Abstract:
An automobile air bag module is provided that includes a housing chute at least partially surrounding an air bag, wherein the housing chute comprises a front wall, a rear wall, at least one sidewall, and a female pocket located adjacent a housing chute sidewall. Also included is a topper cover having a reinforcement protrusion that comprises a male locking tab that matably engages the female pocket.

Description:
FIELD OF THE INVENTION  
       [0001]    The present invention relates to vehicle air bag module assemblies. 
       BACKGROUND OF THE PRESENT INVENTION  
       [0002]    During passenger air bag deployment, the passenger air bag deploys into the rearward wall of an air bag chute. This often creates separation of the chute to a topper by destroying the attachment joint between the chute and the topper. The separation allows the air bag cushion to fill in this area rather than in a more direct path to the occupant. Structural support of the passenger air bag module and reinforcement against excessive bell mouthing during the crash/deployment event would facilitate deployment of an air bag in a more efficient manner. 
         [0003]    Accordingly, an apparatus is desired having the aforementioned advantages and solving and/or making improvements on the aforementioned disadvantages. 
       SUMMARY OF THE PRESENT INVENTION  
       [0004]    In one aspect of the present invention, an automobile air bag module is provided that includes a housing chute at least partially surrounding an air bag, wherein the housing chute comprises a front wall, a rear wall, at least one sidewall, and a female pocket located adjacent a housing chute sidewall. Also included is a topper cover having a reinforcement protrusion that comprises a male locking tab that matably engages the female pocket. 
         [0005]    In another aspect of the present invention, a locking arrangement for an automobile air bag is provided that includes a locking tab having an integral connection with a cover member, wherein the locking tab extends substantially perpendicularly away from a longitudinal axis of the cover member. Also included is a female recess having an integral connection with a housing chute, wherein the female recess matably receives the locking tab. 
         [0006]    In another aspect of the present invention, a method of making an automobile air bag module is provided. The method includes providing a housing chute at least partially surrounding an air bag, wherein the housing chute comprises a front wall, a rear wall, at least one sidewall. Also provided is a female pocket located adjacent a housing chute sidewall, and a topper cover having a reinforcement protrusion that comprises a male locking tab that matably engages the female pocket. The method also includes the step of jointing the topper cover to the housing chute. 
         [0007]    These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0008]    In the drawings: 
           [0009]      FIG. 1  is a perspective view of an interior compartment of an automobile having an air bag module; 
           [0010]      FIG. 2  is a perspective view of the air bag module; 
           [0011]      FIG. 3  is an elevated, side, cross-sectional view taken along line III-III of  FIG. 1 , illustrating the air bag module; 
           [0012]      FIG. 4  is an elevated, side, cross-sectional view of a reinforcement protrusion of the air bag module; 
           [0013]      FIG. 5  is an elevated, side, cross-sectional view of the air bag module in a deployed position; and 
           [0014]      FIG. 6  is a perspective, cross-sectional view of the air bag module in the deployed position. 
       
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS  
       [0015]    For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal” and derivatives thereof shall relate to the invention as oriented in the attached drawings. However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. 
         [0016]    Referring to  FIG. 1 , an interior of an automobile is illustrated having an air bag module  10  located proximate an instrument panel substrate  12 . In the illustrated embodiment, the air bag module  10  is configured in a “top mount” position that being an upper surface of a dashboard or instrument panel  12 . The air bag module  10  could be configured in a “front mount” position, that being a location proximate a glove box. Additionally, the air bag module is suitable for use in a steering wheel air bag module  14 . 
         [0017]    Referring to  FIGS. 2 and 3 , the air bag module  10  comprises a housing chute  16  for at least partially enclosing or surrounding an air bag (not illustrated), as well as a topper  18  that covers the housing chute  16 . The housing chute  16  includes a top wall  34  that is positioned directly beneath the topper  18 . Specifically, the topper  18  comprises a base section  20  that is positioned atop the top wall  34  of the housing chute  16 . The shape of the topper base  20  and the top wall  34  of the housing chute  16  substantially corresponds to the shape of the instrument panel substrate  12 . Although the instrument panel substrate  12  may take on a slightly curved configuration, for purposes of this discussion, it will be referred to as a generally planar configuration. As such, the top wall  34  of the housing chute  16  and the topper base  20  are considered to be generally coplanar with one another, as well as the instrument panel substrate  12 . 
         [0018]    The air bag chute  16  also includes a plurality of walls described as a front wall  24 , a rear wall  26 , and two sidewalls  22 ,  28  which extend downwardly from the top wall  34 . The front and rear walls  24 ,  26  each contain several window apertures  44  for engagement with a corresponding number of attachment hooks extending from an air bag container (not illustrated). The window apertures  44  have pressure tabs  32  that bear against the inserted hooks to tighten the engagement connections and prevent rattling from occurring between the air bag container and the air bag chute  16  during vehicle operation, prior to air bag deployment. 
         [0019]    The top wall  34  of the house chute  16  may include several apertures. Such apertures are positioned to reduce the mass of the top wall  34  without affecting its support or attachment properties. 
         [0020]    Referring now to  FIGS. 2 and 4 , the air bag module  10  is structurally reinforced by one or more reinforcement protrusions  30  that extend away from the base  20  of the topper  18 . The reinforcement protrusions  30  extend downwardly into female pockets  60  that are part of the housing chute  16  and are located proximate the rear wall  26  of the housing chute  16 . The reinforcement protrusions  30  may take on any number of geometric shapes, and in the illustrated embodiment, are wedge-like protrusions  30  that include a first edge  50  and a second edge  52 . The female pocket  60  of the housing chute  16  is shaped to substantially correspond to the protrusion  30 , and in the illustrated embodiment includes a first edge  54  and a second edge  56  for receiving the reinforcement protrusion  30 . Although it is conceivable that a single reinforcement protrusion  30  and female pocket  60  may be employed, typically the air bag module  10  will include a plurality of reinforcement protrusions  30  and female pockets  60  that are spaced longitudinally along the rear wall  26  of the housing chute  16 . 
         [0021]    Any number of fastening methods may be employed to secure the topper  18  to the housing chute  16 , and more specifically the reinforcement protrusions  30  within the female pockets  60 . For example, the topper  18  may be welded to the housing chute  16 , adhered by an adhesive to the housing chute  16 , or snap fitted to the housing chute  16 . These fastening techniques are merely illustrative and one skilled in the art may substitute various other methods of attachment. It is also conceivable that only the portion of the topper  18  containing the reinforcement protrusions  30  are secured to the female pockets  60 , or alternatively may be fastened in a way that differs from the fastening of the base  20  of the topper  18  to the housing chute  16 . Typically, the topper  18  that comprises a base  20  and reinforcement protrusions  30  will be an integrally molded piece or a single extruded piece. Similarly, typically the housing chute  16  and the female pocket  60  are integrally molded or are a single extruded piece. 
         [0022]    The topper cover  18  includes a tear seam  40  that is positioned proximate the rear wall  26  of the housing chute  16  and proximate the second edge  52  of the reinforcement protrusion  30 . The tear seam  40  is pre-weakened to the extent that the instrument panel substrate  12  and a portion of the topper  18  will rupture upon deployment of the air bag. 
         [0023]    Referring to  FIGS. 5 and 6 , deployment of an air bag is illustrated, although the actual air bag is not shown for purposes of clarity. A hinge  36  extends substantially between the front wall  24  and the top wall  34  upon deployment of the air bag. During deployment, the tear seam  40  ruptures, as described above, such that the instrument panel substrate  12 , the base  20  of the topper  18 , as well as the top wall  34  of the housing chute  16 , pivots upwardly to allow the air bag to release towards a passenger. As the force of the air bag projects upwardly and rearwardly towards, at least in part, the rear wall  26  of the housing chute  16 , the reinforcement protrusion  30  that is secured to the female pocket  60  provides structural integrity by preventing deflection or bell mouthing of critical air bag module  10  components, such as the rear wall  26 . 
         [0024]    The inventive concept also provides a method of making the air bag module  10 . The method includes providing the structure described in detail above, as well as securely jointing the topper cover  18  to the housing chute  16 , and more specifically the reinforcement protrusions  30  within the female pockets  60 . Any number of jointing techniques may be employed, as outlined above, for example welding, adhering, and snap fitting. 
         [0025]    It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.