Abstract:
An inflatable knee airbag is typically stored in a packaged state within an airbag housing. The housing often has a cover, which can be either a cosmetic cover or an unfinished cover, if the cover will not be readily visible to an occupant. During inflatable airbag deployment, the housing may contribute to determining the airbag&#39;s trajectory. A car-forward portion of an airbag housing that is horizontally oriented may rotate in a car-downward direction to allow a deployment trajectory of the deploying airbag to be more vertically oriented.

Description:
TECHNICAL FIELD 
       [0001]    The present disclosure relates generally to the field of automotive protective systems. More specifically, the present disclosure relates to housings for inflatable knee airbag assemblies. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0002]    The present embodiments will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that the accompanying drawings depict only typical embodiments, and are, therefore, not to be considered to be limiting of the disclosure&#39;s scope, the embodiments will be described and explained with specificity and detail in reference to the accompanying drawings. 
           [0003]      FIG. 1A  is a side elevation view of an airbag assembly  100 , wherein the assembly is in a packaged state and is located in a low-mount position under a knee bolster of a vehicle. 
           [0004]      FIG. 1B  is a side elevation view of the airbag assembly of  FIG. 1A  after the airbag has begun to be deployed. 
           [0005]      FIG. 2A  is a cross-sectional view of the airbag assembly of  FIGS. 1A-1B , wherein the airbag assembly is in the packaged configuration. 
           [0006]      FIG. 2B  is a cross-sectional view of the airbag assembly of  FIG. 2A , wherein the assembly is in a deployed configuration. 
           [0007]      FIG. 3A  is a rear perspective view of the airbag housing shown in  FIGS. 2A-2B , wherein the housing is in a packaged configuration 
           [0008]      FIG. 3B  is a rear perspective view of the airbag housing shown in  FIG. 3A , wherein the housing is in the deployed configuration. 
           [0009]      FIG. 4  is an exploded perspective view of the airbag assembly shown in  FIGS. 1A-2B . 
           [0010]      FIG. 5A  is a cross-sectional view of another embodiment of an inflatable airbag assembly, wherein the assembly is in a packaged configuration. 
           [0011]      FIG. 5B  is a cross-sectional view of the airbag assembly of  FIG. 5A , wherein the assembly is in a deployed configuration. 
           [0012]      FIG. 6  is a top perspective view of the airbag assembly shown in  FIGS. 5A-5B . 
           [0013]      FIG. 7  is an exploded perspective view of the airbag assembly shown in  FIG. 6 . 
           [0014]      FIG. 8A  is a cross-sectional view of another embodiment of an airbag assembly, wherein the assembly is in the packaged configuration. 
           [0015]      FIG. 8B  is a cross-sectional view of the airbag assembly shown in  FIG. 8A , wherein the assembly is in the deployed configuration. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0016]    It will be readily understood that the components of the embodiments as generally described and illustrated in the figures herein could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of various embodiments, as represented in the figures, is not intended to limit the scope of the disclosure, as claimed, but is merely representative of various embodiments. While the various aspects of the embodiments are presented in drawings, the drawings are not necessarily drawn to scale unless specifically indicated. 
         [0017]    The phrases “connected to,” “coupled to” and “in communication with” refer to any form of interaction between two or more entities, including mechanical, electrical, magnetic, electromagnetic, fluid, and thermal interaction. Two components may be coupled to each other even though they are not in direct contact with each other. The term “abutting” refers to items that are in direct physical contact with each other, although the items may not necessarily be attached together. 
         [0018]    Inflatable airbag systems are widely used to minimize occupant injury in a collision scenario. Airbag modules have been installed at various locations within a vehicle, including, but not limited to, the steering wheel, the instrument panel, within the side doors or side seats, adjacent to roof rail of the vehicle, in an overhead position, or at the knee or leg position. In the following disclosure, “airbag” may refer to an inflatable curtain airbag, overhead airbag, front airbag, or any other airbag type. 
         [0019]    During installation, the airbags are rolled, folded, or both, and are retained in the packaged configuration behind a cover. During a collision event, vehicle sensors trigger the activation of an inflator, which rapidly fills the airbag with inflation gas. Thus the airbag rapidly changes conformations from the packaged configuration to an expanded configuration. 
