Abstract:
An airbag system for a vehicle including an airbag, an inflator and a cover a cover positioned between the airbag and the vehicle interior. The airbag is folded so that at least two portions of the airbag are positioned adjacent the inflator. The two portions of the airbag include only a single layer of material so that the two portions of the airbag deploy outside the cover before a remaining portion of the airbag.

Description:
BACKGROUND 
   The present invention relates generally to systems and devices for protecting vehicle occupants from injury. More specifically, the present invention relates to airbag devices. 
   An airbag device installed in an automobile includes an airbag, a gas generator commonly called an inflator, and a module cover for covering and retaining the airbag. In an emergency of the automobile, such as when the automobile collides, the gas generator operates, causing the airbag to expand and to catch an occupant in the automobile. 
   The airbag may be a driver-side airbag, a passenger-side airbag, a rear-side airbag, and a side-protection airbag. Among various airbag devices, a whole structure of the passenger-side airbag device is stored in an instrument panel at a front of a vehicle cabin. 
   The airbag module generally includes a retainer for retaining the airbag. The retainer is typically connected to the vehicle structure. The airbag module typically includes a cover overlying the airbag and retainer and the outer surface of the module cover faces into the vehicle passenger compartment. For a driver airbag device, the airbag module is mounted to a steering wheel of a vehicle. For a passenger airbag device, the airbag module is mounted to an instrument panel of the vehicle. In the event of a vehicle emergency such as a collision, an inflator in the airbag module delivers inflation gas into the airbag thereby inflating the airbag. As the airbag inflates, the airbag exerts pressure on the module cover. When sufficient pressure is exerted on the module cover, the cover ruptures and opens toward the inside of the vehicle cabin thereby allowing the airbag to be inflated inside the vehicle cabin to protect a vehicle occupant. 
   The airbag is deployed out of the steering wheel or dash and toward an occupant. However, for certain conventional airbags, individuals positioned out of position (“OOP”) are in danger of impacting the airbag at a relatively high force. An OOP situation can be, for example, when an occupant&#39;s chest is adjacent to the dash panel. In this position, three or six year old dummies received chest impact pressures exceeding Federal standards. In addition, such conventional airbags can cause neck injuries to individuals in such an OOP situation. 
   Thus, there remains a need to protect an occupant in an OOP situation. In particular, there remains a need to protect an occupant&#39;s neck and chest in an OOP situation during a collision. 
   SUMMARY 
   According to an embodiment of the present invention, an airbag system for a vehicle is provided. The airbag system comprises an airbag cushion, an inflator for inflating the airbag cushion, a module for holding the airbag cushion, and a cover positioned between the uninflated airbag cushion and the vehicle interior. The airbag cushion is folded such that a single layer of material area is positioned over a central portion of the inflator. 
   According to an embodiment of the present invention, an airbag system for a vehicle is provided. The airbag system comprises an airbag cushion with a first portion and a second portion; an inflator for inflating the airbag cushion; a module for holding the airbag cushion; and a cover positioned between the uninflated airbag and the vehicle interior. The airbag cushion is configured to deploy initially laterally left and right of an opening of the cover. 
   It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only, and are not restrictive of the invention as claimed. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     These and other features, aspects, and advantages of the present invention will become apparent from the following description, appended claims, and the accompanying exemplary embodiments shown in the drawings, which are briefly described below. 
       FIG. 1  is a sectional view of an airbag module according to an embodiment. 
       FIG. 2  is a perspective view of a filled cushion according to  FIG. 1 . 
       FIG. 3  is a front view of the cushion upon initial inflation, according to  FIG. 1 . 
       FIG. 4  is a front view of the cushion, according to  FIG. 1 . 
       FIG. 5  is a side view of the cushion fully inflated. 
       FIG. 6  is a view of an occupant impacting the cushion. 
       FIG. 7  is a sectional view of an airbag module according to another embodiment. 
       FIGS. 8(   a ) and  8 ( b ) are views of an airbag in the upper portion of a dashboard in deployment.  FIG. 8(   a ) shows the initial path of the deploying airbag and  FIG. 8(   b ) shows the airbag fully deployed. 
       FIGS. 9(   a ) and  9 ( b ) are views of an airbag in the lower portion of a dashboard in deployment.  FIG. 9(   a ) shows the initial path of the deploying airbag and  FIG. 9(   b ) shows the airbag fully deployed. 
       FIG. 10  is an alternative front view of the cushion of  FIG. 3  upon initial inflation. 
       FIG. 11  is another view of the cushion of  FIG. 3  during inflation. 
       FIG. 12  is a view of an airbag module with the cover and airbag shown. 
       FIG. 13  is another view of the airbag module with the cushion of  FIG. 3  during deployment. 
   

   DETAILED DESCRIPTION 
   Hereinafter, embodiments of the present invention will be described with reference to the attached drawings. 
     FIGS. 1-4  show an embodiment of an airbag module  100 . The airbag module  100  includes an airbag cushion  10 , an inflator  20 , a retainer  30 , and a module cover  40 . 
   The airbag module  100  may be mounted in the front dashboard panel or other suitable location in the vehicle. The airbag module  100  is positioned within the dashboard panel of the vehicle in order to protect an occupant in a collision, specifically a frontal collision. However, the airbag module may be mounted along the side, in a door, in a steering wheel, or any other suitable location for protecting a passenger or driver of a vehicle. 
   The inflator  20  provides the inflation gas to inflate and deploy the airbag cushion  10  during a collision. The inflator  20  may comprise a gas generant or propellant in order to provide inflation gas to the airbag cushion  10 . In addition, the inflator  20  may include a decomposing type material as the source of the pressurized gas for the airbag cushion  10 . The inflator  20  may include an igniter or initiator assembly (not shown). The igniter receives a signal from a controller in order to initiate operation of the inflator  20  when the controller determines a collision is occurring. 
   The airbag module  100  is mounted to the vehicle by the retainer  30 . The retainer holds the uninflated airbag cushion  10 . 
   Cover  40  is attached to the retainer  30  such that an open area is created between the cover  40  and the retainer  30 . The cover  40  forms the barrier between the airbag cushion  10  and the inside of the vehicle passenger cabin area. For example, the cover  40  may form the panel along the front dashboard in a vehicle. 
   The cover  40  is generally formed of a plastic material. The cover  40  must be able to withstand any wear and tear derived from its position in the cabin of a vehicle and must also be able to break open upon deployment of the airbag cushion  10 . 
   The cover  40  may include a notch or tear seam, such as shown in  FIGS. 12 and 13 . The notch is a weakened area that allows the cover  40  to break open upon deployment of the airbag cushion  10 . The airbag cushion  10 , as it is being filled with inflation gas, pushes with a force against the inside of the cover  40 . The notch or weakened area allows the cover  40  to break open at an appropriate location and at an appropriate time during deployment of the airbag cushion  10 . 
   The cover  40 , according to an embodiment, is configured to break open along three sides, forming a rectangular shape. The cover  40  is configured to open along a first side  42 , second side  46  and a lower side  44 , as shown in  FIG. 3 . The first, second and lower sides  42 ,  46 ,  44  may open concurrently, or in delayed intervals. As the first, second, and lower sides  42 ,  46 ,  44  open, the cover  40  remains attached to the vehicle along an upper connecting side  48 . As the cushion  10  deploys, the cushion  10  extends into the vehicle cabin area adjacent the first and second sides  42 ,  46 , and then as the airbag cushion  10  later deploys, the cushion  10  expands adjacent the lower side  44 . Upon final deployment, the cover  40  is capable of flipping up and backwards to allow the cushion  10  to fully inflate and protect an occupant. 
   The cover  40  at the connection side  48  may be hingedly connected, connected by a crease, or any other suitable mechanism. It should be recognized by one skilled in the art that the connecting side  48  may be located on any side of the cover (first, second, upper, lower, etc.). Furthermore, the cover  40  is not limited to a rectangular shape. The cover  40  may comprise any shape, with any suitable number of sides, such as a circle, oval, triangle, etc. 
   According to another embodiment, the cover  40  may not remain connected to the vehicle upon inflation of the cushion  10 . Rather, the cover  40  may disconnect from the vehicle as the cushion  10  deploys. Further, the cover  40  can break open in any appropriate configuration, such as along one or two sides. 
   The airbag cushion  10  includes two gas bag sections, a first section  12  and a second section  16 , which are formed of a single airbag. The sections  12 ,  16  are configured to deploy away from each other, such as shown in  FIGS. 2 and 3 . The first section  12  creates a first lobe which deploys out of a first side  42  of the cover  40 . The second section  16  creates a second lobe which deploys out of a second side  46  of the cover  40 . As the first and second sections  12 ,  16  deploy, they deploy laterally left and right of the cover  40  opening. This lateral deployment causes the airbag cushion  10  to initially contact the occupant  50  towards the sides of the chest and shoulders, rather than directly in the center of the chest and face. This initial contact distributes the total force imposed on the occupant  50  over a larger area and at a lower force level per unit of area. 
   The airbag cushion  10  may be formed of a fabric, such as a nylon or polyester weave. However, the airbag cushion  10  may be comprised of any suitable material. 
   According to an embodiment, the cushion  10  with the first and second sections  12 ,  16  can be formed by a twin fold utilizing a random fold such as a crunch fold, as shown in  FIG. 1 . The crunch fold is a random fold that the cushion  10  is folded essentially randomly on a small scale. On a larger scale, the cushion  10  can be folded with areas of generally fine, medium or relatively course crunch folds. Upon deployment, the crunched cushion  10  simply expands from its crunched state into an expanded state. The cushion  10 , according to this embodiment, may be crunched randomly into the module  10 , but formed such that the two sections  12 ,  16  will deploy laterally left and right of the module cover  40  opening. 
   According to another embodiment, the cushion  10  with the first and second sections  12 ,  16  may be formed by folding the cushion  10  in an appropriate geometric pattern. Such methods are commonly known in the art. The geometric pattern should, according to an embodiment, minimize the bulk of the cushion  10 , such that the space required in the airbag module  10  between the cover  40  and the retainer  30  is relatively small. For example, one possible fold is shown in  FIG. 7 . 
   According to another embodiment, the cushion  10  may be folded and/or packed into the module  100  such that a single layer  18  of material is directly over the center of the deployment area, as shown in  FIG. 1 . The single layer of material area  18  may be comprised of, for example, a single layer of airbag material, as opposed to an area containing the numerous folds or crunched portion of the cushion  10 . As shown in  FIG. 1 , the single layer of material section  18 , according to an embodiment of the present invention, is the only portion of the airbag  10  positioned over the exit port  72  for the inflator  20 . One possible advantage is that the airbag module  100  requires relatively less pressure and therefore less time to accelerate the single layer of material, as opposed to the multiple layers packed above the inflator  20 , as shown in  FIG. 7 . In this embodiment, the aim or initial movement of the cushion  10  is determined by the location of the single layer area  18  in relation to the remaining portion of the airbag; the thickly packed and randomly folded areas  19 . The airbag  10  can include multiple single layer area  18 , such as shown in  FIG. 1 . For example, the single layer area  18  may be positioned at either end of the inflator  20  in order to project the first section  12  and second section  16  laterally left and right. 
   The positioning of the single layer of material areas  18  can direct the deployment of the of lobes  12 ,  16  the airbag  10 . As shown in  FIGS. 3 and 4 , the lobes  12 ,  16  deploy laterally left and right due to the location of the single layer of material areas  18  over the inflator  20 . 
   According to another embodiment, the first section  12  and the second section  16  are formed by two separate and distinct airbags to form the airbag cushion  10 . The first section  12  comprises a first airbag and the second section  16  comprises a second airbag. The first and second sections airbags  12 ,  16  may be connected at the inflator  20 . The first and second sections  12 ,  16  are positioned within the airbag module  100  so that upon deployment, the sections  12 ,  16  deploy laterally left and right. 
   According to another embodiment, the airbag module  100  may also include a sheet or sheet-like element  60 , shown in  FIG. 5 . The sheet  60  spans the area  14  between the first airbag portion  12  and the second airbag portion  16  so that, in the case of an impact directed toward the front side of the gas bag, the occupant  50  to be protected is intercepted by the sheet or sheet-like element  60 . The sheet  60  may connect the airbag sections  12 ,  16  that are a single airbag, or the sheet  60  may connect the airbag sections  12 ,  16  which are formed of separate, distinct airbags. 
   As a result, a body part of the occupant  50  may penetrate into the area  14  for a certain distance; but the occupant  50  is not permitted to completely penetrate into the area  14  past the sheet or sheet-like element  60 . The airbag cushion  10  and sheet or sheet-like element  60  provides for the restraining action for protecting a vehicle occupant  50  to be essentially taken on by the sheet or sheet-like element  60  and, as a result, the two inflatable gas bag sections  12 ,  16  are used essentially only for the purpose of tightening the sheet or sheet-like element  60 . As a result, the restraining action required for protecting the vehicle occupant  50  is achieved with the occupant  50  coming into contact with the covering  60  of the airbag cushion  10  and not with portions of the airbag cushion  10  which are possibly hot. 
   According to an embodiment, in order to fasten the sheet or sheet-like element  60  may be sewn to the airbag cushion  10 . The seams used may be those that are also used for connecting different parts of the airbag sections  12 ,  16 . According to another embodiment, any other suitable mechanism for connecting the sheet  60  to the cushion  10  may be used, such as, for example, tethers, fasteners, adhesives, etc. 
   The airbag module  100  may also include a diffuser  70 , shown in  FIG. 1 . The diffuser  70  is configured to disperse the inflation gases from the inflator  20  and into the airbag cushion  10 . Dispersing the gas allows the gas to expand and cool. The diffuser  70  may also include a surface which further allows the gas to transfer some of its heat. The diffuser  70  may be used to direct the gas by forcing the gas through specific exit ports or holes  72 . Gas may be directed to cause the airbag cushion  10  to inflate in a particular manner, such as, for example, laterally left and right of the cover  40  opening. Once the gas passes through the diffuser  70 , the gas is sufficiently cooled and/or not concentrated to prevent burning holes in the airbag cushion  10 . Without a diffuser  70 , the hot gas is concentrated on the airbag cushion  10 . The concentrated hot gas and the confined space may combine to cause the gas to burn one or more holes in the airbag cushion  10  material. The holes cause the airbag cushion  10  to inflate improperly. The single layer areas  18  of the airbag  10  can be placed over the openings in the diffuser to deploy those areas  18  first. 
   According to another embodiment of the present invention, the remaining randomly folded portions  19  of the airbag  10  can fall over on top of the single layer areas  18  in the folded airbag  10 , as can be seen in  FIG. 7 . In this configuration, the single layer areas  18  will still deploy first, thus determining the shape and location of the deploying airbag. 
   The position of the single layer material area  18  over the inflator  20  determines the location of the initially deployed airbag  10 . Thus, the configuration of the airbag  10  as it initially deploys can be determined or targeted by the positioning of a single layer area  18  over the inflator  20 . For example,  FIGS. 8(   a ) and  8 ( b ) show a side view an airbag  10  positioned in the top portion of a dashboard  82 , near a windshield  84 . In this embodiment, the single layer area  18  of the airbag  10  is positioned over deployment area of the inflator  20 . Thus, in the initial deployment of the airbag  10 , as shown in  FIG. 8(   a ), the single layer area  18  deploys up towards the windshield  84 . When the airbag  10  fully deploys, the airbag  10  extends closer to the occupant, with the single layer area  18  still near the windshield, in the upper portion of the airbag  10 . 
   While the invention is described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention. Furthermore, any combination of embodiments may be used. All references and publications cited herein are incorporated by reference in their entireties.