Abstract:
An airbag module for a vehicle includes a first storage compartment for use by an occupant of the vehicle and a second storage compartment for storing a first folded airbag prior to deployment. A single integrated cover overlies the storage compartments. The cover is configured to be integrated and installed into an instrument panel of the vehicle when the airbag module is installed in the vehicle. The cover includes a manually operable first door covering a first opening to the first storage compartment, and wherein, in an open position, the first door permits access to the first storage compartment. The cover includes a second door configured to open when the first airbag thereby creating a second opening in the cover to permit the first airbag to deploy into the vehicle.

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS 
     This application claims priority from Provisional U.S. Application 61/097,785, filed Sep. 17, 2008, and Provisional U.S. Application 61/118,120, filed Nov. 26, 2008. The foregoing provisional applications are incorporated herein by reference in their entirety. 
    
    
     BACKGROUND 
     The present disclosure relates generally to the field of vehicle airbags which provide occupant protection when deployed (e.g., during a dynamic vehicle impact). Specifically, the disclosure relates to an airbag module which incorporates a first storage compartment for the use of the vehicle occupant, a second storage compartment for storing an airbag to protect the head or torso, and a cover overlying all of the storage compartments to form one integrated airbag module. More specifically, this disclosure relates to an airbag to protect the head and torso, an airbag to protect the knees, and a glove box integrated into one unit that the vehicle manufacturer would install into a motor vehicle. 
     Airbags are located in vehicles to protect occupants from injury during a vehicle dynamic impact event, which triggers sensors located in the vehicle to initiate deployment of an airbag(s). An airbag may deploy and inflate, by gas rapidly entering its cushion(s), typically through the use of an inflator containing an explosive charge (e.g., pyrotechnic device). Passenger torso and knee airbags are typically stored within and deployed from the passenger dashboard compartment. Passenger torso and knee airbags are typically packaged through a process of folding and rolling to compact the airbag in order to minimize its required packaging space. During a vehicle dynamic impact event, a passenger torso airbag deploys, typically from the upper portion (i.e., above the glove box) of the dashboard, in substantially rearward and upward directions to protect the torso and head of the occupant, while the knee airbag deploys, typically from the lower portion (i.e., below the glove box) of the dashboard, in substantially rearward and downward directions to protect the knees and legs of the occupant. The terms dashboard, dashboard assembly and instrument panel refer to the same component and are used interchangeably throughout this application. 
     It has been known to construct a vehicle to include a passenger torso airbag, a glove box assembly, and a passenger knee airbag, such that the three are assembled and shipped as independent assemblies and installed independently into a vehicle. It has also been known to construct a glove box to include a knee protection device, typically by coupling a trim plate to the leading edge of a deploying airbag. 
     It would be advantageous for a vehicle manufacturer to receive and install one assembly which integrates a glove box with protection devices to protect both the knees and torso of the occupant. This integration of assemblies reduces assembly labor, time, and costs for the customer by reducing the quantity of components and operations required to install the integrated assembly into the vehicle. Additionally, this integration reduces the number of components within the integrated assembly, which in turn reduces the packaging space required, reduces the mass of the system and vehicle, and reduces cost. The reduction of mass has always been a driving force behind vehicle manufacturers, but it has become even more important as the need for fuel efficiency continues to increase. 
     SUMMARY 
     According to a disclosed embodiment, an airbag module for a vehicle includes a first storage compartment for use by an occupant of the vehicle and a second storage compartment for storing a first folded airbag prior to deployment. A single integrated cover overlies the storage compartments. The cover is configured to be integrated and installed into an instrument panel of the vehicle when the airbag module is installed in the vehicle. The cover includes a manually operable first door covering a first opening to the first storage compartment, and wherein, in an open position, the first door permits access to the first storage compartment. The cover includes a second door configured to open when the first airbag deploys thereby creating a second opening in the cover to permit the first airbag to deploy into the vehicle. 
