Abstract:
Inflatable curtain airbags deploy smoothly with an integrated pillar guide that minimizes interference with a vehicle pillar. The integrated pillar is a thin piece of semi-flexible, semi-rigid material housed in a pocket that is coupled to a curtain airbag.

Description:
TECHNICAL FIELD 
       [0001]    The present disclosure relates generally to the field of automotive protective systems. More specifically, the present disclosure relates to inflatable curtain airbags having a deployment guide. The present disclosure also relates to methods of guiding the deployment of inflatable curtain airbags. 
     
    
     
       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, which may not be to scale. 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 perspective view of one embodiment of an airbag assembly, wherein the airbag assembly comprises a mounting assembly that is coupled to an airbag, wherein the mounting assembly is configured to retain the airbag in a packaged configuration. 
           [0004]      FIG. 1B  is a perspective view of the airbag assembly of  FIG. 1A , wherein the airbag is in a deployed configuration. 
           [0005]      FIG. 2A  is a cross-sectional view of an inflatable curtain airbag as shown in  FIG. 1A  and as taken along cutting line  2 A- 2 A. 
           [0006]      FIG. 2B  is a cross-sectional view of the inflatable curtain airbag shown in  FIG. 2A  after the ramp has been positioned adjacent to a pillar. 
           [0007]      FIG. 2C  is a cross-sectional view of the inflatable curtain airbag shown in  FIGS. 2A-2B  as the airbag begins to expand. 
           [0008]      FIG. 2D  is a cross-sectional view of the inflatable curtain airbag shown in  FIGS. 2A-2C  after the airbag has expanded as shown in  FIG. 1B  and as taken along cutting line  2 D- 2 D. 
           [0009]      FIG. 3A  is a perspective view of a ramp ready to be placed in a pocket of the inflatable curtain airbag. 
           [0010]      FIG. 3B  is a perspective view of an inflatable curtain airbag with a ramp in a pocket before the pocket has been sewn closed. 
           [0011]      FIG. 3C  is a perspective view of an inflatable curtain airbag with a ramp sewn into a pocket. 
           [0012]      FIG. 4  is a perspective view of another embodiment of an inflatable curtain airbag with a pocket that was woven to enclose a ramp. 
           [0013]      FIG. 5  is a cross-sectional view of another embodiment of an inflatable curtain airbag after the airbag has expanded. 
           [0014]      FIG. 6  is a cross-sectional view of an additional embodiment of an inflatable curtain airbag after the airbag has expanded. 
           [0015]      FIG. 7  is a cross-sectional view of yet another embodiment of an inflatable curtain airbag after the airbag has expanded. 
       
    
    
