Energy absorption cover for passenger-side airbag module

Abstract: The cover (20) of a passenger-side airbag module is provided with an energy absorption zone to protect the passenger (H) during head impact. The zone is in the form of corrugations (30) which extend across the mouth of the airbag module (12). The corrugations crush upon impact, thereby absorbing energy.

Description: This invention relates to motor vehicle passenger-side airbag modules and to an instrument panel door for such a module designed to absorb energy from an occupant impact. Passenger-side airbag modules are normally installed behind the instrument panel of motor vehicles. (As used herein, the term "instrument panel" refers to the extended dashboard faced by the motor vehicle passenger and need not include instruments). The module normally includes a housing for a reaction canister containing a folded airbag and means for inflating the airbag in response to a collision of sufficient severity. This module is installed behind the dashboard. The dashboard itself is provided with some type of door to permit the inflating airbag into the passenger compartment. Since the airbag module is, of necessity, very close to the instrument panel, it presents a problem in the case of impacts or collisions below the severity required to actuate the airbag. The instrument panel is normally soft and flexible, but the airbag module is metal or a hard plastic. Accordingly, in the event of a collision less severe than that required to actuate the airbag, an occupant may be injured by impact with the housing through the instrument panel. In fact, this presents enough of a problem to result in a "Standard No. 201" by the National Highway Traffic Safety Administration of the US Department of Transportation. 49 CFR chapter V, §571.201 provides, in pertinent part "Instrument panels, . . . when that area of the instrument panel that is within the head impact area is impacted . . . by a 6.8 kg (15-pound), 16.5 cm (6.5-inch) diameter head form at a relative velocity of 19.3 kin (12 miles) per hour, the deceleration of the head form shall not exceed 80g continuously for more than 3 milliseconds". The reason for establishing this standard was to protect the vehicle occupant during crashes occurring below the threshold speed required to deploy the airbag system. Even at these low speeds, head injuries may occur on impact with a dashboard which is too rigid. In the past this problem has been met by weakening the airbag housing so that it crushes under impact. An example of such an approach will be found in US-A-5505484 of Jon E. Miles, Scott L. Hansen and John T. Jensen for COLLAPSIBLE AIRBAG CANISTER, published April 9, 1996, and assigned to the same assignee as the present invention. While such an approach has been successful, it is often desirable to have a rigid airbag housing to ensure that the airbag is restrained and deploys correctly. Furthermore, from GB-A-2265337 is known a module and a door according to the preamble of claim 1 and of claim 12, comprising a relatively complicated separate energy absorbing element mounted between the door and the housing. Accordingly, it is a primary object of the present invention to provide a module and a door of the kind set forth with an energy absorbing zone which is separate from the airbag housing and of simple construction. The present invention consists in a motor vehicle passenger side restraint module of the type including a housing mounted behind the instrument panel (P) of the vehicle having edges defining an open mouth closely adjacent said panel, an airbag stowed within said housing, means for inflating said airbag upon the occurrence of a collision of preselected magnitude, and a door in said instrument panel covering the open mouth of said housing and displaceable by the inflation of said airbag, characterised in that a relatively thin sheet mounted between said door and said housing defining a plurality of elongated corrugations spanning the open mouth of said housing and crushable against the edges of said housing to absorb energy and protect an occupant upon impact with said door. Preferred embodiments of the invention will now be described with reference to the accompanying drawings wherein: FIG. 1 is an elevational view of an airbag module in accordance with the present invention; FIG. 2 is a bottom view of the module of Fig. 1; FIG. 3 is an elevational view of a modification of the invention; FIG. 4 is a bottom view of the modification of Fig. 3; FIG. 5 is an enlarged detail illustrating the functioning of the Fig. 1 version; and FIG. 6 illustrates the functioning of the Fig. 3 version of the invention. Referring first to Figs. 1 and 2, there is illustrated a passenger-side airbag module 10. The module 10 is mounted to the vehicle's structure S and behind the instrument panel P which is shown in cross-section. The airbag module 10 comprises a substantially rectangular housing 12 enclosing a folded airbag 14. The portion of the housing 12 to the right as viewed in Figs. 1 and 2 is cylindrical and encloses a cylindrical inflator 16. These portions are conventional, well known to those skilled in the art, and need not be described in detail. The rectangular housing 12 may be of metal such as steel or extruded aluminium and its edges define an open rectangular mouth 18 positioned just behind the instrument panel P. The instrument panel P includes an opening which is closed by a door 20. The door 20 is mounted to the housing 12 by a hanger 22. When the airbag 14 inflates, as illustrated by the dash-dotted lines 14' in Fig. 1, it pushes open the door 20', shown in its partially open position, while the hanger 22 straightens and serves as a retaining tether. As illustrated in more detail in Fig. 5, the door 20 is laminated, comprising a sheet steel substrate 24, a foam interior 26, and an outer skin 28 to add aesthetic features such as colour, grain, trim, and contour lines. Returning to FIGS. 1 and 2 , a crushable impact zone is provided on the door 20 by a metal corrugated sheet 30. The sheet 30 is secured to the substrate 24 of the door 30 as by welding along the regions 32 intermediate the corrugations. In the embodiment shown, the corrugations are substantially parallel. However, they may be arranged in any suitable configuration. The corrugations are substantially triangular in cross section and are long enough to span the mouth 18 of the housing 12 as illustrated in FIG. 1 . In one embodiment of this invention both the metal substrate 24 and the corrugated sheet 30 are of steel having thicknesses of about 0.5-2mm. The triangular corrugations provide a "truss" effect which stiffens the door 20 and resists bending. This permits the use of thinner materials than would otherwise be required. FIG. 5 illustrates a body part such as a head H making impact with the door 20 . In this illustration, the corrugations in the sheet 30 are shown crushing against the edges of the housing, collapsing, thereby dissipating energy and cushioning the impact of the head H against the housing 12 . The door structure illustrated in FIGS. 1, 2, and 5 would be used primarily in top-of-the-line and luxury cars, due to the expense of the laminated door 20 . FIGS. 3, 4 , and 6 illustrate a modification of the invention which permits the use of a cheaper, molded plastic, door. It is particularly useful when the worst case head impact location is in the center of the airbag module directly over the folded airbag. The airbag module itself is similar to that previously described and, accordingly, similar reference numerals are employed. In this modification, the door 34 is of one piece molded plastic and may be unitary with the hanger 36 . However, an additional element is added in the form of a single sheet stamping 38 positioned intermediate, and spaced from, each of the door 34 and housing 18 . The stamping 38 is of sheet steel as previously described and the corrugations are drawn from the main body 40, thereby leaving an encircling flange or peripheral stiffening rim 41 as illustrated in FIGS. 3 and 4 . This flange may also have an integral bracket or hanger 42 which may be attached to the housing 12 at the same location as the hanger 36 for the door. Under normal operation, both the door 34 and the stamping 38 are opened outwardly by the expanding airbag in the same fashion as illustrated in FIG. 1 . Also, as illustrated in FIG. 3 , the corrugations of the stamping 38 span the mouth 18 of the airbag housing 12 in the same manner as previously described. As a result, the stamping 38 provides a bridge across the open mouth 18. As illustrated in FIG. 6 , the impact of a head H against the door 34 pushes inwardly against the stamping 38 which bends into the mouth 18 , thereby absorbing energy.

Claims: A motor vehicle passenger side restraint module (10) of the type including a housing (12) mounted behind the instrument panel (P) of the vehicle having edges defining an open mouth closely adjacent said panel, an airbag (14) stowed within said housing, means (16) for inflating said airbag upon the occurrence of a collision of preselected magnitude, and a door (20, 34) in said instrument panel covering the open mouth of said housing and displaceable by the inflation of said airbag, characterised in that: a relatively thin sheet (30, 38) is mounted between said door and said housing (12) defining a plurality of elongated corrugations spanning the open mouth of said housing and crushable against the edges of said housing to absorb energy and protect an occupant upon impact with said door. A restraint module according to claim 1 wherein said corrugations are substantially parallel. A restraint module according to claim 2 wherein said sheet (30) is attached to said door (20) along attachment regions (32) intermediate said corrugations. A restraint module according to claim 3 wherein said door (20) comprises a sheet metal substrate (24) forming a rear surface facing said housing (12) and a decorative surface (28) forming a portion of said instrument panel and wherein said corrugated sheet (30) is attached to said substrate. A restraint module according to claim 4 additionally comprising a compressible layer (26) intermediate said rear surface (24) and decorative surface (28). A restraint module according to claim 1 wherein the corrugated sheet (38) is positioned intermediate, and spaced from each of, said door (34) and said housing (12). A restraint module according to claim 6 additionally comprising means (42) for supporting said corrugated sheet (38) on said housing (12). A restraint module according to claim 7 wherein said supporting means (42) is a bracket. A restraint module according to any preceding claim wherein said corrugated sheet (30, 38) is made of metal. A restraint module according to claim 9 wherein said corrugated sheet (38) comprises formed sheet metal having a peripheral stiffening rim (41). A restraint module according to any preceding claim wherein said corrugations are substantially triangular in cross section. A door (20) mountable in an opening in an automotive instrument panel (P) over the open mouth of an airbag housing (12), said door comprising: a sheet metal substrate (24) having a rear surface adapted to face said housing (12) and a front surface (28); and a decorative coating on the front surface (28) of said substrate (24) adapted to close said opening and form a continuation of said instrument panel; characterized in that a corrugated sheet (30) is mounted on the rear surface of said substrate, having corrugations positioned to span the open mouth of said airbag housing (12) and crushable against the edges of said housing (12) to absorb energy and protect an occupant upon impact with said door (20). A door according to claim 12 wherein said corrugations are substantially parallel and said sheet (30) is mounted to said substrate (24) along attachment regions (32) intermediate said corrugations. A door (20) according to claim 12 or claim 13 wherein said corrugations are substantially triangular in cross section. A door according to any one of claims 12 to 14 wherein said sheet (30) is metal.

Inventors: GANS RUSSELL S, JARBOE PATRICK G, RAVENBERG MICHAEL J, RICHARDS STEWART L, ROGERS MARK, ROSE LARRY D, GANS, RUSSELL S., JARBOE, PATRICK G., RAVENBERG, MICHAEL J., RICHARDS, STEWART L., ROGERS, MARK, ROSE, LARRY D.
Applicants: AUTOLIV ASP INC, AUTOLIV ASP, INC.
Application year: 1996
Main classification: B60R21
IPC codes: B60R21