     According to another disclosed embodiment, a motor vehicle includes a passenger seat for containing a vehicle occupant and an instrument panel. An airbag module is installed in the instrument panel. The airbag module includes a first storage compartment for use by the vehicle occupant, and a second storage compartment for storing a first folded airbag prior to deployment. A single integrated cover overlies the storage compartments. The cover is configured to be integrated and installed into the instrument panel of the vehicle when the airbag module is installed in the vehicle. The cover includes a manually operable first door covering a first opening to the first storage compartment, and wherein, in an open position, the first door permits access to the first storage compartment. The cover includes a second door configured to open when the first airbag deploys thereby creating a second opening in the cover to permit the first airbag to deploy into the vehicle. 
     According to another disclosed embodiment, an integrated glove box and airbag module for a vehicle includes a glove box configured to be installed in an instrument panel of a vehicle, first and second airbag compartments, and first and second inflators. The glove box includes a storage compartment and a door, wherein the glove box is configured so that an occupant of the vehicle may open the door to the glove box in order to access the storage compartment. The first airbag compartment contains a first airbag, and the second airbag compartment contains a second airbag. The first and second inflators are configured to provide inflation gas for the first and second airbags, respectively. A single integrated cover overlies the glove box and first and second airbag compartments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an exemplary embodiment of an automotive vehicle that includes an airbag module. 
         FIG. 2  is a perspective view of the interior passenger compartment of an exemplary automotive vehicle that includes an airbag module. 
         FIG. 3   a  is a cross-car section view of the interior passenger compartment of  FIG. 2  according to an exemplary embodiment illustrating an airbag module in the folded (non-deployed) state. 
         FIG. 3   b  is a cross-car section view of the interior passenger compartment of  FIG. 2  according to an exemplary embodiment illustrating an airbag module in the unfolded (deployed) state. 
         FIG. 4  is a cross-car section view of an exemplary embodiment of an airbag module illustrated in the folded (non-deployed) state. 
         FIG. 5  is a cross-car section view of another exemplary embodiment of an airbag module illustrated in the folded (non-deployed) state. 
         FIG. 6  is a cross-car section view of another exemplary embodiment of an airbag illustrated in the folded (non-deployed) state. 
         FIG. 7  is a cross-car section view of an example of a mid-mount passenger airbag that may be utilized in any of the embodiments of  FIGS. 3   a - 6 . 
         FIG. 8  is a cross-car section view of the example of a mid-mount passenger airbag of  FIG. 7  illustrated in the folded state. 
         FIG. 9  is a cross-car section view of an example of a top-mount passenger airbag that may be utilized in any of the embodiments of  FIGS. 3   a - 6 . 
         FIG. 10  is a cross-car section view of the example of a top-mount passenger airbag shown in  FIG. 9 . 
         FIG. 11  is a cross-car section view of an example of a non-deployed top-mount passenger airbag and an example of a non-deployed knee airbag mounted in a glove box door that each may be utilized in any of the embodiments of  FIGS. 3   a - 6 . 
         FIG. 12  is a cross-car section view of an example of a deployed top-mount passenger airbag and an example of a deployed knee airbag mounted in a glove box door that each may be utilized in any of the embodiments of  FIGS. 3   a - 6 . 
         FIG. 13  is a cross-car section view of a second example of a non-deployed top-mount passenger airbag and an example of a non-deployed knee airbag mounted in a glove box door that each may be utilized in any of the embodiments of  FIGS. 3   a - 6 . 
     
    
    
     DETAILED DESCRIPTION 
     Generally referring to the FIGURES, an exemplary embodiment of vehicle  10  includes a dashboard assembly  20 , a passenger seat  22 , a cross-car beam  24 , and a windshield  28 . An exemplary embodiment of the dashboard assembly  20  includes a dashboard  25  and an airbag module  30 . An exemplary embodiment of the airbag module  30  includes an integrated glove box and occupant protection assembly including a torso airbag  32  in a first airbag storage compartment  31 . The torso airbag  32  inflates to protect the head and torso of an occupant. The airbag module  30  also includes a knee airbag  34  in a second airbag storage compartment  33 . The knee airbag inflates to protect the knees and legs of an occupant  26 . The airbag module  30  also includes a glove box assembly  40  to provide storage utility to an end user. The glove box assembly includes a glove box storage compartment  42 . Finally, the airbag module  30  includes a housing  50  having a cover  51 . The housing  50  couples the components of the airbag module  30  together, provides structural rigidity to the airbag module  30 , and provides a mechanism for attachment to the vehicle  10 . The airbag module  30  has reduced mass and reduced package size by utilizing more efficient and common structural components, which may be assembled as one unit at the vehicle manufacturing location, thereby reducing manufacturing labor required to install into the vehicle  10 . The airbag module includes the following three compartments: a first storage compartment for use by an occupant of the vehicle (e.g., the glove box storage compartment  42 ); a second storage compartment for storing an airbag (e.g., the first airbag storage compartment  31 ); and a third storage compartment for storing an airbag (e.g., the second airbag storage compartment  33 ). 