         [0020]      FIGS. 1A-1B  depict side views of an airbag assembly  100 , wherein the airbag assembly is in a low-mount position under a knee bolster  12  of a vehicle. Airbag assembly  100  may comprise an inflatable airbag  110 , an inflatable airbag housing  120 , a cover  140 , and an inflator  150 . Airbag  110  is coupled to inflator  150  and housing  120 , such that the inflator can inflate the airbag. Housing  120  may comprise a car-downward portion  125 , a car-forward wall  126 , and a hinge  129 . In the depicted embodiment, hinge  129  comprises a mechanical hinge; however, in other embodiments the hinge may comprise a living hinge. Cover  140  may be rotatably coupled to a car-rearward opening of housing  120 . Cover  140  may not rotate about hinge  129 . In the depicted embodiment, cover  140  is flush with a car-rearward surface of knee bolster  12 ; however, in other embodiments, the airbag assembly may lack a cosmetic cover, and/or the cover may be recessed from the knee bolster. 
         [0021]      FIG. 1A  depicts airbag assembly in a packaged configuration, wherein housing  120  is in a contracted configuration. Housing  120  may also be said to be in the packaged configuration, an undeployed configuration, an unexpanded configuration, or an unrotated configuration. In  FIG. 1B , car-downward portion  125  has rotated about hinge  129 , such that car-forward wall  126  has expanded. Cover  140  has been forced open by pressure from expansion of airbag  110 . As a result of the articulation of housing  120 , an initial deployment trajectory of airbag  110  is in a more car-upward and car-rearward direction than if housing  120  did not articulate. 
         [0022]      FIGS. 2A-2B  depict cross-sectional views of airbag assembly  100  of  FIGS. 1A-1B , wherein more details can be appreciated in the views of  FIGS. 2A-2B . Assembly  100  is depicted in a low-mount position below knee bolster  12 . Cover  140  is configured to block the car-rearward opening of housing  120 , such that airbag  110  is retained within a void of the housing. An optional lower cover  141  may be employed in some embodiments. Inflator  150  may be coupled to airbag  110  and car-upward portion  121  of housing  120  via at least one inflator mounting stem  151 . Inflator mounting stem  151  may be coupled to housing  120  via mounting hardware  102 , which in the depicted embodiment comprises a threaded nut. 
         [0023]    Car-upward portion  121  and car-downward portion  125  each comprise car-forward walls  122  and  126 , which are configured such that they can move independently of each other within a predetermined range, when the car-downward portion of housing  120  rotates about hinge  129 . A car-forward tether  130  may be coupled to each car-forward wall  122  and  126  using tether mounting hardware  131 . Car-forward tether  130  may comprise a flexible member, such as fabric or plastic, such that the tether allows the housing to adopt the contracted and expanded configurations. 
         [0024]    In  FIG. 2A , assembly  100  is in the packaged configuration, wherein housing  120  is in the contracted configuration. When housing  120  is in the contracted configuration, car-forward tether  130  is in a slack state. In  FIG. 2B , assembly  100  is in the deployed and inflated configuration, wherein housing  120  is in the expanded configuration. Upon receiving electronic communication from vehicle sensors, inflator  150  may release and/or produce inflation gas into an inflatable void  114 , which may begin to inflate a throat portion  111  of airbag  110 . Pressure from inflation gas may act on car-downward portion  125  of housing  120 , and thereby cause the car-downward portion of the housing to rotate about the hinge, which causes car-forward wall  126  to rotate in the car-downward direction. Car-forward wall  126  may continue to rotate downward until stopped by car-forward tether  130  and/or side tether  135 , which is shown In  FIGS. 3A-3B . Housing  120  may comprise one or more side tethers  135 , which may be coupled to sidewalls of car-upward and car-downward portions  121  and  125  of the housing via side tether mounting structures  136 . Side tethers  135  may comprise a fabric. 
         [0025]    As will be appreciated by those skilled in the art, a variety of types and configurations of airbag housings can be utilized without departing from the scope and spirit of the present disclosure. For example, the size, shape, and proportions of the housing may vary from the depicted embodiment. One skilled in the art will also appreciate that the airbag housing may comprise a variety of materials or combinations of materials. For example, the housing may comprise metal, plastic, or composite materials. 
