Airbag mounting assemblies with double-locking wrappers

Mounting assemblies can be used to retain an inflatable curtain airbag in a packaged configuration and attach the inflatable curtain airbag to a vehicle structure. The mounting assemblies can have a mounting structure and a wrapper that are both coupled to inflatable curtain airbag. The mounting structure is attached to a vehicle structure and the wrapper wraps and retains the inflatable curtain airbag in a packaged configuration. During airbag deployment, the wrapper releases the airbag so that the airbag can adopt a deployed configuration, wherein the mounting structure continues to anchor the inflatable curtain airbag to the vehicle structure.

TECHNICAL FIELD

The present disclosure relates generally to the field of automotive protective systems. More specifically, the present disclosure relates to mounting assemblies with wrappers and related methods.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

It will be readily understood that the components of the 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 more detailed description of various embodiments, as represented in the figures, is not intended to limit the scope of the disclosure, as claimed, but is merely representative of various embodiments. While the various aspects of the embodiments are presented in drawings, the drawings are not necessarily drawn to scale unless specifically indicated. Further, analogous structures or features in different depicted embodiments are identified with like reference numerals, with a leading hundreds numeral incremented to a higher value.

Inflatable airbag systems are widely used to minimize occupant injury in a collision scenario. Airbag modules have been installed at various locations within a vehicle, including, but not limited to, the steering wheel, the instrument panel, within the side doors or side seats, adjacent to the roof rail of the vehicle, in an overhead position, or at the knee or leg position. In the following disclosure, “airbag” may refer to an inflatable curtain airbag110, overhead airbag, front airbag, or any other airbag type.

Inflatable curtain airbag110may be used to protect the passengers of a vehicle during a side collision or roll-over collision. Inflatable curtain airbag110typically extend longitudinally within the vehicle and are usually coupled to or next to the roof rail of the vehicle. The inflatable curtain airbag110may expand in a collision scenario along the side of the vehicle between the vehicle passengers and the side structure of the vehicle. In a deployed state, an inflatable curtain airbag110may cover at least a portion of side windows and a B-pillar of the vehicle. In some embodiments, inflatable curtain airbag110may extend from an A-pillar to a C-pillar of the vehicle. In other embodiments, inflatable curtain airbag110may extend from the A-pillar to a D-pillar of the vehicle.

Inflatable curtain airbag110is typically installed adjacent the roof rail of a vehicle in an undeployed state, in which the inflatable curtain airbag110is rolled or folded or a combination thereof and retained in the folded or rolled configuration by being wrapped at certain points along the airbag. In this state, the airbag may be said to be in a packaged configuration. When deployed, the airbag exits the packaged configuration and assumes an extended shape. The extended and inflated airbag may be said to be in a deployed configuration. Thus, an airbag mounting apparatus typically allows for a secure connection between the vehicle and the airbag, yet allows the airbag to change configurations from the packaged configuration to the deployed configuration.

FIG. 1Adepicts airbag assembly100from a perspective view, wherein a mounting assembly120is coupled to an inflatable curtain airbag110that is in a packaged configuration, and is mounted adjacent a roof rail12of a vehicle. Airbag assembly100may comprise an inflatable curtain airbag110, and an airbag mounting assembly120. A plurality of mounting assemblies120may be employed to couple curtain airbag110to a vehicle. Mounting assembly120may comprise a mounting member130and a wrapper140. Mounting assembly120may be employed to couple inflatable curtain airbag110adjacent a vehicle roof rail12, or other vehicle structure. Airbag assembly100may further comprise an inflator (not shown). In the depicted embodiment, inflatable curtain airbag110extends from an A-pillar14to a D-pillar19. Inflatable curtain airbag110also extends past a B-pillar16and a C-pillar18such that in a deployed configuration, the inflatable curtain airbag at least partially covers the B- and C-pillars, as depicted inFIG. 1B.

FIG. 1Bis a perspective view of inflatable curtain airbag assembly100, wherein the airbag is depicted in a deployed configuration. Inflatable curtain airbag110is configured to become inflated upon activation of one or more inflators such that the airbag transitions from the packaged configuration to the deployed configuration. During deployment, wrapper140is configured to rupture such that inflatable curtain airbag110can adopt the deployed configuration. In the deployed and in an extended configuration, such as before rolling and/or folding, inflatable curtain airbag110may be described as having an upper portion111, a lower portion112, a front face113, and a rear face (not visible). The various faces of inflatable curtain airbag110define an inflatable void118, which is in fluid communication with an inflator (not visible). Inflatable void118may be divided into inflation cells119via stitching. The various faces of inflatable curtain airbag110may comprise panels of a woven nylon fabric that are coupled together at a seam to form the inflatable void.

Upper portion111of inflatable curtain airbag110is the portion of the airbag that is closest to the headliner of a vehicle when the airbag is in a deployed state. Lower portion112is below upper portion111when inflatable curtain airbag110is in a deployed state, and is closest to a floor of the vehicle. The term “lower portion” is not necessarily limited to the portion of inflatable curtain airbag110that is below a horizontal medial plane of the inflatable curtain airbag, but may include less than half, more than half or exactly half of the bottom portion of the inflatable curtain airbag. Likewise, the term “upper portion” is not necessarily limited to the portion of inflatable curtain airbag110that is above a horizontal medial plane of the airbag, but may include less than half, more than half or exactly half of the top portion of the airbag.

Upon activation, the inflator rapidly generates and/or releases inflation gas, which rapidly inflates the inflatable curtain airbag110. The inflator may be one of several types, such as pyrotechnic, stored gas, or a combination inflator and may comprise a single or multistage inflator. As inflatable curtain airbag110becomes inflated, tension is applied to wrapper140, which causes the wrapper to rupture, and therefore, cease to retain the airbag in the packaged configuration.

As will be appreciated by those skilled in the art, a variety of types and configurations of airbag inflatable curtain airbags can be utilized without departing from the scope and spirit of the present disclosure. For example, the size, shape, and proportions of the inflatable curtain airbag may vary according to its use in different vehicles or different locations within a vehicle. Also, the inflatable curtain airbag may comprise one or more of any material well known in the art, such as a woven nylon fabric. Additionally, the airbag inflatable curtain airbag may be manufactured using a variety of techniques such as one piece weaving, cut and sew, or a combination of the two techniques. Further, the inflatable curtain airbag may be manufactured using sealed or unsealed seams, wherein the seams are formed by stitching, adhesive, taping, radio frequency welding, heat sealing, or any other suitable technique or combination of techniques.

FIG. 2depicts airbag assembly100from an exploded perspective view in which inflatable curtain airbag110is partially cutaway. Mounting assembly120may comprise mounting member130and wrapper140. Mounting member130may comprise a flexible fabric, such as a woven nylon material. In one embodiment, the mounting member may comprise a nylon monofilament, such as seat belt webbing. Mounting member may comprise more than one layer of fabric. In the depicted embodiment, mounting member130comprises a rectangular piece of seat belt webbing. Mounting member130has a mounting aperture132, a front side133, a rear side (not visible), a top portion135, and a bottom portion136. The mounting aperture132is located on the top portion135. Mounting aperture132is configured to receive a fastener, such as a bolt or a mounting structure coupled to the vehicle that protrudes through the aperture. Top and bottom portions135and136refer to an approximate upper half and lower halves, respectively, when mounting member130is in the same orientation as depicted inFIG. 2.

By way of example, and not of limitation, mounting member130may comprises a width W1that is within a range of from about 40 mm to about 80 mm, and a length L1that is within a range of from about 80 mm to about 150 mm. A center of aperture132is located within a range of from about 20 mm to about 30 mm from a top edge of top portion135. One skilled in the art will recognize that the width and length of the mounting member may be varied for use with different vehicles, wrappers, or airbags. In the depicted embodiment, W1is 48 mm, L1is 100 mm, aperture132is 25 mm from the top edge of top portion135, and stitching122is 40 mm from the top edge of top portion135.

One skilled in the art will also recognize that a variety of types of fabrics may be used to form the mounting member without departing from the spirit of this disclosure. In another embodiment, the mounting member may comprise any one of a variety of materials, such as a thermoplastic material or other polymer. Likewise, the mounting member may comprise a variety of shapes. For example, the mounting member may be square, triangular, round, trapezoidal, or pentagonal. Further, the mounting member may comprise more or fewer apertures than described herein. For example, in one embodiment, the mounting member comprises two mounting apertures, and in another embodiment, the mounting member comprises three mounting apertures. Further, the location of the apertures may vary from the depiction ofFIG. 2.

Wrapper140may comprise a rectangular piece of a frangible material, such as a non-woven nylon, polypropylene, or a plastic film. Wrapper140has a first half141and a second half142. First half141is configured such that it can be attached to mounting member130via stitching122. Second half142has a first opening145and a second opening146, which are each configured as an elongated slot. Openings145and146may each comprise a cutout portion of wrapper140, or a slit cut into the wrapper. First and second openings145and146are each configured to receive, or slide over, mounting member130and thereby retain airbag assembly100in the packaged configuration. As such, a length of wrapper140and a width of each of the openings145and146are of predetermined magnitudes and may vary according to their use with different airbags. Generally, first and second openings145and146may each be about the same as the width of mounting member130(W1). Wrapper140also comprises a portion147that is located between first and second openings145and146.

As noted herein, wrapper140is configured to fail during airbag110deployment since wrapper140comprises a frangible material, the wrapper may rupture at any point; however, when deployed from the packaged configuration, wrapper140is most likely to rupture at first opening145. As such, when curtain airbag110is packaged in a predetermined manner, predetermined deployment characteristics such as trajectory and speed can be consistently achieved. Wrapper140is configured to be completely severed such that after airbag110deployment, the wrapper comprises two separate pieces of material. In another embodiment, the wrapper may comprise a predetermined rupture point that may be defined by perforations, tear stitching, or a portion of the wrapper that is weakened in some manner.

Mounting member130and wrapper140may be attached together independent of an airbag; thus, when coupled together, the mounting member and wrapper may be called a mounting assembly. The coupled mounting member and wrapping member may also be called a sub-assembly of an airbag assembly. Mounting assembly120is configured to be attached to an airbag cushion via stitching124, which may extend through airbag cushion110, wrapper140, and mounting member130. As such, stitching122, which is employed to attach mounting member130to wrapper140may comprise a tack stitch.

By way of example, and not of limitation, a width W2of wrapper140may be between about 60 mm and about 100 mm, a length L2may be between about 145 mm and about 175 mm, stitching122may be between about 3 mm and about 10 mm from a top edge of first half141, a center of first opening145may be located between about 85 mm and about 105 mm from the top edge of the first half, and a center of second opening146may be located between about 135 mm and about 155 mm from the top edge of the first half. In the depicted embodiment, W2of wrapper140is 75 mm, L2is 160 mm, stitching122is located 5 mm from the top edge of first half141, first opening145is 95 mm from the top edge of the first half, second opening146is 148 mm from the top edge of the first half, and a width of each of the first and second openings is 48 mm.

For clarity, inflatable curtain airbag110is cutaway inFIG. 2. Curtain airbag110has been manipulated into a rolled configuration and oriented such that top portion111is turned downward, and rear face114is facing forward. In the rolled configuration, airbag110has an outer surface115, which may be defined by the front face of the airbag. Top portion111of inflatable curtain airbag110may be coupled to mounting assembly120at first half141of wrapper140. Inflatable curtain airbag110may be coupled to the assembly at a non-inflatable portion, such as an area outside of seam117. As noted above, inflatable curtain airbag110may be coupled to mounting assembly120via stitching124, which protrudes through wrapper140and mounting member130. If mounting member120and wrapper130are not attached together as a sub-assembly before being coupled to airbag110, airbag assembly100may not comprise both stitching122and124, but rather may only comprise one set of stitching that couples together the airbag, the wrapping member, and the mounting member.

FIGS. 3A-Bdepict airbag assembly100being manipulated into the packaged configuration, starting at a point after airbag110has been coupled to mounting member130and wrapper140. Collectively,FIGS. 2-4, and their associated text, may be said to comprise a method for manufacturing an inflatable curtain airbag assembly, a method for manufacturing a mounting assembly, a method for packing an inflatable curtain airbag, a method for coupling an inflatable curtain airbag to a vehicle, and any combination of the preceding methods.

FIG. 3Ais a perspective view of airbag assembly100, wherein inflatable curtain airbag110has been partially cutaway. Rolled airbag110, mounting member130and wrapper140are coupled together via stitching122and124. As depicted in the view ofFIG. 3A, airbag110is most forward, mounting member130is most rearward, and wrapper140is sandwiched between them. These components are assembled in a predetermined orientation such that second half142of wrapper140, with first and second openings145and146, extends beyond mounting member130and airbag110, such that the second half can be directed away from mounting member130in the direction of airbag110. Wrapper140may continue to be wrapped around outer surface115of airbag110until first opening145is adjacent to the top portion of mounting member130.

FIG. 3Bis a cutaway perspective view of airbag assembly100ofFIG. 3Aafter wrapper140has been wrapped around outer surface115of inflatable curtain airbag110and is being coupled to mounting member130. Second half142of wrapper140may continue to be directed toward mounting top portion135of mounting member130until first opening145is adjacent to, and aligned with, the top portion of the mounting member. First opening145may be slid over top portion135such that first opening145receives top portion135and such that second opening146of wrapper140is located on the rear-face side of mounting member130. Second half142may then be pushed down toward airbag110and first half141. Second half142and specifically, second opening146may continue to be wrapped toward the back face of mounting member130in the direction of bottom portion136, such that portion147, which is located between openings145and146, is adjacent to the rear face of the mounting member.

FIG. 4is another cutaway perspective view of airbag assembly100ofFIG. 3Bafter inflatable curtain airbag110has been wrapped and retained in a packaged configuration. The view ofFIG. 4is from a lower perspective thanFIGS. 3A-Bsuch that relationships between mounting member130and wrapper140are visible. Second opening146of wrapper140has been slid over bottom portion136of mounting member130such that the second opening has received the bottom portion and second half142of the wrapper is retained on the mounting member. Second half142of wrapper140partially overlaps first half141, but is separated by mounting member130. In the depicted embodiment, bottom portion136of mounting member130has squared corners with right angles and no features to aid the retention of second half142of wrapper140on the bottom portion of the mounting member; however in another embodiment, the bottom portion of the wrapping member may comprise features to aid in the retention of the wrapper. For example, in one embodiment, the sides of the bottom portion of the mounting member comprises indentations into which the second opening of the wrapper can fit and thereby be retained.

Wrapper140retains airbag110by circumnavigating the rolled airbag, wherein the wrapper abuts outer surface115. Wrapper140may determine the circumference of rolled airbag110, or alternatively, the circumference of the rolled airbag may determine the length of the wrapper. Wrapper140may fit snugly around airbag110such that the wrapper applies a squeezing pressure to the airbag. Mounting member130is depicted as having a bolt126projecting into and through the mounting aperture, which is located on top portion135of the mounting member. When mounted in a vehicle, gravity may tend to exert a downward force on assembly100; however, because wrapper140is coupled to mounting member via the two wrapper openings, wrapper140does not tend to tighten or “creep” on airbag110.

FIGS. 5A and 5Bare cross-sectional views of airbag assembly100, whereinFIG. 5Adepicts the assembly before the inflatable curtain airbag110has been rolled and wrapped andFIG. 5Bdepicts the assembly in the packaged configuration. Mounting member130comprises front side133, back side134, top portion135, which has mounting aperture132, and bottom portion136. Wrapper140comprises first half141that is coupled to mounting member130via stitching122to form mounting assembly120. The wrapper also has a second half142, which extends below rolled airbag110and has first opening145and second opening146. Portion147is located on second half142, between first and second openings145and146. Upper portion111of inflatable curtain airbag110is coupled to first half141of wrapper140via stitching124.

In the depiction ofFIG. 5B, airbag assembly100is in the packaged configuration. Wrapper140has been wrapped around the outer surface of rolled inflatable curtain airbag110. First opening145in second half142has been placed over top portion135of mounting member130. First opening145may receive part of first half141as well as mounting member130. Second opening146in second half142has been placed over bottom portion136of mounting member130. As such, first half141of wrapper140is attached on front side133of mounting member130; portion147, located between openings145and146on second half142of wrapper140, is located on back side134of mounting member130; and an end portion148of second half142is located on front side133.

FIG. 6depicts another embodiment of a mounting assembly220from a front elevation view. Mounting assembly220may be configured similarly and may function similarly as mounting assembly120, described herein. Mounting assembly220may comprise a mounting member230and a wrapper240. Mounting member230may comprise a woven nylon fabric, such as seatbelt webbing, which is configured such that the mounting member comprises a top portion235and a bottom portion236. Top portion235may comprise one or more mounting apertures232.

Wrapper240comprises a non-frangible material with a first half241and a second half242, wherein the first half is coupled to mounting member230via stitching222. Wrapper240is configured to function similarly as wrapper140, described herein. As wrapper240is non-frangible, a rupture point244may be introduced into the wrapper. In the depicted embodiment, rupture point244comprises perforations; however, in other embodiments, the rupture point may comprise a tear seam or a weakened portion of the wrapper. Rupture point244is located at a predetermined position, such that during deployment, an inflatable curtain airbag wrapped by the wrapper will follow a predetermined deployment trajectory. Wrapper240has a first opening245and a second opening246, wherein first opening245is configured to receive top portion235of mounting member230and second opening246is configured to receive bottom portion236of the mounting member, as described herein for openings145and146.

The mounting assemblies disclosed herein may be attached to the airbag cushion at predetermined locations by employing a variety of mechanisms and/or techniques which are well known in the art. In one embodiment, the mounting assembly and airbag may be placed on a work table that has features that aid the working in placing the mounting assembly on the airbag at the predetermined location. The mounting assembly itself may comprise assembly aids, which allow the mounting assembly to be located at a predetermined location on the airbag. In one embodiment, bottom portion236of mounting member230and first half241of wrapper240may comprise one or more assembly aids250. In the depicted embodiment, the assembly aids comprise apertures250. Apertures250are located in predetermined locations on mounting member230and wrapper240such that when the mounting member and wrapper are coupled together, the apertures overlap. Apertures250may be employed in conjunction with a feature located on the inflatable airbag, such that the feature on the cushion may be viewed through the apertures when the mounting assembly is correctly located on the cushion.

FIG. 7is a front elevation view of another embodiment of an airbag mounting assembly320, wherein the mounting assembly comprises an integrated mounting member330and wrapper340. Mounting assembly320may be called a one-piece mounting assembly. One skilled in the art will recognize that although the embodiment depicted inFIG. 7is not an “assembly”of disparate parts, it is another embodiment of the mounting assemblies described herein. Mounting assembly320may also be called an integrated mounting member and wrapper; or an airbag mounting and wrapping unit. Mounting member portion330of the one-piece mounting member/wrapper320may comprise a mounting aperture332that is located on top portion335. Bottom portion336of mounting member portion330may terminate in a slot338that defines a terminus339of mounting member portion330. Terminus339is configured to receive second opening346of wrapper portion340, when mounting assembly320is retaining an airbag in a packaged configuration. Shoulder portions337define contiguous extensions of the material from which mounting assembly is formed, wherein the shoulder portions connect mounting member portion330with wrapper portion340.

Wrapper portion340may be configured similarly and may function similarly as wrappers140and240, described herein. Wrapper portion340may comprise a first opening345, a second opening346, a portion347that is located between the first and second openings, a rupture point344, and an end portion348. First opening345, second opening346, portion347, and rupture point344may be configured similarly as analogous structures described herein. Rupture point344may comprise perforations that are located between slot338and first opening345. End portion348may be configured similarly as analagous end portions, described herein; however end portion348may have a different orientation when in a packaged configuration compared to analogous end portions described herein.

Mounting assembly320may comprise multiple layers of material formed by folding a contiguous piece of material one or more times or by sewing disparate pieces of material togethers. In one embodiment, the multiple layer portion extends from the top edge of the top portion of the mounting member to below the shoulder portions. In another embodiment, the multiple layer portion extends below the slot in the mounting member portion. In another embodiment, the multiple layer portion extends to a location just above the rupture point, which may be located in a different location than depicted inFIG. 7.

One skilled in the art will recognize that a variety of configurations of one-piece mounting assemblies may be employed without diverging from the spirit of the present disclosure. For example, the mounting portion may be any suitable shape, and is not restricted to the rectangular shape of the depicted embodiment. Also, the shoulder portions may vary from the depicted embodiment; for example, the shoulder portions may be rounded, or may comprise squared edges with substantially right angles. Further, in some embodiments, the shoulder portions may not be present at all. For example, in one embodiment, the width of the mounting portion is similar to the width of the wrapper portion, such that shoulder portions are not apparent. In such an embodiment, the one-piece mounting assembly may still comprise a flexible portion that is located adjacent to the slot.

FIG. 8is a cross-sectional view of airbag mounting assembly320ofFIG. 7, wherein the mounting assembly is coupled to an inflatable curtain airbag310and is retaining the airbag in a packaged configuration. In the depicted embodiment, mounting assembly320is coupled to an inflatable curtain airbag310via stitching324, such that the airbag and mounting assembly comprise an inflatable airbag assembly300. Mounting member portion330comprises a top portion335, a bottom portion336, which comprises a terminus. Wrapper portion340comprises a rupture point344, a first opening345, a second opening346, a portion347that is between the first and second openings, and an end portion148. In the depiction ofFIG. 8, inflatable curtain airbag310is in a rolled configuration and is retained in the rolled configuration by wrapper portion340.

Wrapper portion340may be retained in a packaged configuration by first opening345being placed over top portion335of the wrapper portion, and second opening346being placed over bottom portion336of mounting member portion330. Rupture point344is located at a predetermined position such that during inflatable curtain airbag deployment, the rupture point aids in the airbag achieving a predetermined trajectory. As described herein, the mounting members and mounting member portions may comprise more than one layer of material, wherein the additional layers of material end before the wrapper or the shoulder portions of the one-piece mounting assembly. In the embodiment depicted inFIGS. 7-8, wrapper portion340may flex or bend at shoulder portion337, as well as along the length of wrapper portion340.