     According to another exemplary embodiment, the airbag module  30  includes at least one inflator  36  for inflating the airbags  32  and  34 . According to another exemplary embodiment, the airbag module  30  includes two inflators  36   a  and  36   b . The inflator  36   a  inflates a torso airbag  32  stored in the first airbag storage compartment  31 . The inflator  36   b  inflates a knee airbag  34  stored in the second airbag storage compartment  33 . 
     According to an exemplary embodiment, the glove box door  46  may include the knee airbag  34  to protect the knees and legs of an occupant and an inflator  36   b  for inflating the knee airbag  34 . 
     Referring to  FIG. 1 , an exemplary embodiment of the vehicle  10  is illustrated and includes the dashboard assembly  20 . The vehicle  10  is illustrated as a typical sedan, but the airbag module  30  may be utilized in any type of passenger vehicle as well as other moving vehicles that offer seating capacity to passengers. 
     Referring to  FIG. 2 , the passenger compartment of the vehicle  10  is illustrated and includes the dashboard assembly  20  and the passenger seat  22 . The dashboard assembly  20  includes the dashboard  25  and the airbag module  30 , which is configured to fit within the unique packaging requirements of the vehicle  10 . The airbag module  30  is flexibly configurable for use in varying package requirements, and may be tailored to satisfy specific needs of the vehicle manufacturer. 
     Referring to  FIG. 3   a , a cross-section of the passenger compartment of the vehicle  10  of  FIG. 2  is illustrated. The dashboard assembly  20 , which is located below and rearward of the windshield  28 , may include an integrated glove box and occupant protection assembly embodiment of the airbag module  30 . The integrated glove box and occupant protection assembly includes a torso airbag  32 , which may be folded and stored in a first airbag storage compartment  31  until deployment. The assembly also includes a knee airbag  34 , which is folded and stored in a second airbag storage compartment  33  until deployment. At least one inflator  36  may be provided to inflate the airbags  32  and  34 . The assembly also includes a glove box assembly  40 , to provide storage utility to the user. The glove box assembly  40  includes a glove box storage compartment  42  and a glove box door or fascia  46 . The glove box storage compartment  42  may be configured to meet customer needs for storage or be configured to include other useful features. The glove box door  46  may be configured to be pivotably coupled to the glove box assembly  40  through conventional means and may also include a release handle and locking mechanism, to provide traditional utility features. The integrated glove box and occupant protection assembly further includes a housing  50 . The housing  50  includes a cover  51  which is configured to be integrated and installed into the dashboard assembly  20 . The cover  51  includes a first airbag door  54  for providing access through an opening to the first airbag storage compartment  31 . The cover  51  also includes the glove box door  46 , and a second airbag door  56  for providing access through an opening to the second airbag storage compartment  33 . The airbag doors  54  and  56  are configured to have conventional methods (e.g., hinge) to allow its respective airbag to breach the cover  51  during deployment. The airbag doors  54  and  56  may be configured to remain forward of the respective deploying airbag to allow proper deployment trajectory in order to maximize protection of the occupant  26 . According to an exemplary embodiment, the integrated glove box and occupant protection assembly may be configured to couple through conventional means (e.g., fasteners) to the cross-car beam  24 , which provides structural support to the integrated glove box and occupant protection assembly during deployment of the airbags. 