         [0026]    As will be appreciated by those skilled in the art, a variety of types and configurations of inflatable knee airbags can be utilized without departing from the scope and spirit of the present disclosure. For example, the size, shape, and proportions of the airbag cushion may vary according to its use in different vehicles or different locations within a vehicle such that the airbag may comprise an inflatable curtain cushion; a rear passenger side airbag; a driver&#39;s airbag; a knee airbag; and/or a front passenger airbag. Also, the airbag may comprise one or more of any material well known in the art, such as a woven nylon fabric, which may be coated with a substance, such as silicone. Additionally, the airbag cushion may be manufactured using a variety of techniques such as one piece weaving, cut and sew, or a combination of the two techniques. Further, the cushion membrane may be manufactured using sealed or unsealed seams, wherein the seams are formed by stitching, adhesive, taping, radio frequency welding, heat sealing, or any other suitable technique or combination of techniques. 
         [0027]      FIGS. 3A-3B  are perspective views of a portion of airbag assembly  100 . In  FIG. 3A , housing  120  is in the contracted configuration, and in  FIG. 3B , the housing is in the expanded configuration. Housing  120  may comprise car-upward portion  121 , car-forward wall  122  of upward portion  121 , an inflator connection aperture  123 , car-downward portion  125 , car-forward wall  126 , hinge  129 , car-forward tether  130 , tether mounting hardware  131 , sidewall  133  of car-upward portion  121 , sidewall  134  of car-downward portion  126 , a plurality of side tethers  135 , and side tether mounting hardware  136 . Mounting tabs  104  may be coupled to housing  120 , wherein the mounting tabs may be employed to couple the housing to a vehicle structure. Inflator mounting stems  151  protrude through apertures in car-upward portion  121  of airbag housing  120 , and may be coupled to the airbag housing via mounting hardware  102 . 
         [0028]      FIG. 4  is an exploded perspective view of airbag assembly  100 . Assembly  100  may comprise airbag  110 , housing  120 , and inflator  150 . Airbag  110  comprises throat portion  111 , inflator inset aperture  113 , and inflator mounting stem aperture  112 . Housing  120  may comprise car-upward portion  121 , car-forward wall  122  of upward portion  121 , an inflator connection aperture  123 , a plurality of inflator mounting stem apertures  124 , car-downward portion  125 , car-forward wall  126 , hinge  129 , hinge hardware  107 , car-forward tether  130 , tether mounting hardware  131 , sidewall  133  of car-upward portion  121 , sidewall  134  of car-downward portion  126 , a plurality of side tethers  135 , and side tether mounting hardware  136 . Tethers  130  and  135  may be coupled to housing  120  via mounting brackets  106 . Mounting tabs  104  may be coupled to housing  120 , wherein the mounting tabs may be employed to couple the housing to a vehicle structure. Inflator  150  is configured to be partially inserted into inflator insert aperture  113  of housing  110 , such that inflator mounting stems  151  protrude through the airbag apertures  112  and  113  and also protrude through apertures  124  of car-upward portion  121 . Mounting hardware  102  may be employed to secure inflator  150  and airbag  110  to housing  120 . 
         [0029]      FIGS. 5A-7  depict another embodiment of an inflatable airbag assembly  200  with an articulating housing  220 , wherein assembly  200  and housing  220  resemble assembly  100  and housing  120 , described above, in certain respects. Accordingly, like features may be designated with like reference numerals, with the leading hundreds numeral incremented from “1” to “2.” Any suitable combination of the features described with respect to assembly  100  can be employed with assembly  200 , and vice versa. 
         [0030]      FIG. 5A  depict cross-sectional views of airbag assembly  200  Assembly  200  is depicted in a low-mount position below knee bolster  12 . Assembly  200  may comprise an inflatable airbag  210 , a housing  220 , a cover  240 , and an inflator  250 . Cover  240  may comprise an extension of housing  220 , or may comprise a separate piece that is attached to housing  220 . Cover  240  is configured to block the car-rearward opening of housing  220 , such that airbag  210  is retained within a void of the housing. 