     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 the 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]    Inflatable curtain airbags may be used to protect the passengers of a vehicle during a side collision or roll-over event. Inflatable curtain airbags typically extend longitudinally within the vehicle and are usually coupled to or next to the roof rail of the vehicle. The inflatable curtain airbag may expand in a collision scenario along the side of the vehicle between the vehicle passengers and the side structure of the vehicle. In a deployed state, an inflatable curtain airbag may cover at least a portion of side windows and a B-pillar of the vehicle. In some embodiments, inflatable curtain airbags may extend from an A-pillar to a C-pillar of the vehicle. In alternative embodiments, inflatable curtain airbags may extend from the A-pillar to a D-pillar of the vehicle. 
         [0020]    Inflatable curtain airbags are typically installed adjacent to the roof rail of a vehicle in an undeployed state, in which the inflatable curtain airbag is rolled or folded or a combination thereof and retained in the folded or rolled configuration by being wrapped at certain points along the airbag. In this state, the airbag may be said to be in a packaged configuration. When deployed, the airbag exits the packaged configuration and assumes an extended shape. When extended and inflated, the airbag may be said to comprise a deployed configuration. Thus, an airbag mounting apparatus typically allows for a secure connection between the vehicle and the airbag, yet allows the airbag to change configurations from the packaged configuration to the deployed configuration. 
         [0021]      FIG. 1A  depicts an interior of a side of a vehicle  10  and an airbag assembly  100  that comprises an inflatable side curtain airbag cushion  110 . Cushion  110  is mounted adjacent to a vehicle roof rail  20  and extends from an A-pillar  12  to a D-pillar  18 . Inflatable curtain airbag  110  also extends past a B-pillar  14  and a C-pillar  16 . 
         [0022]      FIG. 1A  provides a perspective view of airbag assembly  100 , wherein inflatable curtain airbag  110  is in a packaged configuration. A bridge  120  couples a pocket  140  to the inflatable curtain airbag  110 . A ramp  130  is positioned within pocket  140 . Ramp  130  and pocket  140  are referred to together as pillar guide  150 . Pillar guide  150  is described in detail with respect to  FIGS. 2A-2D  and  FIGS. 3A-3C . The airbag assembly may also comprise an airbag mounting assembly  160 , tethers  170 , a wrapper  180 , and an inflator  190 . 
         [0023]    Inflatable curtain airbag  110  is configured to rupture wrapper  180  during deployment such that inflatable curtain airbag  110  can adopt the deployed configuration. Inflatable curtain airbag  110  becomes inflated upon activation of one or more inflators, such as inflator  190 , such that the inflatable curtain airbag transitions from the packaged configuration to the deployed configuration. Upon activation, inflator  190  rapidly generates and/or releases inflation gas, which rapidly inflates the inflatable curtain airbag. The inflator may be one of several types, such as pyrotechnic, stored gas, or a combination inflator and may comprise a single or multistage inflator. Tethers  170  are located outside inflatable curtain airbag  110 , and in the deployed configuration, the tethers are configured to apply tension to the curtain airbag  110 . 
         [0024]      FIG. 1B  is a perspective view of airbag assembly  100 , wherein inflatable curtain airbag  110  is depicted in a deployed configuration. Inflatable curtain airbag  110  may be described as having an upper portion  111 , a lower portion  112 , an inboard-facing face  113 , an outboard-facing face (not visible) a first end  115 , and a second end  116 . The faces of inflatable curtain airbag  110  define an interior inflatable void  118 , which is in fluid communication with inflator  190 . Inflatable void  118  may be divided into inflation cells  119 . The faces of inflatable curtain airbag  110  may comprise panels of a woven nylon fabric that are coupled together at a seam or opposing sides that are woven as one-piece. 
         [0025]    Upper portion  111  of inflatable curtain airbag  110  is the portion of the curtain airbag that is closest to the headliner of a vehicle when the airbag is in a deployed state. Lower portion  112  is below upper portion  111  when inflatable curtain airbag  110  is in a deployed state, and is closest to a floor of the vehicle. The term “lower portion” is not necessarily limited to the portion of inflatable curtain airbag  110  that is below a horizontal medial plane of the inflatable curtain airbag, but may include less than half, more than half or exactly half of the bottom portion of the inflatable curtain airbag. Likewise, the term “upper portion” is not necessarily limited to the portion of inflatable curtain airbag  110  that is above a horizontal medial plane of the inflatable curtain airbag, but may include less than half, more than half or exactly half of the top portion of the inflatable curtain airbag. 
         [0026]    As will be appreciated by those skilled in the art, a variety of types and configurations of inflatable curtain airbag membranes can be utilized without departing from the scope and spirit of the present disclosure. For example, the size, shape, and proportions of the airbag membrane 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; and/or a front passenger airbag. Also, the cushion membrane may comprise one or more of any material well known in the art, such as a woven nylon fabric. 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]    A plurality of mounting assemblies  160  may be employed to couple inflatable curtain airbag  110  to a vehicle. Mounting assembly  160  may comprise a mounting member  162  having an aperture  164 , and a wrapping member  166  that is connected to airbag cushion  110  via threads  168 . A bolt  22  may attach mounting member  162  to vehicle roof rail  20 . Mounting assembly  160  may be employed to couple airbag  110  adjacent to a vehicle roof rail  20  or other vehicle structure. As such, a mounting assembly may be said to be a portion of an airbag assembly, which may comprise an inflatable curtain airbag and a mounting assembly. 
