Aspirating airbag module assemblies and components

Airbag cushion assemblies for aspirating ambient air and related assemblies, methods, and components. Some embodiments may comprise an aspirating airbag cushion assembly comprising an airbag cushion housing, an aspiration housing coupled to the airbag cushion housing and comprising an aspiration inlet configured to allow for receipt of ambient air into an airbag cushion, and an inflation module slidably coupled to the aspiration housing. The inflation module may comprise an inflator and one or more inflation tubes or other conduits fluidly coupled with the inflator and configured to deliver inflation gas from the inflator into the airbag cushion.

SUMMARY

Various improvements in vehicle technologies, such as autonomous vehicles, may require changes in the way airbag assemblies operate. For example, in some autonomous vehicles, or other newer vehicles, larger airbags may be used. This may be needed, for example, due to a larger distance between the airbag module and the vehicle occupant. In some systems, it is even contemplated that a single cushion may be used to provide protection to multiple occupants.

However, existing aspirating airbag assemblies suffer from many drawbacks, such as being large, bulky, and/or complicated, often requiring many different components and valve mechanisms. Such existing assemblies are often complicated and/or unnecessarily difficult to assembly, adding further to costs.

The present inventors have therefore determined that it would be desirable to provide systems and methods that overcome one or more of the foregoing limitations and/or other limitations of the prior art. In some embodiments, the inventive concepts disclosed herein may allow for providing an assembly that has relatively few modules/sub-assembly elements, each of which may be configured to facilitate simple coupling during an assembly process. Such assemblies may, for example, be configured with modules/sub-assembly elements that are slidably couplable to each of the other major modules/sub-assembly elements and/or that “snap-fit” together. In some embodiments, this may be accomplished without requiring, or at least substantially without requiring, any external fasteners for coupling these elements to one another.

In a more particular example of an airbag cushion assembly according to some embodiments, the assembly may comprise an airbag cushion housing comprising an airbag cushion configured to deploy from the airbag cushion housing. An aspiration housing may be coupled to the airbag cushion housing and may comprise an aspiration inlet configured to allow for receipt of ambient air into the airbag cushion during inflation of the airbag cushion. An inflation module may be slidably coupled to the aspiration housing. The inflation module may comprise an inflator, or may at least comprise an opening, recess, or other region configured to receive an inflator. The inflation module may further comprise at least one inflation tube or other inflation conduit fluidly coupled with the inflator. The at least one inflation conduit may be configured to deliver inflation gas from the inflator into the airbag cushion during an inflation event, which may result in entraining of aspirating air from the ambient environment as well.

Some embodiments may further comprise a valve assembly comprising one or more valves, such as flap valves, configured to open upon actuation of the inflator. Preferably the valve(s) are configured to close during inflation of the airbag cushion to prevent air and inflation gas from exiting through the aspiration inlet at a particular phase of inflation (either during or after inflation, for example).

In some embodiments, the inflation module may further comprise an endcap configured to at least substantially close at least one side of the housing upon coupling the inflation module with the aspiration housing. In some such embodiments, the endcap may be an integrally formed element of the inflation module. In some embodiments, the endcap may comprise a gas inlet port, which gas inlet port may be fluidly coupled with the inflator and the inflation tube/conduit.

In some embodiments, the inflation module may further comprise a first mating component, the aspiration housing may further comprise a second mating component, wherein the first mating component is configured to mate with the second mating component to couple the inflation module with the aspiration housing. In some such embodiments, the first mating component may comprise one or more elongated grooves and the second mating component may comprise one or more elongated protrusions. In some such embodiments, the elongated groove(s) may be configured to slidably receive the elongated protrusion(s).

In some embodiments, the aspiration module may further comprise at least one protrusion configured to be received within the at least one inflation conduit to facilitate coupling the inflation module to the aspiration housing. In some such embodiments, the protrusion(s) may define a rim and a hollow region for receiving and engaging the inflation conduit(s) therein.

In an example of an aspirating airbag cushion assembly according to another embodiment, the assembly may comprise an airbag cushion and a housing comprising an aspiration inlet configured to allow for receipt of ambient air into the airbag cushion during inflation of the airbag cushion. In some embodiments, the assembly may further comprise another housing configured to receive the airbag cushion. The assembly may further comprise an inflator, which may be received in and/or configured to be received in an inflation module comprising a plurality of inflation conduits configured to deliver inflation gas from the inflator. Each of the plurality of inflation conduits may comprise a plurality of inflation ports, such as high-velocity inflation ports configured to entrain ambient air through the aspiration inlet. The inflation module may be configured to be coupled with the housing by way of at least one groove configured to mate with and receive at least one protrusion.

In some embodiments, the inflation module may be configured to be slidably coupled to the housing. In some embodiments, the inflation module may comprise a pair of opposing, elongated protrusions, and the housing may comprise a plurality of opposing, elongated grooves configured to slidably receive the pair of opposing, elongated protrusions.

Some embodiments may further comprise a valve assembly comprising at least one valve flap. Some such embodiments may comprise an elongated bead or other protrusion. In some such embodiments, this bead/protrusion may be formed along a pivot point/line of the valve flaps and may be slidably received within a corresponding, elongated slot, which may be formed along an interior portion of the housing comprising the aspiration inlet. In some such embodiments, one or both of the bead and slot may comprise a bulbous lower portion and a narrowed neck portion to ensure that valve assembly is locked in place within the aspiration housing.

In some embodiments, the valve assembly may be configured such that the at least one valve flap opens upon actuation of the inflator. The valve assembly may further be configured such that the at least one valve flap closes following aspiration of the airbag cushion to prevent air and inflation gas from exiting through the aspiration inlet following inflation of the airbag cushion.

In yet another example of an aspirating airbag cushion assembly according to other embodiments, the assembly may comprise an airbag cushion and a housing, such as an aspiration housing, comprising a first side comprising an aspiration inlet configured to allow for receipt of ambient air into the airbag cushion during inflation of the airbag cushion; a second side opposite from the first side, wherein the second side comprises a first opening for receiving the airbag cushion; a third side extending between the first side and the second side at a first end of the housing, wherein the third side is at least substantially closed; and a fourth side opposite from the third side at a second end of housing, wherein the fourth side comprises a second opening. The assembly may further comprise an inflation module configured to be received in the second opening. The inflation module may comprise an endcap, which may be configured to at least substantially close (in some embodiments, fully close) the fourth side upon coupling the inflation module with the housing. In some such embodiments, the endcap may be integrally formed element of the inflation module along with, in some embodiments, one or more inflation conduits.

In some embodiments, the endcap may comprise a gas inlet port, which may be configured to fluidly couple the inflator with one or more inflation tubes or other inflation conduits. Thus, in some embodiments, the inflation module may comprise an inflator and a plurality of inflation conduits. The gas inlet port may be fluidly coupled with the inflator to allow for delivery of inflation gas into the plurality of inflation conduits. In some embodiments, the inflation module further may further comprise a frame, which may be configured to stabilize the inflation conduits during inflation. The frame may comprise one or more (in some embodiments, a plurality) of support members extending, for example, parallel to and/or perpendicular to the inflation conduits.

The features, structures, steps, or characteristics disclosed herein in connection with one embodiment may be combined in any suitable manner in one or more alternative embodiments.

DETAILED DESCRIPTION

A detailed description of apparatus, systems, and methods consistent with various embodiments of the present disclosure is provided below. While several embodiments are described, it should be understood that the disclosure is not limited to any of the specific embodiments disclosed, but instead encompasses numerous alternatives, modifications, and equivalents. In addition, while numerous specific details are set forth in the following description in order to provide a thorough understanding of the embodiments disclosed herein, some embodiments can be practiced without some or all of these details. Moreover, for the purpose of clarity, certain technical material that is known in the related art has not been described in detail in order to avoid unnecessarily obscuring the disclosure.

As used herein, the term “substantially” refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result to function as indicated. For example, an object that is “substantially” cylindrical or “substantially” perpendicular would mean that the object/feature is either cylindrical/perpendicular or nearly cylindrical/perpendicular so as to result in the same or nearly the same function. The exact allowable degree of deviation provided by this term may depend on the specific context. The use of “substantially” is equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result. For example, structure which is “substantially free of” a bottom would either completely lack a bottom or so nearly completely lack a bottom that the effect would be effectively the same as if it completely lacked a bottom.

Similarly, as used herein, the term “about” is used to provide flexibility to a numerical range endpoint by providing that a given value may be “a little above” or “a little below” the endpoint while still accomplishing the function associated with the range.

Apparatus, methods, and systems are disclosed herein relating to aspirating airbag cushion assemblies configured to utilize ambient air, in some cases along with inflation gas, to inflate larger airbag cushions, such as, in some embodiments, airbag cushions for multiple occupants, airbag cushions for autonomous vehicles, or pedestrian airbag cushions. Various embodiments disclosed herein may provide unique features to improve, for example, the coupling mechanisms, components, and/or functionality of such assemblies.

The embodiments of the disclosure may be best understood by reference to the drawings, wherein like parts may be designated by like numerals. It will be readily understood that the components of the disclosed embodiments, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following detailed description of the embodiments of the apparatus and methods of the disclosure is not intended to limit the scope of the disclosure, as claimed, but is merely representative of possible embodiments of the disclosure. In addition, the steps of a method do not necessarily need to be executed in any specific order, or even sequentially, nor need the steps be executed only once, unless otherwise specified. Additional details regarding certain preferred embodiments and implementations will now be described in greater detail with reference to the accompanying drawings.

FIG. 1depicts an aspirating airbag cushion assembly100. Aspirating airbag cushion assembly100comprises an airbag cushion housing110comprising an airbag cushion124(not shown inFIG. 1; seeFIG. 5) positioned and configured to deploy therefrom. Aspirating airbag cushion assembly100further comprises an aspiration housing120coupled to the airbag cushion housing110. The aspiration housing120comprises an open side and/or opening at its upper side for receiving an airbag cushion and/or coupling and/or receiving airbag cushion housing110thereto. Opposite this open side, aspiration housing120comprises an aspiration inlet122configured to allow for receipt of ambient air into the airbag cushion during inflation. In the depicted embodiment, aspiration inlet122comprises a plurality of openings aligned in a grid pattern along this side of aspiration housing120. However, it is contemplated that, in alternative embodiments, the aspiration inlet may comprise a single opening (in some such embodiments, the entire lower side of aspiration housing120may be open) or may comprise any other suitable number of openings as desired.

An inflation module130may be coupled to the aspiration housing120. As described in greater detail below, in preferred embodiments, including the embodiment depicted inFIGS. 1-11, inflation module130may be slidably coupled to the aspiration housing120. Inflation module130comprises an inflator132. Inflator132in the depicted embodiment comprises a disc inflator. However, other embodiments are contemplated in which inflator132may instead comprise another type of inflator, such as a tubular inflator or another suitable inflator.

Inflator132is configured to be received in a recess134formed in an endcap136of inflation module130and may be configured to be coupled therein by way of one or more fasteners, as best shown inFIG. 2. As discussed below in connection with other embodiments, however, the inflation may be coupled to the inflation module and/or another portion of the inflation assembly without use, or at least substantially with use, of any such fasteners.

Endcap136comprises an inflator hub138protruding from a plate portion139. Hub138defines recess134for receiving inflator132therein. Again, as described in greater detail below, endcap136is, preferably and in the depicted embodiment, configured to close, or at least substantially close, one side (possibly more than one side in other embodiments) of the aspiration housing120upon coupling the inflation module130with the aspiration housing120. In some embodiments, endcap136is an integrally formed element of the inflation module130, which may simplify the assembly process and/or provide a more secure finished assembly.

More particularly, aspiration housing120comprises a first or lower side comprising an aspiration inlet122configured to allow for receipt of ambient air into the airbag cushion124during inflation. Aspiration housing120further comprises a second or upper side opposite from the first side that is configured to receive airbag cushion124and/or airbag cushion housing110therein. A third side of aspiration housing120extends between the upper and lower sides/ends and is closed or at least substantially closed. As shown inFIG. 2, this third side, which comprises coupling elements and/or protrusions127, is open (other embodiments are contemplated in which this side is at least substantially open or comprises one or more openings, however).

This open side or, in other embodiments, one or more openings, may be configured to be closed, or at least substantially closed, by inflation module130. More particularly, inflation module130is configured to be received in the open side of aspiration housing120and to close this side/opening upon being fully coupled with, which in the case of the depicted embodiment means fully slid into, inflation module130. Endcap136is therefore configured to close this side of aspiration housing120, which may be facilitated by providing plate portion139of inflator hub138. Again, in preferred embodiments, endcap136is an integrally-formed element of inflation module130to further simplify manufacturing and/or assembly.

