, bushing240, and fastener258may be utilized in various combinations in connection with the inflatable curtain to form a novel inflatable curtain or airbag device.