     Referring to  FIG. 3   b , a cross-section of the passenger compartment of vehicle  10  of  FIG. 2  is illustrated.  FIG. 3   b  is similar to  FIG. 3   a , except that the airbag module  30  shown in  FIG. 3   a  is in a folded or non-deployed state, while the airbag module  30  shown in  FIG. 3   b  is in an unfolded or deployed state. During a dynamic impact event of the vehicle  10 , sensors provide relevant data to a controller that directs the initiation of the inflator  36  to generate gas, typically through an explosive charge (e.g., pyrotechnic device). The gas is emitted from the inflator  36  into the folded cushions of the torso airbag  32  and the folded knee airbag  34 , causing the airbags to unfold and breach the airbag module  30  by forcing open the first and second airbag doors  54  and  56 . The torso airbag  32  inflates to protect the head and torso of the occupant  26  from impacting the upper components of the vehicle  10  (e.g., dashboard  25 , windshield  28 ). The knee airbag  34  inflates to protect the knees and legs of the occupant  26  from impacting the lower components of the vehicle and to prevent the occupant  26  from sliding under the dashboard assembly  20 . 
     According to the exemplary embodiments in  FIGS. 3   a  and  3   b , the torso airbag  32  may be configured above the glove box storage compartment  42  and configured to deploy or inflate in a direction substantially rearward and upward to protect the head and torso of the occupant. In this arrangement, the first airbag storage compartment  31  shares a common wall with the glove box storage compartment  42 . The knee airbag  34  may be configured below the glove box storage compartment  42  and configured to deploy or inflate in a direction substantially rearward and downward to protect the knees and legs of the occupant  26 . In this arrangement, the second airbag storage compartment  33  shares a common wall with the glove box storage compartment  42 . 
     Referring to  FIG. 4 , a cross-car (side) view of an exemplary embodiment of the airbag module  30  is illustrated in the folded (non-deployed) state, and includes the torso airbag  32  stored in the first airbag storage compartment  31 . The airbag module  30  also includes the knee airbag  34  stored in the second airbag storage compartment  33 ; the inflator  36 ; a plurality of coupling members  38 ; the glove box assembly  40 ; and the housing  50 . According to the exemplary embodiment, the glove box assembly  40  includes the glove box storage compartment  42 , a glove box frame  44 , and the glove box door  46 . The glove box frame  44  is configured to comprise of a plurality of walls coupled together, which may enclose the glove box storage compartment  42 , and may further comprise a mechanism for coupling an airbag through one of the coupling members  38 . According to the exemplary embodiment, the housing  50  includes a plurality of fixed walls  52  (some of which comprise the cover  51 ), and a vehicle attachment mechanism  58 . The fixed walls  52  may be configured to accommodate the packaging constraints of the vehicle  10 , to offer structural support to withstand the forces generated during deployment of the torso airbag  32  and the knee airbag  34 , and to provide structure for coupling the inflator  36  and for directing the gas generated by the inflator  36  into the airbags  32  and  34 . The inflator  36  is configured to generate and force gas into both the torso airbag  32  and the knee airbag  34 . This embodiment reduces the mass, the packaging size required, and the cost by integrating all components in an efficient manner. Other useful systems or features (e.g., fuses) may be incorporated into this embodiment. 
     Referring to  FIG. 5 , a cross-car (side) view of another exemplary embodiment of airbag module  30  is illustrated in the folded (non-deployed) state, and includes the torso airbag  32  in the first airbag storage compartment  31 . The airbag module  30  also includes the knee airbag  34  in the second airbag storage compartment  33 , inflators  36   a  and  36   b , the plurality of coupling members  38 , the glove box assembly  40 , and the housing  50 . The two inflators  36   a  and  36   b  may be configured such that inflator  36   a  generates and supplies gas to the torso airbag  32 , while the inflator  36   b  generates and supplies gas to the knee airbag  34 . 
     Referring to  FIG. 6 , a cross-car (side) view of another exemplary embodiment of airbag module  30  is illustrated in the folded (non-deployed) state, and includes the torso airbag  32  in the first airbag storage compartment  31 . The airbag module  30  also includes the knee airbag  34  in the second airbag storage compartment  33 , the inflator  36 , the plurality of coupling members  38 , the glove box assembly  40 , and the housing  50 . The cover  51  of housing  50  may be configured to minimize the packaging space required by reducing the number of the fixed walls  52  which comprise it. This exemplary embodiment optimizes the mass, the packaging size required, and the cost of the integrated assembly. 
