Tethered cover airbag system

Abstract: An airbag system for motor vehicles (20) and the like includes an inflatable airbag (38) contained in a housing (36) having a protective cover (40) normally closing a panel (30) opening (32) aligned with an open end of the airbag housing (36). The cover (40) is bodily movable away from the opening (32) during deployment of the airbag (38) and a flexible tether (60) is interconnected between the cover (40) and the panel (30) or the housing (36) for limiting the travel of the cover (40) away from the panel opening (32) during deployment. The cover (40) includes an integral outer skin (44) and inner skin (46) folded over and spaced therefrom having slots (73) to permit passage of tethers (60) into a space formed between the skins (44,46) and eventually filled with foam. An anchor (70) in the form of an elongated element is placed between the skins (44,46) and the tether (60) and is secured to the anchor (70) for spreading the load exerted by the tether (60) over a wide area of the cover (40) to prevent fracturing or breakage thereof. After the anchor (70) and tether (60) are in place, the inner and outer skins (44,46) are secured together along an edge in a heat staking operation.

Description: The present invention relates to a tethered cover for an airbag system and more particularly to a tethered cover which is bodily movable away from a panel opening upon airbag deployment and which is positively retained by the tether so that injury from the cover to occupants or damage to parts of the vehicle does not occur in an emergency airbag deployment. EP-A-0 695 670 describes an airbag system comprising : cover means normally closing a panel opening in said vehicle adjacent said open end of said housing for protecting said airbag, said cover means movable to uncover said opening during deployment of said airbag; flexible tether means interconnected between said cover means and at least one of said panel means and said housing means for limiting the movement of said cover means away from said panel means upon inflatable deployment of said airbag; said cover means including an integral outer and an inner skin folded over along an edge portion, said inner skin having slot means formed to permit passage of said tether means into a space formed between said skins; and anchor means in said space, comprising an elongated bar formed of stiff material and engaging said tether means for securing the same to said cover means. It is an object of the present invention to provide a new and improved tethered cover for an airbag system in motor vehicles and the like and more particularly to provide a tethered cover system which positively retains the cover after opening upon airbag deployment. The present invention relates to a new and improved tether and cover combination for an airbag system which caracterises in that the outer skin of the cover means is formed with one or more support members extended toward said inner skin in said space for engaging said anchor means to position the same. U.S. Patent No. 5,195,776 to Sakakida et al. discloses an airbag installation having two curved airbag cover lids which are reliably opened by rotation about a center point so as not to restrict the inflation of the airbag. When the airbag inflates, a bent portion connecting each lid to a casing is deformed to extend outwardly of the instrument panel. The Rogers et al., U.S. Patent No. 5,332,257 discloses an airbag system comprising a tether tethering a cover to an airbag module. A bar passes through a loop of the tether and is secured to the cover by rivets. U.S. Patent No. 3,822,894 to Muller et al. discloses a steering wheel having a built-in air cushion employing a strong hinge between a cover and a dish containing the airbag so that on inflation, the cover is pushed away but not completely liberated from attachment to the steering wheel. The Wulf et al., U.S. Patent No. 3,944,250, discloses an automatically inflatable gas cushion for the protection of passengers in vehicles employing a cover which is opened upon inflation of the airbag or gas cushion and which is retained by a flexible band so that the cover is restrained after opening. The DiSalvo et al., U.S. Patent No. 4,893,833 discloses a closure for an airbag deployment opening wherein an integral aluminum hinge flange on the closure is bolted to the frame of the vehicle permitting pivotal opening movement of the closure. The Hirabayashi, U.S. Patent No. 4,911,471, discloses an arrangement of an airbag device in a motor vehicle wherein angular pivotal movement of a door over the airbag is restricted by a strap to limit the angular degree of opening when the airbag is inflated. U.S. Patent No. 4,964,653 to Parker discloses a self-skinned foam closure element for an inflatable restraint door assembly having a combination hinge and tether for restraining travel of the closure element during airbag deployment. U.S. Patent No. 5,064,217 to Shiracki discloses a cover for an airbag unit having "Nylon" yarn bands molded in place and wrapped around a retaining band of resin provided on the airbag enclosure or housing. U.S. Patent No. 5,150,919 to Sakakida et al. discloses an airbag system for a vehicle having a pair of doors or lids which pivotally open in opposite direction and which are restrained by belt members so that the lids pivot about transverse axes and open smoothly upon airbag deployment. U.S. Patent No. 5,072,967 to Batchelder et al. discloses