         [0031]    Housing  220  may comprise a car-upward portion  221 , a car-forward wall  222 , a car-downward portion  225 , a plurality of apertures  227 , a plurality of extensions  228 , and a hinge region  229 . Car-downward portion  225  may also be called a car-downward wall of the car-downward portion. Car-upward portion  221  may comprise a reaction plate that may comprise a rigid member. In some embodiments, the reaction plate may comprise a piece of metal. Reaction plate  221  may comprise a plurality of extensions  238 , which are depicted as “hooks”  238 . Hooks  238  are configured to be received by apertures  227 , which may be called “windows.” In some embodiments, an entirety of the airbag housing may be described as being flexible, and may comprise plastic. In the depicted embodiment, an entirety of housing  220  comprises plastic, except reaction plate  221 . Car-forward wall  222  of housing  220  comprises a plurality of folds, undulations, or ribs, which may also be described as accordion folds. Inflator  250  may be coupled to airbag  210  and reaction plate  221  of housing  220  via at least one inflator mounting stem  251  and mounting hardware, such as a threaded nut. 
         [0032]    In  FIG. 5A , assembly  200  is in a packaged configuration, wherein housing  220  is in a contracted configuration. In  FIG. 5B , assembly  200  is in the deployed and inflated configuration, wherein housing  220  is in the expanded configuration. Upon receiving electronic communication from vehicle sensors, inflator  250  may release and/or produce inflation gas into an inflatable void  214 , which may begin to inflate a throat portion  211  of airbag  210 . Pressure from inflation gas may act on car-downward portion  225  of housing  220 , and thereby cause the car-downward wall of the car-downward portion of the housing to rotate about hinge region  229 , which causes the accordion folds of car-forward wall  222  to expand. Hinge region  229  may not comprise a mechanical hinge, but rather, may comprise a living hinge. Further hinge region  220  may not comprise a specific location about which car-downward portion  225  rotates. Rather, housing  220  may generally flex at any of the car-rearward areas of the housing. 
         [0033]      FIG. 6  is a perspective view of airbag housing  220 , wherein the housing is in the constricted configuration. Housing  220  may comprise reaction plate  221 , which may comprise an aperture  223  for connecting the inflator, a plurality of hooks  238 , and flanges  239 . Flanges  239  may be employed to help couple airbag housing  220  to a vehicle structure. Inflator mounting stems  251  may protrude through reaction plate  221 , and the mounting stems may be secured to the plate via nuts  202 . Housing  220  further comprises a car-forward wall  222  and two lateral sidewalls  232 . Lateral sidewalls  232  may be called side portions. Walls  222  and  232  may each at least partially comprise plurality of folds, such as accordion folds. Housing  220  may further comprise cover  240 , which may have a tear seam  242  that in the depicted embodiment comprises perforations. Hooks  228  of housing  220  may protrude through windows in reaction plate  221  to help secure the reaction plate to the housing. 
         [0034]      FIG. 7  is an exploded perspective view of airbag assembly  200 . Housing  200  comprises reaction plate  221 , which may comprise inflator connecting aperture  223 , a plurality of inflator mounting stem apertures  224 , windows  237 , hooks  238 , and flanges  239 . Housing  220  may also comprise car-downward portion  225 , car-forward wall  222 , longitudinal sidewalls  232 , windows  227 , hooks  228 , cover  240 , and perforations  243 . Reaction plate  221  is configured to be coupled to car-downward portion  225  via hooks  238  of the reaction plate being received by windows  227  the car-downward portion  225 . The reaction plate is configured to be further coupled to car-downward portion  225  via hooks  228  of the car-downward portion being received by windows  237  in the reaction plate. 
         [0035]    For clarity, airbag  210  is cutaway In  FIG. 7 . Airbag  210  and inflator  250  are configured to be coupled together via the inflator being inserted in to an inflator insert aperture  213  of throat portion  211 , such that inflator mounting stems  251  protrude through apertures  212  and  213  of the airbag. Airbag  210  and inflator  250  may be coupled to housing  220  via inflator mounting stems  251  of inflator  250  extending through apertures  224  of reaction plate  221 . 
         [0036]      FIGS. 8A-8B  depict another embodiment of an inflatable airbag assembly  300  with an articulating housing  320 , wherein assembly  300  and housing  320  resemble assemblies  100  and  200 , as well as housings  120  and  220  described above, in certain respects. Accordingly, like features may be designated with like reference numerals, with the leading hundreds numeral incremented from “1” or “2” to “3”. Any suitable combination of the features described with respect to assemblies  100  and/or  200  can be employed with assembly  300 , and vice versa. 
         [0037]      FIGS. 8A-8B  depict cross-sectional views of airbag assembly  300  Assembly  300  is depicted in a low-mount position below knee bolster  12 . Assembly  300  may comprise an inflatable airbag  310 , a housing  320 , a cover  340 , and an inflator  350 . Cover  340  may comprise an extension of housing  320 , or may comprise a separate piece that is attached to housing  320 . Cover  340  is configured to block the car-rearward opening of housing  320 , such that airbag  310  is retained within a void of the housing. 
         [0038]    Housing  320  may comprise a car-upward portion  321 , a car-forward wall  322 , a car-downward portion  325 , a plurality of apertures  327 , a plurality of extensions  328 , and a hinge region  329 . Car-upward portion  321  may comprise a reaction plate that in some embodiments may comprise a piece of metal. Reaction plate  321  may comprise a plurality of extensions  338 , which are depicted as “hooks”  338 . Hooks  338  are configured to be received by apertures  327 , which may be called “windows”. In some embodiments, an entirety of the airbag housing may comprise plastic. In the depicted embodiment, an entirety of housing  320  comprises plastic, except reaction plate  321 . Car-forward wall  322  of housing  320  comprises a plurality of undulations, or ribs, which may also be described as accordion folds. Inflator  350  may be coupled to airbag  310  and car-downward portion  225  of housing  320  via at least one inflator mounting stem  351  and mounting hardware, such as a threaded nut. 
         [0039]    In  FIG. 8A , assembly  300  is in a packaged configuration, wherein housing  320  is in a contracted configuration. In  FIG. 8B , assembly  300  is in the deployed and inflated configuration, wherein housing  320  is in the expanded configuration. Upon receiving electronic communication from vehicle sensors, inflator  350  may release and/or produce inflation gas into an inflatable void  314 , which may begin to inflate a throat portion  311  of airbag  310 . Pressure from inflation gas may act on car-downward portion  325  of housing  320 , and thereby cause the car-downward portion of the housing to rotate about hinge region  329 , which causes the accordion folds of car-forward wall  322  to expand. Hinge region  329  may not comprise a mechanical hinge, but rather, may comprise a living hinge. Further hinge region  320  may not comprise a specific location about which car-downward portion  325  rotates. Rather, housing  320  may generally flex at any of the car-rearward areas of the housing. 
         [0040]    Any methods disclosed herein comprise one or more steps or actions for performing the described method. The method steps and/or actions may be interchanged with one another. In other words, unless a specific order of steps or actions is required for proper operation of the embodiment, the order and/or use of specific steps and/or actions may be modified. 
         [0041]    Reference throughout this specification to “an embodiment” or “the embodiment” means that a particular feature, structure or characteristic described in connection with that embodiment is included in at least one embodiment. Thus, the quoted phrases, or variations thereof, as recited throughout this specification are not necessarily all referring to the same embodiment. 
         [0042]    Similarly, it should be appreciated that in the above description of embodiments, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure. This method of disclosure, however, is not to be interpreted as reflecting an intention that any claim require more features than those expressly recited in that claim. Rather, as the following claims reflect, inventive aspects lie in a combination of fewer than all features of any single foregoing disclosed embodiment. Thus, the claims following this Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment. This disclosure includes all permutations of the independent claims with their dependent claims. 
         [0043]    Recitation in the claims of the term “first” with respect to a feature or element does not necessarily imply the existence of a second or additional such feature or element. Elements recited in means-plus-function format are intended to be construed in accordance with 35 U.S.C. §112 ¶ 6. It will be apparent to those having skill in the art that changes may be made to the details of the above-described embodiments without departing from the underlying principles of the invention. Embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows.