Vehicle airbag support assembly

A vehicle airbag support assembly comprises a vehicle cross-car beam and an airbag support structure. The vehicle cross-car beam includes rearward and forward surfaces facing rearward and forward directions of a vehicle. The airbag support structure includes a mounting portion, and elongated extension portion and a support portion. The mounting portion is fixedly coupled to the rearward surface of the vehicle cross-car beam. The elongated extension portion includes a first end fixedly coupled to the mounting portion and a second end spaced from the first end such that the first end is situated closer to the rearward surface than the forward surface and the second end extends beyond the forward surface. The support portion supports an airbag device and is fixedly coupled to the second end of the extension portion such that the support portion is situated closer to the forward surface than the rearward surface and is cantilevered.

CROSS-REFERENCE TO RELATED APPLICATION

Related subject matter is disclosed in U.S. patent application Ser. No. 13/012,498, filed on Jan. 24, 2011, the entire contents of which are hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a vehicle airbag support assembly. More specifically, the present invention relates to a vehicle airbag support assembly that is configured to position a vehicle airbag in a desired location, such as in a high-mounted location behind a vehicle dashboard.

2. Background Information

Various portions of vehicles are continuously being re-designed and modified to increase performance, reduce cost or weight, and/or comply with regulatory standards. For example, airbags are typically installed to protect passengers in the event of an impact. Airbags are operably connected to an airbag deployment system which typically includes a triggering device. The triggering device detects rapid changes in acceleration due to an impact event. Upon the detection of an impact event above a prescribed threshold, the triggering device sends a signal to the airbag deployment system instructing the system to deploy the airbag(s) in a vehicle.

SUMMARY

In view of the state of the known technology, one aspect of the present invention is directed to a vehicle airbag support assembly comprising a vehicle cross-car beam and an airbag support structure. The vehicle cross-car beam includes a rearward surface facing a rearward direction of a vehicle and a forward surface facing a forward direction of the vehicle. The airbag support structure includes a mounting portion, and elongated extension portion and a support portion. The mounting portion is fixedly coupled to the rearward surface of the vehicle cross-car beam. The elongated extension portion includes a first end fixedly coupled to the mounting portion and a second end spaced from the first end such that the first end is situated closer to the rearward surface than the forward surface and the second end of the extension portion extends beyond the forward surface of the vehicle cross-car beam. The support portion supports an airbag device and is fixedly coupled to the second end of the extension portion such that the support portion is situated closer to the forward surface than the rearward surface and is cantilevered with respect to the mounting portion.

DETAILED DESCRIPTION OF EMBODIMENTS

Referring initially toFIGS. 1 and 2a vehicle10has a passenger compartment12and a dashboard14generally at the front of the passenger compartment12. The dashboard14typically includes an instrument panel16, and a plurality of grill openings18and20which can accommodate vent outlets, speakers and so on. As shown inFIG. 2, an airbag region22associated with a high-mounted airbag is identified on the dashboard14. Those skilled in the art will appreciate that the dashboard14can be formed to maintain an overall appearance as shown inFIG. 2, which conceals the presence of the high-mounted airbag for aesthetic purposes. Alternatively, the dashboard14can define an airbag cover panel or conceal a hidden airbag cover panel that facilitates deployment of the high-mounted airbag.

As shown in more detail inFIGS. 3 and 4, a vehicle airbag support assembly24is disposed behind the airbag region22. In this example, the vehicle airbag support assembly24supports a vehicle airbag device26that houses an airbag28and an airbag inflator30. The vehicle airbag support assembly24further includes an airbag support structure32that secures the vehicle airbag device26to a structural support member, such as a vehicle cross-car beam34. The components of the vehicle airbag support assembly24and the vehicle cross-car beam34can be made of metal or any other suitable material. The vehicle cross-car beam34is secured to the vehicle10by welds, bolts or other suitable securing members. The vehicle cross-car beam34can be situated adjacent to or behind the dashboard14as shown inFIGS. 3 and 4. However, a vehicle airbag support assembly24according to the present invention can be located in various other locations within a particular vehicle.

As shown inFIG. 4, when an impact event is detected, the airbag inflator30is detonated in order to inflate the airbag28. The airbag28forcibly penetrates the dashboard14in the airbag region22(e.g., separates the dashboard14along a frangible seam) and the airbag28deploys into the passenger compartment12to provide a cushioning surface for a vehicle occupant36.

As shown inFIGS. 5-10, the vehicle cross-car beam34has a rearward surface40facing in a rearward direction of the vehicle10and a forward surface42facing in a forward direction of the vehicle10. The airbag support structure32includes a mounting portion44, an elongated extension portion46and a support portion48. The mounting portion44is fixedly coupled to the rearward surface40of the vehicle cross-car beam34. The elongated extension portion46has a first end50fixedly coupled to the mounting portion44and a second end52spaced from the first end50. As shown, with the airbag support structure32in an installed position, the first end50of the elongated extension portion46is situated at or on the rearward surface40of the vehicle cross-car beam34, and the second end52of the elongated extension portion46extends beyond the forward surface42of the vehicle cross-car beam34. Moreover, the elongated extension portion46further extends in an upward direction of the vehicle10when the mounting portion44is fixedly coupled to the rearward surface40of the vehicle cross-car beam34. Thus, the elongated extension portion46enables positioning of the airbag28.

As further shown, the vehicle cross-car beam34extends within a cavity54defined by the dashboard14such that the vehicle cross-car beam34positions the mounting portion44in the cavity54. In this example, the entire vehicle airbag support assembly24and the vehicle airbag device26are positioned within the cavity54. Also, the support portion48supports the airbag device26. That is, the support portion48is fixedly coupled to the second end52of the elongated extension portion46such that the support portion48is situated beyond the forward surface42of the vehicle cross-car beam34and is cantilevered with respect to the mounting portion44. In this arrangement, the airbag device26is thus in a high-mounted configuration. The support portion48in this example has a planar support surface56that is configured to support the airbag device26. The support portion48also defines an opening58that is configured to receive a portion60of the airbag device26therein. The opening58has a central axis A that extends at an acute angle θ (shown inFIG. 8) relative to a horizontal plane L toward the rearward direction of the vehicle10. The central axis A also extends perpendicular or substantially perpendicular to the direction in which the elongated extension portion46extends (i.e., normal to the support surface56). Accordingly, the support portion48and the support surface56position and support the airbag device26such that a direction of deployment of the airbag device26(e.g., along the central axis A) is normal (i.e., perpendicular or substantially perpendicular) to the support surface48and toward the rearward direction of the vehicle10. The support portion48can further define a plurality of openings62. Each of the plurality of openings62can receive a fastener64, such as a screw, rivet, bolt and so on, which secures the airbag device26to the support portion48. Thus, the elongated extension portion46of the airbag support structure32positions the airbag28car-forward of the vehicle cross-car beam34within the cavity, which enables the airbag device26to meet low risk deployment (LRD) regulatory standards.

As can be appreciated from the above, the mounting portion44can be fixedly coupled to the rearward surface40of the vehicle cross-car beam34in any suitable manner. In this example, a plurality of mounting brackets66couple the mounting portion44to the vehicle cross-car beam34, and each of the plurality of mounting brackets66at least partially conform to a radial contour of the vehicle cross-car beam34. The mounting brackets66can be secured to the vehicle cross-car beam34using any suitable fasteners, such as welds, screws, rivets, bolts and so on. Thus, each of the mounting brackets66contacts the rearward surface40of the vehicle cross-car beam34as shown. Alternatively, the mounting brackets66can be combined into a single centrally-located mounting bracket as desired to couple the mounting portion44to the vehicle cross-car beam34.