an instrument panel having an invisible airbag deployment door with weakened sections formed therein but hidden from view for facilitating fracture of the door along predetermined lines for opening movement during airbag deployment. The Combs et al., U.S. Patent No. 5,096,221, discloses an airbag door having plural substrates on the inside which normally retain the door in a closed position and at least one of which is notched or provided with a hidden tear seam to facilitate fracture for opening of the door. The Catron et al., U.S. Patent No. 5,211,421, discloses an airbag cover door retainer having bifurcated engagement franges on the door normally retaining the door in a closed position and releasable to permit door opening during airbag deployment. The Fujiwara et al., United States Patent No. 5,199,739, discloses an airbag cover opening mechanism for a motor vehicle including a sheer pin which is severed upon opening pressure exerted on the inside of the door by the deploying airbag. The Wang, United States Patent No. 5,219,177, discloses a releasable latch for an airbag deployment door which is activated by airbag deployment to permit the door to open. U.S. Patent to Faigle et al. No. 5,242,191, discloses a tethered airbag cover system wherein the cover is retained after opening attached to the airbag itself. European Patent Application No. EP 0 415 362 A2 discloses an airbag supporting system having two fly-away covers restrained by loose flexible straps. German Patent No. DE 38 43 686 A1 discloses an airbag cover for a car which is retained in one piece in relation to the dashboard of the automobile by a retaining hinge element. It is another object of the present invention to provide a new and improved airbag cover wherein integral inner and outer skins of the cover are spaced apart and an anchoring element is mounted between the skins with a tether element looped around the element to spread the load exerted by the tether over a substantiel area of the cover so that fracturing and/or séparation of the cover from the tether does not occur. Still another object of the present invention is to provide a new and improved airbag system having a cover in which inner and outer skins are formed in one molded piece, which piece is subsequently folded over and subjected to a heat staking opération for securing the inner skin in place after a tether and anchor element have been installed between the inner and outer skins. For a better understanding of the present invention, reference should be had to the following detailed description taken in conjonction with the drawings, in which: FIG. 1 is a longitudinal cross-sectional view of a motor vehicle illustrating a tethered cover airbag system in accordance with the present invention and shown with the cover in place on a panel opening while the bag is in deflated condition; FIG. 2 is a longitudinal cross-sectional view similar to FIG. 1 but illustrating the airbag in a deployed position with the cover open but retained by the tether a limited distance away from the panel opening; FIG. 3 is an underside view of a cover in accordance with the features of the present invention; FIG. 4 is an enlarged, fragmentary cross-sectional view similar to that of FIG. 1 showing the cover in place closing the panel opening and the airbag in a deflated condition therebelow ready for deployment; FIG. 5 is a transverse cross-sectional view through a mold utilized for molding an integral outer and inner skin of the cover in accordance with the present invention; FIG. 6 is an enlarged, transverse cross-section of the tethered cover in accordance with the present invention illustrating the inner and outer skins in readiness for a heat staking operation; FIG. 7 is an underside view of the cover taken substantially along lines 7-7 of FIG. 6; and FIG. 8 is an underside view of the tethered cover taken substantially along lines 8-8 of FIG. 6. DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION Referring now more particularly to the drawings, in FIGS. 1-2 is illustrated a motor vehicle 20 having a passenger compartment 22 for accommodating a person 24 in seated position on a vehicle seat 26. Forward of the occupant 24, the vehicle 20 includes a dashboard 28 and a panel 30 having an enlarged opening 32 spaced directly above an airbag and inflator assembly generally indicated by the reference numeral 34. The airbag and inflator assembly 34 includes a housing or canister 36 fixedly mounted in place beneath the panel 30 and the opening 32. An airbag 38 in deflated condition is stored and contained within the housing 36 until deployed as illustrated in FIG. 2 to protect the vehicle occupant 24 from injury in an accident. The panel opening 32 is normally closed by a movable cover 40, which as shown in FIGS. 1 and 4 forms part of the upper surface of the panel 30 above the opening 32. When the airbag 38 is inflated during a crash or emergency and expands outwardly, the cover 40 is rapidly moved away from the panel opening 32 permitting the expanding airbag to rapidly inflate as shown in FIG. 2. When airbag deployment occurs, the cover 40 if otherwise untethered or unrestrained could bounce off a windshield 42 or other interior surface in passenger compartment 22. The cover 40 includes an outer skin 44 and an inner skin 46 integrally formed in a single piece and thereafter folded over along a forward edge 47 (FIG. 6). The integral skins 44 and 46 are constructed of molded resinous plastic material such as polypropylene to provide strength and integrity for the cover 40 as a whole so that break up or fracture of the cover into several pieces does not occur upon airbag deployment. Normally the cover 40 is retained in a closed position (FIG. 1) directly above and over the panel opening 32 by a plurality of break-away fasteners 52 provided at opposite end portions of the cover (FIG. 3). Inner ends 52b of the fasteners 52 are inserted in and snap locked into apertures 54 (FIGS. 4 and 4A) provided in a lower flange 30a of the panel 30, at the opposite ends of the opening 32. Until the airbag 38 is deployed, the cover 40 acts as an integrated part of the panel 30 and at the same time protects the airbag assembly 34 from damage by limiting external access thereto. At a position closely adjacent the inside surface of the outer skin 44, each leg 52a of a fastener 52 is notched as at 52c to provide a fracture line of reduced cross-section. When opening pressure from the inflating airbag 38 acts against the underside of the cover 40, the legs 52a of each latch element are readily fractured or broken at the notches 52c to release the cover 40 to move bodily away from the panel opening 32 from the closed position of FIG. 1 to the open position of FIG. 2. In accordance with the present invention, one or more tethers 60 of strong, flexible material such as "Nylon" webbing, scrim material, web belting, or the like is interconnected between the underside of the cover 40 and the housing or canister 36 of the airbag inflator assembly 34. Inner ends of the flexible tethers 60 are interconnected to the upper sidewall of the canister 36 by means of metal or plastic clips 62 (FIG. 4). Referring now to FIGS. 5-8, the cover 40 including the integral inner and outer skins 46 and 44 is formed in a single mold 80 as shown in FIG. 5. After sufficient curing time, the molded resinous plastic piece is removed from the cavity of the mold 80 as a single piece or unitary member comprising both of the integrally molded skins 44 and 46. The respective inner and outer skins 46 and 44 are folded over on one another into an overlying relation as shown in FIG. 6 about a fold line 47 extending along and forming a forward edge of the cover 40. In accordance with the invention, an inside face 44a of the outer skin 44 is molded to include one or more pairs of spaced apart positioning ribs 64 which are normal to the inside face and which extend toward a facing portion of an inside face 46a of the folded over inner skin 46. Each pair of positioning ribs 64 is spaced apart by a distance "d" (FIG. 7) slightly greater than the width "w" (FIG. 6) of the tethers 60. Parallel facing surfaces of each pair of ribs 64 form guide surfaces 64a for facilitating the passage of looped, outer end portions 60a of the tethers 60 (FIG. 6) around an elongated anchor bar 70 formed of a metal strip or strip of stiff, strong plastic material for spreading loads exerted by the tethers 60 over a wide area extending generally parallel of the fold line 47 for a substantial portion of the length of the cover 40. Outer edges of the ribs 64 are formed with recess 64b of trapezoidal shape (FIGS. 5 and 6) for positioning the anchor bar 70 parallel relative to the fold line 47 and substantially close to or flush with the adjacent inside surface 46a of the folded over inner skin 46. The inner skin 46 is formed with slots 73 (FIGS. 6 and 8) aligned with the center line of anchor bar 70 in order to permit the looped outer end portions 60a of the tethers 60 to pass out through the inner skin 46 and extend toward the airbag housing 36. As shown in FIG. 8, a bitter end of each tether 60 is stitched as at 65 or otherwise permanently fastened to the body of the tether. Along an edge 49 of the cover 40 facing toward the passenger 24 and opposite the fold line 47, the outer skin 44 is formed with a downturned edge flange 44b against which an edge 46b of the inner skin 46 abuts when the inner and outer skins are folded over ready for joining together along a rearward edge portion of the cover 40. Joinder of the rearward edge portions of the inner and outer skins 44 and 46 is accomplished in a heat staking operation. Heat stakes 44c are integrally molded on the inside surface 44a of the outer skin 44 and are positioned at spaced apart intervals in a row adjacent and inwardly of the edge 46b. The inner skin 46 is formed with appropriately positioned slots 46c to receive the heat stakes 44c and outer ends of the heat stakes are spread and deformed as caps 51 in a heat staking operation to secure the inner and outer skins 46 and 44 together along a rearward edge portion of the cover 40. The cover tether combination of the present invention provides for spreading the restraining load exerted by the tethers 60 on the cover 40 over a substantially large area thereon by means of the internal anchor bar 70 placed between the inner and outer skins 46 and 44. The one piece, integrally formed folded over resinous plastic inner and outer skins 46 and 44 provide an exceedingly strong cover structure and the anchor bar 70 serves as further internal reinforcement which reduces stress and minimizes the chances of severance of the cover 40 from the tethers 60 or break up or fracture of the cover into pieces. Obviously, many modifications and variations of the present invention are possible in light of the above teachings. Thus, it is to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described above.

Claims: An airbag system for motor vehicles (20) and the like, including an inflatable airbag (38) contained in a housing (36) while in a deflated condition, said housing having an open end for permitting said airbag to pass outwardly when inflatably deployed to provide cushioning support for an occupant of a vehicle seat (26), comprising: cover means (40) normally closing a panel opening (32) in said vehicle adjacent said open end of said housing for protecting said airbag, said cover means movable to uncover said opening during deployment of said airbag; flexible tether means (60) interconnected between said cover means and at least one of said panel means and said housing means (36) for limiting the movement of said cover means away from said panel means upon inflatable deployment of said airbag; said cover means including an integral outer (44) and an inner (46) skin folded over along an edge portion (47), said inner skin having slot means (73) formed to permit passage of said tether means into a space formed between said skins; and anchor means in said space, comprising an elongated bar (70) formed of stiff material and engaging said tether means for securing the same to said cover means, characterised in that said outer skin (44) of said cover means is formed with one or more support members (64) extended toward said inner skin (46) in said space for engaging said anchor means (70) to position the same. The airbag system of claim 1, characterised in that said anchor means (70) extends beyond said slot means for spreading the load exerted by said tether means over a large area of said inner skin of said cover means upon deployment of said airbag. The airbag system of claim 2, characterised in that said tether means includes a first portion (60a) wrapped around said anchor means (70). The airbag system of claim 1, characterised in that : said inner (46) and outer (44) skins are integrally molded together in a unitary piece and thereafter folded over along a fold line (47) extending along an edge of said cover means. The airbag system of claim 4, characterised in that : said inner and outer skins are also interconnected adjacent an opposite edge portion (46b) of said cover means spaced opposite said fold line. The airbag system of claim 5, characterised in that : said inner and outer skins are interconnected by heat staking along said opposite edge portion of said cover means. The airbag system of claim 6, characterised in that : said outer skin is formed with at least one integral heat stake (44c) extending toward said inner skin and said inner skin is formed with a hole (46c) to receive said heat stake. The airbag system of claim 7, characterised in that : said outer skin has a plurality of said heat stakes (44c) spaced apart along said opposite edge portion of said cover means and said inner skin has a plurality of matching holes (46c) for receiving respective ones of said heat stakes. The airbag system of claim 7, characterised in that : said heat stake is deformed by heat, ultrasonics or other means at an outer end portion to bear against an outside face of said inner skin to secure said inner and outer skins together along said opposite edge portion of said cover means. The airbag system according to one of the claims 1 to 9, characterised in that : said support members (64) includes surfaces (64a) for guiding said tether means so that said outer end portion (60a) is looped around said anchor means. The airbag system of claim 10, characterised in that : said support members includes at least one pair of ribs (64) integrally formed on one (44) of said skins to extend toward a facing surface of the other (46) and spaced on opposite sides of said outer end portion of said tether means looped around said anchor means. The airbag system of claim 11, characterised in that : said ribs (64) are positioned at opposite ends of said slot means (73) on said inner skin.

Inventors: BENTLEY MICHAEL F, TOSTAIN DENIS JULES, BENTLEY, MICHAEL F., TOSTAIN, DENIS JULES
Applicants: ALLIBERT IND, MORTON INT INC, ALLIBERT INDUSTRIE, MORTON INTERNATIONAL, INC.
Application year: 1995
Main classification: B60R21
IPC codes: B60R21