     Referring to  FIG. 7 , a cross-car (side) view of an example of a mid-mount passenger torso airbag  32   a  is illustrated within the dashboard of a vehicle in the unfolded (deployed) state. One method of folding the mid-mount passenger airbag of  FIG. 7  is shown in  FIG. 8 . The mid mount passenger airbag  32   a  is an example of the type of torso airbag  32  in  FIGS. 3   a - 6  that may be integrated with a glove box and a passenger knee airbag into one airbag module  30 . Other examples of mid-mount passenger torso airbags  32   b  may include different methods of folding to modify deployment of the torso airbag  32  to accommodate other design factors. 
     Referring to  FIG. 9 , a cross-car (side) view of an example of a top-mount passenger torso airbag  32   b  is illustrated within the dashboard of a vehicle in the unfolded (deployed) state. One method of folding the top-mount passenger airbag of  FIG. 9  is shown in  FIG. 10 . The top mount passenger airbag  32   b  is an example of the type of torso airbag  32  in  FIGS. 3   a - 6  that may be integrated with a glove box and a passenger knee airbag into one airbag module  30 . Other examples of mid-mount passenger torso airbags  32   b  may include different methods of folding to modify deployment of the torso airbag  32  to accommodate other design factors. 
     Referring to  FIG. 11 , a cross-car (side) view of an example of a non-deployed top-mount passenger airbag  32   b  and an example of a non-deployed knee airbag  34   a  mounted in a glove box door  46   a  is shown. The second storage compartment  33  in  FIGS. 3   a - 6  may be located similarly to a storage compartment  33   a . The storage compartment  33   a  is attached to the glove box door  46   a  inside of a glove box storage compartment  42   a . The knee airbag  34  may then be located similar to the knee airbag  34   a . The knee airbag  34   a  is located in the storage compartment  33   a . An inflator  36   c  is shown inside the storage compartment  33   a  but may be positioned outside of the glove box door  46   a  and may be positioned within or external to the glove box assembly  40   a . The knee airbag  34   a  may be rolled, folded, or an combination thereof to improve deployment or to accommodate different packaging requirements of customers. Referring to  FIG. 12 , the top-mount passenger airbag  32   b  and the knee airbag  34   a  mounted in the glove box door  46   a  from  FIG. 11  are shown deployed. 
     The exemplary airbag placements of  FIGS. 11-12  provide efficient safety having reduced packaging space and reduced mass. Often the glove box door  46   a  is located within a vehicle such that its positioning is optimal for protecting the knees of the occupant, since glove box door  46   a  may be located proximate to and forward of the knees of the occupant. This forward and proximate position may be optimal because during a substantially frontal impact of a vehicle, the knees of the occupant will move forward from the forces generated by the decelerating mass of the occupant, and move towards the knee airbag  34   a . This proximate position allows for a smaller airbag curtain, using less material, which costs less and requires a smaller package. Additionally, this position may eliminate the need for additional features (e.g., tethers) that modify airbag deployment to achieve optimal deployment when non-optimal positioning is required. 
     Referring to  FIG. 13 , a cross-car section view of a second example of a non-deployed top-mount passenger airbag  32   c  and the example of a non-deployed knee airbag  34   a  mounted in the glove box door  46   a  is shown. The top mount passenger airbag  32   c  is an example of the type of torso airbag  32  in  FIGS. 3   a - 6  that may be integrated with a glove box and a passenger knee airbag into one airbag module  30 . 
     As utilized herein, the terms “approximately,” “about,” “substantially”, and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims. 
     It should be noted that the terms “example” and “exemplary” as used herein to describe various embodiments is intended to indicate that such embodiments are possible representations and/or illustrations of possible embodiments (and such terms are not intended to connote that such embodiments are necessarily extraordinary or superlative representations). 
     The terms “coupled,” “connected,” and the like as used herein mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. 
     References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below,” etc.) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure. 
     It is important to note that the construction and arrangement of the airbag module as shown in the various exemplary embodiments is illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention.