Driver airbag assemblies for emblem accommodation

Decorative emblem assemblies and related airbag modules and methods. In some embodiments, a decorative emblem may be coupled to a plate having a plurality of holes formed therein. A plurality of non-threaded fasteners may extend from the decorative emblem, wherein each of the plurality of non-threaded fasteners is configured to extend through a hole of the plurality of holes formed in the plate. The assembly may further comprise a clip configured to engage each of the plurality of non-threaded fasteners to secure the emblem assembly to an airbag cover and compress the plate between the decorative emblem and the airbag cover.

SUMMARY

Driver airbag modules often have decorative emblems displaying, for example, a logo of a vehicle manufacturer. Such modules, however, suffer from many drawbacks, including inadequate heat dissipation for electronics and/or lighting elements, loose coupling techniques, which can result in noise (BSR), and typically offer little or no ability to present lighting effects to highlight the emblem.

The present inventors have therefore determined that it would be desirable to provide apparatus, 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 therefore provide an airbag module that provides an emblem assembly having a clip to keep the various elements of the emblem assembly in place, preferably within a preconfigured pocket formed in an airbag cover. Various other features/elements may be present in various embodiments, including, for example, light guides, selective control of light bleeding, heat dissipation, and/or a secure mounting clip for securely mounting the emblem assembly, which may comprise a plurality of plates configured in a stack, to an airbag cover.

In a more particular example of a driver airbag assembly, the assembly may comprise a cover comprising a pocket for receiving an emblem assembly therein, and an emblem assembly coupled to the cover within the pocket. The emblem assembly may comprise a plate having a hole formed therein; a decorative emblem configured to be coupled with the plate; a fastener extending from the decorative emblem and through the hole; and a clip configured to engage the fastener to couple the emblem assembly to the cover.

In some embodiments, the fastener may comprise an enlarged head, which enlarged head may comprise a semicircular enlarged region in some such embodiments. In some embodiments, the clip may be configured to engage the fastener along a proximal surface of the enlarged head, which may face towards the decorative emblem.

In some embodiments, the plate may comprise a plurality of holes, and wherein the emblem assembly comprises a plurality of fasteners, each fastener being configured to be received through a respective hole of the plurality of holes.

In some embodiments, the pocket may be configured to provide clearance spacing between the emblem assembly and the cover. In some such embodiments, the pocket may comprise a plurality of ribs protruding from the pocket, wherein the plurality of ribs may be configured to space the emblem assembly apart from structure defining the pocket to provide the clearance spacing.

In some embodiments, one or more of the plates may comprise a PCB.

In some embodiments, the pocket may comprise an oversized slot configured to receive a ribbon cable coupled with the PCB. The oversized slot may be configured to dissipate heat generated from the PCB.

In a specific example of an emblem assembly according to some embodiments, the emblem assembly may comprise a decorative emblem; a plate having a plurality of holes formed therein; and a plurality of non-threaded fasteners extending from the decorative emblem. The fasteners may integrally extend from the decorative emblem in preferred embodiments. Each of the plurality of non-threaded fasteners may be configured to extend through a hole of the plurality of holes formed in the plate. The assembly may further comprise a clip configured to engage each of the plurality of non-threaded fasteners to secure the emblem assembly to an airbag cover and compress the plate between the decorative emblem and the airbag cover.

In some embodiments, each of the plurality of non-threaded fasteners may comprise an enlarged head. In some such embodiments, the clip may be configured to engage each of the plurality of non-threaded fasteners at a proximal surface of each of the enlarged heads. In some embodiments, each of the enlarged heads may extend only partially about a circumference of its respective non-threaded fastener, such as forming a semicircular enlarged head, for example.

In some embodiments, each of the enlarged heads may extend along about half of the circumference of its respective non-threaded fastener.

In an example of a method for installation of an emblem assembly to an airbag cover according to some implementations, the method may comprise steps of extending one or more fasteners, such as preferably one or more non-threaded fasteners, through a plate opening formed in one or more plates. The one or more fasteners may each extend, in some cases integrally, from a decorative emblem. The decorative emblem and the plate may be seated within a pocket formed in an airbag cover. The one or more fasteners may be extended through a cover opening formed in the pocket of the airbag cover. A clip may then be engaged to the non-threaded fastener, preferably at a distal surface of the pocket adjacent to the cover opening, to secure the decorative emblem to the airbag cover.

In some implementations, the decorative emblem and the plate may be a part of an emblem assembly. In some such implementations, the emblem assembly may be seated within the pocket so as to provide clearance spacing between the emblem assembly and an adjacent region of the pocket. The clearance spacing may be provided, in some embodiments and implementations, by way of one or more ribs, which may protrude from and/or be formed within the pocket.

In some implementations, the step of engaging the clip to the non-threaded fastener may comprise engaging a flexible prong of the clip to the non-threaded fastener. In some such implementations, the step of engaging the clip to the non-threaded fastener may comprise engaging two flexible prongs of the clip to two non-threaded fasteners of the decorative emblem and seating a third non-threaded fastener of the decorative emblem within a slot of the clip.

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.

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.

FIGS.1A and1Bdepict an airbag module100comprising an airbag cushion positioned within an airbag cover110. Cover110comprises a pocket115for receiving an emblem assembly120therein. Emblem assembly120comprises a decorative emblem125that may face towards a driver when airbag module100is positioned within a steering wheel and therefore comprises a driver airbag module100. As will be discussed in greater detail below, emblem assembly120may, in some embodiments, comprise a stack of various elements, such as plates, which may serve a variety of functions, including, for example, providing a light seal, facilitating heat dissipation, nesting the assembly within pocket115, and/or selectively allowing for light bleed in desired regions to provide a unique aesthetic and/or functional effect.FIG.1Afurther depicts a ribbon wire135, which, as discussed below, may extend from a PCB that may be a part of emblem assembly120and which may terminate in a connector136.

FIG.1Bdepicts cover110with emblem assembly120removed. As illustrated in this figure, pocket115comprises a plurality of ribs114protruding upward (towards the driver/occupant). As discussed in greater detail below, these ribs114may be used to provide increased spacing between various elements of emblem assembly120and cover110, such as between a PCB (not shown in this figure) and the lowermost surface of pocket115, to increase heat dissipation.

As also shown in this figure, various holes112may be formed, which may receive protruding fasteners for coupling the emblem assembly120to the cover110. These holes112may comprise an enlarged portion113, which may comprise a semicircle, which may couple with the other semicircle of each hole112along a ledge portion. As discussed in greater detail below, this feature may facilitate accommodation and locking of a unique head of the fasteners that will extend through each hole112to lock the emblem assembly120in place.

Finally,FIG.1Bfurther depicts the presence of a slot116. Slot116may be configured to receive one or more wires, such as a ribbon wire, that may be electrically coupled to a PCB for lighting one or more portions of the decorative emblem125and/or, in some embodiments, one or more portions of the surrounding parts of emblem assembly120. It is also contemplated, however, that in some embodiments, lighting may be provided by way of fiber optics rather than, or in addition to, LED lights or other lights, in which embodiments fiber optic cables may extend through slot116. As discussed in greater detail below, in some preferred embodiments, slot116may be oversized relative to the ribbon wire or the other wires, cables, and/or other elements extending therethrough, which may provide further heat dissipation.

FIG.2is a perspective view of airbag cover110from the opposite side, which would typically be the inner side—i.e., the portion facing the airbag cushion. This view illustrates how pocket115is depressed into the inner portion of the airbag cover110and depicts various other elements of the assembly from this perspective, including openings112having respective enlarged, semicircular regions113, and slot116.

FIG.3depicts this same view but with an emblem assembly clip140positioned adjacent to pocket115and its openings112. As discussed in great detail below, this clip is specifically configured to operate with a plurality of fasteners, each of which comprises a mushroom head in preferred embodiments, to both couple the emblem assembly to the pocket/cover and preferably to provide active tension to maintain a rigid coupling, in some cases a seal, between various components of the assembly, which may be useful to improve lighting conditions, such as by providing a suitable light seal to prevent unwanted light bleeding in desired regions. To this end, in the depicted embodiment, the clip140comprises a pair of flexible prongs142that, as discussed below, are configured to engage a corresponding portion of an adjacent fastener to secure the clip140in place, and thereby secure the entire emblem assembly120to the cover110. Clip140may be manufactured from a suitable metal, such as steel or aluminum, or a thermoplastic material, for example.

FIG.4is another perspective view from the same general position asFIGS.2and3. However,FIG.4depicts the presence of fasteners122extending through corresponding openings112in pocket115and engaging clip140. Fasteners122may, in preferred embodiments, comprise an integral part of the decorative emblem125of emblem assembly120. However, it is contemplated that, in alternative embodiments, fasteners122may instead be coupled to decorative emblem125and/or another portion of emblem assembly120. Preferably, fasteners122are non-deformable, which distinguishes them from the pins often used in known assemblies.

FIG.4illustrates the enlarged heads123of fasteners122. These enlarged heads123may, similar to the holes112through which fasteners122extend, comprise a semicircular-shaped, or at least substantially semi-circular shaped, region, which region may correspond in shape and/or extent to the respective enlarged, semicircular regions113of holes112. In this manner, the enlarged heads123of fasteners122may be configured to extend through holes112in only one rotational orientation, which may serve the benefit of, for example, ensuring that the decorative emblem125of emblem assembly120has the proper orientation within pocket115and with respect to cover110.

As also depicted inFIG.4, two of the three fasteners122(of course, more or fewer than three fasteners may be used in alternative embodiments) are directly coupled with a corresponding flexible prong142. The third fastener122of these three fasteners122is positioned within an elongated opening or slot of the clip140, the functionality of which will be explained in greater detail below in connection with enlarged views of these features.

FIG.4also depicts a ribbon wire135extending through preferably enlarged slot116formed in pocket115. As previously mentioned, ribbon wire135may terminate in a connector136, which may be used to connect a PCB, which may, in some embodiments, be a part of emblem assembly120, to a source of power and/or electrical signals for controlling the PCB and/or LEDs or other light sources of the emblem. In some embodiments, ribbon135may also comprise structural reinforcements and may therefore serve as a tether for affixing the door of the cover110to the emblem assembly120, which may improve the safety of the assembly100. Preferably, the cable ribbon135is configured to exit/extend from assembly120and/or from an opening in cover110at the 12:00 or 6:00 positions.

FIG.5is a cross-sectional view of the full emblem assembly120coupled within pocket115of cover110by way of clip140. Several important features and aspects of the assembly are depicted in this view. For example, this view best illustrates how fasteners122integrally extend from the decorative emblem piece125of emblem assembly120.

In addition, this view illustrates that emblem assembly120may, in preferred embodiments including the one depicted in this figure, comprise a plurality of stacked elements (plates, in this embodiment). More particularly, emblem assembly comprises a decorative plate126, a light diffuser plate130, and a PCB132. As illustrated inFIG.5, PCB132may, in some embodiments, be sandwiched between two (or more, or fewer) other layers, which may serve as further heat dissipation layers, if desired.

Decorative plate126may serve a variety of functions. For example, as shown inFIG.5, decorative plate126may be configured to seat and/or seal the assembly120to the cover110by, for example, providing a seating, sealing, and/or mating interface within pocket115. More specifically, decorative plate126comprises a mating surface or joint comprising one or more surfaces that are configured to match and/or mate with corresponding surfaces of pocket115.

Thus, in the depicted embodiment, decorative plate126comprises an angled surface128that is configured to mate, or at least substantially mate with and/or nest within, a corresponding angled surface118of pocket115. Similarly, decorative plate126comprises a second surface129, which is angled with respect to surface128and which is configured to mate with and/or nest within a second, corresponding angled surface117of pocket115. By providing such mating surfaces, in preferred embodiments along with a means for tensioning the assembly120within pocket115, such as clip140, lighting may be selectively controlled within the assembly. More specifically, unwanted light bleeding may be preventing, at least substantially prevented, or at least inhibited in this manner by providing one or more of these desirable features.

In some embodiments, the decorative plate126may comprise an opaque, or at least substantially opaque materials but may have transparent portions to selectively control the areas at which light should be allowed to pass through to the emblem125. In some embodiments, the back side of the decorative plate may be translucent, or at least substantially translucent, and the opposite side may be formed using opaque films and/or coatings to allow only certain regions, such as the perimeter/outline of the logo of emblem125, to be translucent and allow for selective lighting of the logo.

As also shown inFIG.5, ribs114are shown protruding from within pocket115and contacting the bottom element of emblem assembly120—in this case one of the layers of PCB132—to create space that may, for example, be used for heat dissipation from, for example, the electrical components of PCB132.

FIG.5also illustrates the coupling between clip140and fasteners122. More particularly, as the cross-section of this figure is taken through the two fasteners122that are positioned adjacent to the prongs142, these prongs142are shown abutting the enlarged heads123of fasteners122. Clip140can facilitate a tight engagement between the emblem assembly120and the pocket115of cover110, which, as mentioned above, can, in some embodiments in combination with other features described herein, provide tension to facilitate a desirable seal to prevent or at least reduce/inhibit light bleeding.

Clip140can also facilitate other desired features/functions, such as preventing or at least reducing BSR (buzz, squeak, rattle) during use. Clip140can also improve retention during airbag deployment. In some embodiments, clip140may be integrally molded or otherwise attached directly to the cover110.

FIG.7is a perspective view of clip140. As better seen in this figure, clip140comprises a pair of open-ended slots144, each lying adjacent to a respective flexible prong142. These slots144are each configured to receive a respective fastener, such as integral fasteners122, therein. Moreover, the open-ended configuration allows the clip140to be coupled to the fasteners122by sliding the clip in the direction of the respective open ends of slots144. The enlarged, semicircular heads123of fasteners122can thereby be seated with the proximally facing surface/ledge of these heads123seated against a respective distal-facing surface of clip140that defines a respective slot144.

Moreover, the adjacent prongs142, which may be resiliently biased away from the plane of the clip140in preferred embodiments, can each engage a respective fastener head123to lock the clip140, and thereby lock the emblem assembly, in place, as illustrated inFIG.7. Prongs142may extend from opposing sides of a centrally positioned tab145, as best shown inFIG.6.

At the opposite end of clip140, a closed-loop slot148is formed by a protruding neck146of the clip140. Slot148preferably narrows in width from the end closest to the open-ended slots144to the opposite end at which neck146terminates to define a fastener seat149for the third of the three fasteners122of the preferred embodiment depicted in the figures.

As shown inFIG.7, this allows for this third fastener122to extend through a wider portion of slot148, after which the clip140can be slid downward (from the perspective ofFIG.7) to seat the enlarged head123of this fastener122in the fastener seat149and, simultaneously, for the other two fasteners122to be seated in respective open-ended slots144.

In some embodiments, prongs142may be configured to engage a ledge124that faces in a direction parallel to the plane of the clip140, as also shown inFIG.7. In this manner, the clip140may be, following complete seating of each enlarged head123of each respective fastener122, prevented from being slid or translated in the opposite direction, which may otherwise release/unlock the clip140. In some contemplated embodiments, however, one or both prongs142may be configured to engage the lower surface/ledge of their respective enlarged fastener heads123to provide tension/force against the fasteners122in their respective insertion directions to thereby provide a compression force to maintain the emblem assembly tightly in its seated position within the cover pocket115. In either case, the preferably resiliently flexible nature of the prongs142may be beneficial to the function of the clip140.

FIG.8is a perspective view of the full emblem assembly120from the front of the assembly. This figure therefore depicts the decorative emblem125that may face towards a driver when the airbag module to which emblem assembly120is coupled is positioned, for example, within a steering wheel. One of the fasteners122, along with its enlarged head123, is also shown in this figure. Ribbon wire135is shown extending from the emblem assembly120and terminates in connector136.

FIG.9is an exploded view of the emblem assembly120. As best seen in this view, emblem assembly120comprises a stack of various plates. In particular, a decorative plate126is shown positioned at the top of the stack adjacent to the decorative emblem125. This piece, like each of the other pieces/plates of the stack, comprises a series of openings configured to receive the fasteners122that extend from the decorative emblem125. Preferably, each of these openings comprises a semicircular enlarged region corresponding with the enlarged region of the fasteners122to facilitate proper assembly and rigid coupling between the various elements of the assembly.

Decorative plate126is, as previously discussed, preferably configured to seat and/or seal the assembly120to the cover110by, for example, providing a seating, sealing, and/or mating interface within the aforementioned pocket115of the cover110. In some embodiments, decorative plate126accomplishes this by providing a mating surface or joint comprising one or more surfaces that are configured to match and/or mate with one or more corresponding surfaces of the pocket115. This may provide a light seal to prevent, or in some cases selectively permit in certain desired regions, light bleed to provide a unique aesthetic and/or functional effect.

Beneath the decorative plate126, a light diffuser plate130may be present in the stack/assembly120. Light diffuser plate130may be configured to disperse the lighting from one or more LEDs131, which may be discrete, to a more uniform distribution such that, when the light from the LEDs131or other light source transmitted into the decorative plate126, the light is homogeneous, or at least more homogenous. Thus, preferably light diffuser plate130is manufactured from a translucent, or semi-translucent material. In some embodiments, the LEDs131may be at least partially positioned within slots or openings formed in the light diffuser plate130, which may further facilitate this light diffusing process.

Finally, at the bottom of the stack/assembly120, a PCB132may be present, which may provide the power and/or signals to the LEDs131and/or other light sources. As previously mentioned, PCB132may, in some embodiments, be sandwiched between two or more other layers, which may serve as further heat dissipation layers, if desired. Again, a ribbon wire135may extend from the PCB132layer, which ribbon wire135may terminate in a plug/connector136. As shown inFIG.9, each of the various plate layers of the assembly preferably comprises openings to receive the fasteners122, preferably along with corresponding alignment features, such as the aforementioned widened regions that are also depicted in the figure, to ensure proper assembly and provide a secure coupling.

FIGS.10and11depict decorative plates according to alternative embodiments.FIG.10, for example, depicts a decorative plate226comprising an inner region228, an outer region229, and an outline region227. Outline region227may correspond with the outline of the decorative emblem (not shown) on the outermost layer of the assembly, as previously shown and discussed. In the depicted embodiment, the outline region227may be relatively translucent compared to the inner region228and the outer region229. By selecting configuring certain regions with higher translucency than others, unique lighting effects may be created, such as creating a “halo”-like outline about the periphery of a decorative emblem and/or words, for example.

In some embodiments, plate226may be formed from a translucent, or relatively translucent, material, in which case this effect may be created by using an opaque film or coating, such as, for example, a PVD film. In other words, the outline region227may be created by leaving this region uncoated and/or lacking the opaque film. The inner and outer regions228/229may be formed using the same coating/film to create the same translucency or, in some embodiments, one of these regions may be intentionally formed with a higher translucency than the other. For example, the outer region229may be less translucent than the inner region228, to highlight the logo/emblem, or vice versa, which may, for example, create a unique background for the emblem. Varying amounts of translucency may be created, for example, by varying the thickness, such as the number of coats or layers, of the applied film/coating. Of course, in alternative embodiments, the plate226may be formed from a relatively opaque material or a material having an opaque film/coating, in which case regions of higher translucency may be created by etching away this opaque film/coating in desired regions, such as the outline region227ofFIG.10.

Decorative plate226may otherwise be similar or identical to decorative plate126and may therefore comprise, for example, openings232comprising enlarged regions233for receiving a corresponding enlarged region of respective fasteners, as previously discussed.

FIG.11depicts a decorative plate326according to another alternative embodiment. In this embodiment, decorative plate326comprises an inner region328and an outer region329. Inner region328may be translucent, or at least more translucent, than outer region329. Again, this may be accomplished in any of the ways previously mentioned. For example, inner region328may be etched away to reveal a more translucent region of the plate326. Alternatively, plate326may be formed from a translucent material and one or more layers, films, and/or coatings may be applied to outer region329in order to render this portion of the plate326less translucent.

FIG.12depicts an airbag module400comprising an airbag cushion positioned within an airbag cover410according to other embodiments. Like cover110, cover410comprises a pocket415for receiving an emblem assembly420therein. Emblem assembly420again comprises a decorative emblem425that may face towards a driver when airbag module400is positioned within a steering wheel and therefore again comprises a driver airbag module400.

As previously discussed, emblem assembly420may, in some embodiments, comprise a stack of various elements, such as plates, which may serve a variety of functions, including, for example, providing a light seal, facilitating heat dissipation, nesting the assembly within pocket415, and/or selectively allowing for light bleed in desired regions to provide a unique aesthetic and/or functional effect.FIG.12further depicts a ribbon wire435, which, again, may extend from a PCB that may be a part of emblem assembly420and which may terminate in a connector436.

However, unlike airbag module100, airbag module400comprises a groove411formed in the exterior surface of cover410, which may be configured to allow ribbon wire435to nest therein. This provides a possible alternative route for the cable ribbon435in between an outer cover405, which may be, for example a leather cover, which may be positioned adjacent to a molded substrate of the cover410. The ribbon435may therefore be loaded from the A-surface prior to leather-wrapping, which may address process/design concerns regarding routing of the ribbon435within the cushion environment, affixation of the ribbon435to the cover410, and/or how the ribbon435is routed thru/around structural features of the cover410, which can help reduce or eliminate structural issues regarding the ribbon.

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.