Inflation module130further comprises a plurality of inflation tubes140or other inflation conduits fluidly coupled with inflator132. Each of the inflation tubes140comprises a plurality of inflation ports142and each of the inflation tubes140and/or inflation ports142is configured to deliver inflation gas from inflator132into the airbag cushion. Preferably, assembly100is configured such that the inflation gas is delivered at a sufficiently high velocity to draw ambient air through aspiration inlet122and into the airbag cushion during inflation. In alternative embodiments, each of inflation ports142may be formed on a nozzle or the like, which may extend from one or more of inflation conduits140.

It is preferred that a relatively large number of inflation ports142be used in order to create a sufficient pressure differential to drive the aspiration and to provide uniform distribution of the inflation gas driving aspiration. Although thirty-six nozzles are shown in the preferred embodiments depicted in the drawings, this precise number is not required. In addition, preferably each of the high-velocity ports142is configured to keep the inflation gas delivered therethrough in a relatively tight column while being delivered into the airbag cushion rather than expanding into a plume of gas. This may further facilitate creation of the desired pressure differential to drive the aspiration process. Thus, it is preferred that the pressure driving inflation ports142not exceed about 500 psi. It may also be preferred that this pressure be at least about 100 psi. Thus, in some preferred embodiments, the pressure within the inflation conduits140is between about 100 and about 500, or, in some such embodiments, between 100 and 500, psi.

Although a relatively high-velocity may be desirable, in some embodiments, it may be preferred to keep the velocity of the gas from ports142from reaching a certain upper limit. For example, in certain preferred embodiments, the airbag inflation module130may be configured such that the gas delivered from ports142is below supersonic velocities. This may be useful in preventing the plume created by the incoming gas from getting too large. Thus, it may be preferred to keep the gas from ports142as close to being delivered in a vertical column/stream as possible.

It may also be preferred that the ports142be spaced apart from one another sufficiently such that the streamlines of the expanding gas do not intersect, or at least intersect minimally. Thus, preferably the ports142are spaced apart with the maximum amount of space in between each adjacent port within the area allotted to the aspiration inlet122, such as the case in the depicted embodiment.

Inflation module130further comprises a frame145defined by a plurality of support members146extending perpendicular to the inflation conduits140. Additional support members148may extend parallel to conduits140. Such parallel support members148may bound conduits140on opposite ends of frame145, as shown in the depicted embodiment. In other contemplated embodiments, parallel support members may be placed in between adjacent conduits140, either in addition to or as an alternative to the perimeter support members148shown in the depicted embodiment. Frame145is preferably configured to provide stability to each of the various tubes/conduits140during deployment.

Assembly100further comprises a valve assembly160. Valve assembly160may comprise one or more valves preferably configured to automatically open upon actuation of inflator132and further configured to automatically close during inflation of the airbag cushion to prevent air and inflation gas from exiting through aspiration inlet122. In some embodiments, the one or more valves of the valve assembly160may be configured to automatically close at a predetermined stage during inflation of the airbag cushion.

In the depicted embodiment, valve assembly160comprises a first valve162aand a second valve162b. Valves162aand162bmay comprise flaps, such as butterfly flaps, that are configured to automatically open and close at least two separate openings of the aspiration inlet122. In some embodiments, including the depicted embodiment, these flaps may be configured to open and close each of the openings defining the aspiration inlet122. In the depicted embodiment, each of valves162aand162bcomprises two flaps that are pivotably coupled to one another at a central portion of the respective valves162. Thus, as shown in phantom onFIG. 2, valves162aand162bmay be configured to pivot to their respective open configurations during inflation by pivoting their respective flaps at this central portion/line.

In some embodiments, the valve flaps of valves162may be sufficiently flexible such that the flaps flex during inflation. In some embodiments, however, these flaps may be sufficiently rigid so as to maintain a bias towards their respective closed configurations. In other words, the valves and/or valve flaps may be configured to require force to open (generated by a partial vacuum within an associated airbag cushion) and are otherwise biased towards their respective closed configurations. Although the valve flaps themselves may be configured to perform this function alone in some embodiments, in other embodiments, a support member of such valve flaps, such as a hinge, may be provided to facilitate a desired opening and closing function.

In some embodiments, the valve flaps162may comprise a relatively rigid material (at least compared to the fabric of airbag cushion124). In some embodiments, such valve flaps may be configured to operate in a desired manner simply by rigidly coupling such flaps adjacent to aspiration inlet122. Alternatively, flap(s)162may be hinged at one end such that flap(s)162are biased towards their respective closed positions. Some embodiments may comprise flaps that partially or fully overlap with one another.

Preferably, one or more novel features may be provided to facilitate assembly and/or a desired coupling between the various components of assembly100. Thus, for example, one or more elements of assembly100may comprising a first mating component configured to mate, in some such embodiments to slidingly mate, with another element. Thus, in the depicted embodiment, inflation module130comprises a first mating component, namely, a pair of elongated rails148, which, as previously mentioned, may also serve as support members for a frame145. At least a portion of rails148are configured to be received in a corresponding second mating component, namely, a pair of elongated grooves125formed within aspiration housing120. In some embodiments, rails148themselves may be received within grooves125or another similar features. However, as better shown in connection with embodiments and/or figures discussed below, in other embodiments, protrusions may be formed on rails148, which protrusions may be received within grooves125.

In the depicted embodiment, other mating components are provided that may further facilitate assembly and/or a desired coupling. In particular, aspiration housing120comprises a pair of elongated channels123configured to receive a corresponding pair of elongated rails113formed on airbag cushion housing110. Each of elongated grooves125is formed adjacent to a respective elongated channel123, which may allow airbag cushion housing110, aspiration housing120, and inflation module130to be slidably coupled to one another, in some embodiments without use of, or at least substantially without the use of, any fasteners.

Still other mating and/or coupling components may be provided to provide enhanced stability, ease of assembly, or other benefits. For example, aspiration housing120further comprises a set of protrusions127, preferably corresponding in number to the number of inflation conduits140, each of which is configured to be received within one of the inflation conduits at its respective distal end (relative to inflator132) to further facilitate coupling inflation module130to aspiration housing120. Protrusions127are circular so as to allow for mating with the ends of the inflation conduits140. In order to do so, in some embodiments, protrusions127may be hollow in the center and defined by a circular rim, again, so as to receive a tube/conduit140therein. In some embodiments, protrusions127may also serve as “plugs” to block the distal ends of the respective inflation conduits140. Alternatively, however, inflation conduits140may otherwise be blocked and the coupling between protrusions127and conduits140may instead be solely used to facilitate a desired coupling between the aforementioned elements of assembly100.

Although in the depicted embodiment each of protrusions127is configured to extend into the distal opening formed in each respective inflation conduit140, it is also contemplated that, in alternative embodiments, protrusions127may instead define a recess and/or other seat for receiving the distal ends of inflation conduits140therein. Thus, elements127may comprise a male component or, alternatively, a female component in a set of coupling elements with inflation module130.

Valve assembly160may similarly be slidably couplable with aspiration housing120. Thus, for example, a pivot point of the flaps162of valve assembly160may comprise an elongated protrusion or bead161, as shown inFIG. 2, which may be slidably received within a corresponding, elongated slot126formed along the lower portion of aspiration housing120. Both protrusion/bead161and slot126preferably comprises a bulbous lower portion and a narrowed neck portion to ensure that valve assembly160is kept in its proper position within aspiration housing120.

Endcap136may further comprise one or more gas inlet ports141. Each of the gas inlet ports141is fluidly coupled with inflator132and one or more of inflation conduits140. In some embodiments, a separate gas inlet port141may be provided for each conduit140. Alternatively, a single gas inlet port141may be provided that is indirectly coupled to either each of, or all but one of, for example, conduits140.

As shown inFIGS. 2 and 3, other features/components may be used to lock various sub-elements of assembly100in place. Thus, for example, one or more clips151may be provided that may be configured to be received in one or more corresponding brackets121. In the depicted embodiment, clips151comprise snap-tabs comprising resiliently flexible prongs formed on opposite sides of plate portion139of inflator hub138. These prongs are configured to be received and locked in slots formed in brackets121, which are formed on opposite sides of aspiration housing120.

The cross-sectional view ofFIG. 5depicts flaps/valves162aand162bof valve assembly160in an open configuration during inflation of airbag cushion124. As previously mentioned, by directing high-velocity inflation gas through inflation ports142, a pressure differential is generated that preferably results in the opening of the valves and/or flaps of valve assembly160automatically (i.e., without further mechanical elements or other forces/actions). This allows the inflation of airbag cushion124to be supplemented by ambient air, which may enter airbag cushion124through the one or more openings of aspiration inlet122. Preferably, inflation ports142may be used to generate a sufficient pressure differential to allow for valve flaps162to automatically open. This same pressure differential may then allow ambient air to assist with inflation of airbag cushion124. Preferably, inflation gases are introduced in a forceful manner into airbag cushion124. Thus, in addition to and/or as an alternative to the pressure differential, the velocity and/or rate of volume of gas delivered through ports142may be sufficient to cause ambient air to be entrained within the inflation gas and therefore aspirated into airbag cushion124along with this inflation gas.

At a desired point during inflation, valves and/or flaps of valve assembly160automatically close to prevent the air and inflation gases from escaping, or at least reduce the amount of air and inflation gases that may escape from, airbag cushion124. Again, this may be accomplished in a number of ways but, preferably, the valves and/or flaps of valve assembly160are biased, either by way of a hinge, by way of their physical makeup and coupling/pivot point(s) of attachment, or otherwise, towards their respective closed positions, preferably such that a threshold amount of force and/or pressure is required in order to reposition them to their open configurations, after which they automatically return to their closed configurations.

Thus, the valve(s)/flap(s) of valve assembly160are preferably configured to operate in a closed configuration initially, and then automatically open during inflation, which may be caused by generating a partial vacuum within the airbag cushion124by, for example, the inflation gas from inflator132. Following inflation, the system may be configured to automatically close again to maintain gases (both ambient air and inflation gas) in the cushion during occupant contact. The system may be specifically configured to provide for these three stages (closed, open during inflation, and re-closing during or following inflation) automatically at desired times by virtue of the positioning and configuration of the valve(s), conduits, ports, etc.

More specifically, upon initial deployment, there may be significant pressure achieved in the cushion124prior to the cushion124breaking through a cover (the “breakout phase” of the deployment). With this high pressure, the potential for leakage out the back of the housing is very high without blocking the aspiration inlet122. Failure to block aspiration inlet122may also inhibit desired cushion restraint. Following the breakout phase, it is preferred that the aspiration inlet122be opened as quickly as possible to allow for ambient air to assist in the inflation process.

Again, following the decrease of the pressure differential previously mentioned, a pressure differential developed in an opposite direction, and/or the cessation of inflation gasses being delivered through inflation ports142, valve flaps162may be configured to automatically close again. As previously mentioned, in some embodiments, valve flaps162may be biased towards their respective closed positions to facilitate this stage of inflation. One or more airbag cushion vents (not shown) may be used and may be tuned to provide desired deployment/restraint characteristics.

As shown in the cross-sectional view ofFIG. 8, in preferred embodiments, one or more (in some embodiments, all) of the inflation conduits140may have a cross-sectional dimension that decreases in size as the inflation conduit140extends away from the inflator132and/or endcap136. This may be useful for having a uniform, or at least more uniform, distribution of gas through each of the various inflation ports142during inflation. Thus, in some such embodiments, the cross-sectional diameter of inflation conduit(s) may have a gradual taper from inflator132and/or endcap136to the distal end of each respective inflation conduit140. In this manner, the velocity and other volume of gas per unit time through each of the inflation ports142may be made more uniform. Thus, in some embodiments, each of ports142may be configured to deliver a flow of air that is at least substantially uniform relative to the other ports142.

However, in alternative embodiments, the cross-sectional diameter and/or other dimension may vary in other ways, such as via one or more steps or otherwise more abrupt changes in such cross-sectional diameter/dimension. In preferred embodiments, inflation conduits140may be made from a molded thermoplastic material.

Hinges, such as spring-loaded hinges, are an example of a means for biasing an aspiration valve towards a closed position. A rigid coupling of a flexible valve flap adjacent an aspiration opening is another example of means for biasing an aspiration valve towards a closed position. As also previously mentioned, in some embodiments, a portion of valve flap(s)162of valve assembly160may be formed with one or more grooves, which groove(s) that may be configured to serve as a “hinge” for facilitating opening and/or closing of the valve by pressure differentials between the inside and outside of the airbag cushion124alone.

As shown in the accompanying drawings, in preferred embodiments, the valve(s) and/or valve assembly, such as valve flaps162, are positioned between the aspiration inlet(s)122and the inflation port(s)142and/or inflation conduit(s)140. The inventors have discovered that, although alternative embodiments are contemplated in which such flaps or other valve elements may be positioned above and/or in the path of inflation gases, such designs may inhibit desired closing of the valve and allow for more leakage through the aspiration inlet(s) than may be ideal. Thus, the depicted embodiment deliberately places these valve elements below the inflation conduits/ports.

In the depicted embodiment, the valve flaps are positioned away from a flow path of the inflation ports142and positioned between the aspiration inlet122and the inflation ports142. In the depicted embodiment, each of these statements is true in both the closed and open configurations, although alternative embodiments are contemplated in which one or more of these statements may only be true in the closed configuration and/or one or more (or all) of these statements may not true. In other words, for example, in some embodiments, the valve flaps162may be partially positioned above the inflation ports142in the open configuration. In addition, although the depicted embodiment comprises non-overlapping valve flaps162, other embodiments are contemplated in which the valve flaps may overlap, either fully or partially, with one another in a desired manner.

Although the embodiment depicted inFIGS. 1-11is configured to be substantially free of fasteners (the only fasteners used are to couple inflator132with inflator with inflator hub138, as best shown inFIG. 2), other embodiments are contemplated that are entirely free of fasteners. It should be understood that assemblies are to be considered entirely free of fasteners even if individual elements, such as inflator132, might themselves have fasteners so long as the individual elements coupled together for the assembly are so coupled without use of fasteners.

An example of an aspirating airbag cushion assembly200that is entirely free of fasteners is shown inFIGS. 12-23. Assembly200differs from assembly100in a few ways. Most notably, inflator232comprises a snap-fit coupling rather than requiring fasteners. To accomplish this, snap-fit coupling means are provided that comprise snap tabs or clips247on inflator232and corresponding brackets/slots237formed on inflator hub238of endcap236. Clips247may, similar to clips151/251, comprise resiliently flexible prongs in some embodiments.

Assembly200may otherwise be similar to assembly100. Thus, as shown inFIG. 12, aspirating airbag cushion assembly200again comprises an airbag cushion housing210comprising an airbag cushion224positioned and configured to deploy therefrom. Aspirating also airbag cushion assembly200further comprises an aspiration housing220coupled to the airbag cushion housing210. The aspiration housing220comprises an open side and/or opening at its upper side for receiving an airbag cushion224and/or airbag cushion housing210. Opposite this open side, aspiration housing220comprises an aspiration inlet222configured to allow for receipt of ambient air into the airbag cushion during inflation. In the depicted embodiment, aspiration inlet222comprises a plurality of openings aligned in a grid pattern along this side of aspiration housing220.

An inflation module230is slidably coupled to aspiration housing220. As previously mentioned, inflation module230comprises an inflator232that is configured to be received in a recess234formed in endcap236of inflation module230. Again, inflator232is configured to snap-fit and lock into place within recess234by way of clips247and recesses/brackets237. In some embodiments, inflator232may comprise an annular diffuser that may be positioned and configured to facilitate a desired distribution of inflation gas from inflator232prior to entering inflation conduits240.

As with endcap136, endcap236comprises an inflator hub238protruding from a plate portion239. Hub238defines recess234for receiving inflator232therein. In addition, as previously mentioned, endcap236is, preferably and in the depicted embodiment, configured to close, or at least substantially close, one side (possibly more than one side in other embodiments) of the aspiration housing220upon coupling the inflation module230with the aspiration housing220. In some embodiments, endcap236is an integrally formed element of the inflation module230.

Inflation module230further comprises a plurality of inflation conduits240fluidly coupled with inflator232. Each of the inflation conduits240again comprises a plurality of inflation ports242configured to deliver inflation gas from inflator232into the airbag cushion224. Preferably, hat the inflation gas is delivered at a sufficiently high velocity to draw or entrain ambient air through aspiration inlet222and into the airbag cushion224during inflation.

Inflation module230further comprises a frame245defined by a plurality of cross-support members246extending perpendicular to the inflation conduits240and/or parallel support members248.

Assembly200further comprises a valve assembly260comprising one or more valves preferably configured to automatically open upon actuation of inflator232and further configured to automatically close during inflation of the airbag cushion224to prevent air and inflation gas from exiting through aspiration inlet222. More particularly, valve assembly260comprises a first valve262aand a second valve262b, each of which may comprise a pair of flaps that are preferably configured to automatically open and close at least two separate openings of the aspiration inlet222at predetermined stages during an inflation process.

As with valve assembly160, valve assembly260may be slidably couplable with aspiration housing220by providing an elongated protrusion or bead261on each valve/flap262, as shown inFIG. 13, which may be slidably received within a corresponding, elongated slot226formed along the lower portion of aspiration housing220.

Inflation module230further comprises one or more pairs of mating coupling elements, as previously mentioned. Thus, inflation module230comprises a pair of elongated rails248, which, as previously mentioned, may also serve as support members for a frame245. An outer portion of each of rails248defines an elongated protrusion249that is configured to be received in a corresponding elongated groove225formed within aspiration housing220.

Aspiration housing220further comprises a pair of elongated channels223configured to receive another pair of elongated rails213formed on airbag cushion housing210. Each of elongated grooves225is formed adjacent to a respective elongated channel223, which may allow airbag cushion housing210, aspiration housing220, and inflation module230to be slidably coupled to one another without use of, or at least substantially without the use of, any fasteners.

Aspiration housing220further comprises a set of protrusions227, preferably corresponding in number to the number of inflation conduits240, each of which may have a cross-sectional shape that corresponds with (circular in the depicted embodiment) and is configured to be received within one of the inflation conduits at its respective distal end to further facilitate coupling inflation module230to aspiration housing220.

As previously mentioned, endcap236may further comprise one or more gas inlet ports fluidly coupled with inflator232and one or more of inflation conduits240to provide a fluid deliver path from inflator232into inflation conduits240. As previously mentioned, one or more clips251may be provided that may be configured to be received in one or more corresponding brackets221to secure inflation module230in place with respect to aspiration housing220.

Once again, in preferred embodiments, one or more (in some embodiments, all) of the inflation conduits240may have a cross-sectional dimension that decreases in size as the inflation conduit240extends away from the inflator232and/or endcap236. Similarly, hinges, a rigid coupling of a flexible valve flap adjacent an aspiration opening, a portion of valve flap(s)262of valve assembly260formed with one or more grooves serving as a “hinge,” or otherwise the material of flaps262and/or points of attachment may be used to control the opening and/or closing parameters of the valve assembly260.

FIG. 23illustrates the ease of assembly of aspirating airbag cushion assembly200. Again, because aspirating airbag cushion assembly200is free, or at least substantially free (again, fasteners may be present in one or more of the individual elements of assembly200depicted inFIG. 23), of fasteners, the assembly process may comprise a gravity-fed or gravity-assisted assembly process whereby each of the depicted elements is simply dropped and/or slid into place to complete the assembly.

More particularly, valve assembly260may be slid into place within aspiration housing220by inserting the elongated bead/protrusion261extending along the pivot lines of both valves/flaps262into the corresponding slot226formed within aspiration housing220adjacent to aspiration inlet222. Similarly, airbag cushion housing210can be slid into place within aspiration housing220by inserting elongated rails213into elongated channels223and inflation module230can be slid into place by inserting at least a portion of rails248, such as elongated protrusions249, into a corresponding elongated groove225of aspiration housing220. The assembly200may then be locked in place by snapping clips247of endcap236in place within their respective slots formed on the exterior surface of aspiration housing220. Similarly, inflator232may be slid and locked in place by sliding inflator232into the recess234of endcap236and then inserting the base portion of inflator232until the clips247have been received within their respective slots237formed on the exterior surface of hub238of endcap236to lock inflator232therein.

It should be understood that the assembly process of aspirating airbag cushion assembly100may also comprise a gravity-fed or gravity-assisted assembly process whereby each of the depicted elements (other than the inflator132) is simply dropped and/or slid into place to complete the assembly. Thus, aspirating airbag cushion assembly100should be considered to comprise an assembly that is substantially free of fasteners (in that each of the major elements of the assembly is configured for being coupled with the other major elements of the assembly without use of fasteners, even though these elements themselves may comprise fasteners).

The foregoing specification has been described with reference to various embodiments and implementations. However, one of ordinary skill in the art will appreciate that various modifications and changes can be made without departing from the scope of the present disclosure. For example, various operational steps, as well as components for carrying out operational steps, may be implemented in various ways depending upon the particular application or in consideration of any number of cost functions associated with the operation of the system. Accordingly, any one or more of the steps may be deleted, modified, or combined with other steps. Further, this disclosure is to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope thereof. Likewise, benefits, other advantages, and solutions to problems have been described above with regard to various embodiments. However, benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced, are not to be construed as a critical, a required, or an essential feature or element.