As further shown, the mounting portion44includes a mounting structure68that defines a plurality of mounting apertures70. In this example, the mounting apertures70are disposed on opposite sides of the elongated extension portion46, but can be at any suitable location. Also, each of the mounting apertures70has a respective center axis B (shown inFIG. 10) that projects toward the second end52of the elongated extension portion46. The mounting structure68can therefore be coupled to the mounting brackets66by any suitable fasteners72such as screws, bolts, rivets and so on. Furthermore, as mentioned above, the airbag device26is arranged in a high-mounted configuration in the illustrated embodiment. However, a different airbag support structure32having an elongated extension portion46of a different length can be used to mount the airbag device26at a higher or lower position within the cavity54.

As further shown inFIGS. 5-7and9, and in more detail inFIGS. 11-14, the elongated extension portion46defines a space74that divides the elongated extension portion46into a first extension arm76and a second extension arm78. The space74extends longitudinally along a central section of the elongated extension portion46. The first and second extension arms76and78each have a respective U-shaped cross-section as viewed in a longitudinal direction of the elongated extension portion46(see, for example,FIG. 14). This U-shaped cross-section provides enhanced structural support across the cantilevered section of the vehicle airbag support assembly24. The elongated extension portion46also includes at least two planar base flanges (support flanges)80and82that are located proximate to the mounting portion44and have curved edges84and86, respectively. The base flanges (support flanges)80and82extend from an upper surface of the elongated extension portion46toward the vehicle cross-car beam34. The shape of the curved edges84and86can correspond or substantially correspond to the outer shape (or radial contour) of the vehicle cross-car beam34. For example, the radii of the curved edges84and86can correspond to or substantially correspond to the outer radius of the vehicle cross-car beam34. Accordingly, the base flanges (support flanges)80and82can provide structural support without contacting the vehicle cross-car beam34due to the clearance provided by the curved edges84and86. However, the base flanges (support flanges)80and82can instead rest on an upper surface88of the vehicle cross-car beam34, such that the vehicle cross-car beam34supports the base flanges (support flanges)80and82. Thus, the upper surface88of the vehicle cross-car beam34can optionally assist in directly supporting the elongated extension portion46.

In addition, the elongated extension portion46defines at least one harness aperture90that is configured to receive a wiring harness mounting structure92(see, for example,FIG. 8). The wiring harness mounting structure92can be coupled to the elongated extension portion46by fasteners94such as screws, bolts, rivets and so on, that are received in the harness apertures86. The wiring harness mounting structure92is coupled to one end of a wiring harness96to which is attached an electrical coupler98. The other end of the wiring harness96is connected to the airbag inflator30. Thus, a controller (not shown) provides signals via the wiring harness96to the airbag inflator30to control the airbag inflator30to deploy the airbag28at the appropriate time, such as during an impact event.

It should also be noted that the airbag support structure32can be directly manufactured (e.g., forged or molded) in its illustrated shape, or can be made from a preform (or blank) that is ultimately formed into the airbag support structure32. For example, as shown inFIG. 15, a preform100having a prescribed shape can be provided from which to manufacture the airbag support structure32. The preform100can be made of metal or any other suitable material that has sufficient rigidity but that can also be folded at prescribed locations. In an unfolded state, the preform100defines certain features of the airbag support structure32, such as the opening58, the plurality of openings62, the space74, the planar base flanges (support flanges)80and82having curved edges84and86, respectively, the harness apertures90, and holes102which define the mounting apertures70.

Accordingly, the preform100can be folded along prescribed fold lines (as indicated by arrows inFIG. 15) to form the shape of airbag support structure32. In this example, the perform100is folded along fold lines104,106,108,110and112to form the mounting portion44. As the preform110is formed along fold lines106and110, the openings102align with each other to define the mounting apertures70. In addition, the perform100is folded along fold lines114,116,118and120to define the first and second extension arms76and78of the elongated extension portion46. Naturally, the airbag support structure32can be formed in any other suitable manner, such as by assembling separate components together to form the airbag support structure32as desired.

GENERAL INTERPRETATION OF TERMS