         [0028]    Airbag assembly  100  may be considered to comprise one or more modular components. A modular component may be defined as a component that is coupled to an inflatable airbag, but is not contiguous with the fabric from which the airbag is formed. A modular component may also be considered to be a sub-assembly of an airbag assembly, wherein the component is coupled to the inflatable airbag after the airbag has been manufactured; however, some components may be coupled to the airbag during airbag manufacture. A modular component may be manufactured before or after the inflatable airbag is manufactured. A modular component need not be suitable for use with more than one type of inflatable airbag or species of airbag. For example, a modular component may have a predetermined length that is intended for use in a specific vehicle make and model and with a predetermined airbag design, such that the component may not be suitable for use in a different vehicle make and model or with a different inflatable curtain airbag. The modular component may be located at or coupled to a periphery of the airbag, such that the component may be called a “peripheral component” or a “peripheral modular component”. Further, the modular component may be called a “feature,” “attachable feature,” or “separate feature”. Mounting assembly  160  and tethers  170  can be considered modular components of inflatable curtain airbag assembly  100 . In other embodiments, modular components may include external or internal vents, such as cinch tubes, internal tethers, baffles, and/or diffusers. 
         [0029]      FIG. 1B  shows inflatable curtain airbag  110  coupled to pocket  140  via a bridge  120 . Also,  FIG. 1B  shows that, upon deployment of inflatable curtain airbag  110 , pillar guide  150  is deployed outboard with respect to inflatable curtain airbag  110  such that pocket  140  is facing the outboard-facing face (not visible) and spans over a top of a B-pillar  14  of the vehicle. The function of pillar guide  150  is best understood with references to  FIGS. 2A-2D . 
         [0030]      FIGS. 2A-2D  depict the sequential deployment of the portion of curtain airbag  110  adjacent to pillar  14 .  FIG. 2A , provides a cross-sectional view of inflatable curtain airbag  110 , before deployment.  FIG. 2D  provides a cross-section view taken along cutting line  2 D- 2 D of curtain airbag  110 , as shown in  FIG. 1B , after full deployment.  FIGS. 2B-2C  show the intermediate steps. 
         [0031]    In  FIG. 2A , curtain airbag  110  is positioned above and adjacent to B-pillar  14  and is ready for deployment. The upper portion of curtain airbag  110  is rolled or folded around the lower portion when the assembly is stored and ready for use. Ramp  130  and pocket  140  are also wound around airbag cushion  110 . Because ramp  130  is semi-flexible, pillar guide  150  can be rolled or folded, as shown, in accordance with a conventional process for rolling or folding a side curtain airbag that lacks a component such as pillar guide  150 . 
         [0032]      FIG. 2B  shows curtain airbag  110  during initial deployment and the position of pillar guide  150  relative to void  30 . Void  30  is the space defined by the top of B-pillar  14  and headliner  20 . In the stage shown in  FIG. 2B , pillar guide  150  deploys (or unrolls) before curtain airbag  110 . Ramp  130  and pocket  140  have a length that permit them to extend over void  30  above B-pillar  14  and along B-pillar  14 , as shown. During a curtain deployment, pillar guide  150  guides curtain airbag  110  by acting as a “ramp” over B-pillar  14  such that the B-pillar  14  and vehicle trim do not interfere with the deployment of curtain airbag  110 . Because ramp  130  is non-inflatable and semi-flexible, it smoothly springs into position without binding on the top of B-pillar  14  and gas moves quickly to curtain airbag  110 . In addition to being sufficiently flexible to be folded or rolled around upper portion  111  when assembly  100  is stored and mounted for use, ramp  130  is sufficiently flexible to be unfolded or unrolled upon deployment of the inflatable curtain and to have a relatively vertical orientation. 
         [0033]      FIG. 2C  shows curtain airbag  110  beginning to expand, which causes it to unroll. Pillar guide  150  continues to extend over void  30  above B-pillar  14  and along B-pillar  14 . Because ramp  130  is non-inflatable and semi-rigid, it prevents curtain airbag  110  from entering void  30 , and pillar guide  150  guides the deployment of curtain airbag  110 . The rigidity of ramp  130  is sufficient to enable curtain airbag  110  to push against ramp  130  via pocket  140  without being pushed substantially into void  30 . For example, pillar guide  150  is not pushed into void  30  in a manner that interferes with the expansion of curtain airbag  110  as curtain airbag  110  unfolds or unrolls. While pillar guide  150  may be pushed into a portion of void  30 , pillar guide  150  spans across the trim that defines an opening into void  30  so that it is not necessary to fill void  30 . 
         [0034]      FIG. 2D  shows curtain airbag  110  fully inflated. Curtain airbag  110  has an outboard-facing face  114  that faces toward pocket  140 . The sequential views provided by  FIGS. 2A-2D  show that pillar guide  150  does not interfere with the deployment of curtain airbag  110  other than preventing interference with a pillar or vehicle trim. 
         [0035]      FIGS. 3A-3C  show a method of manufacturing curtain airbag  110 .  FIG. 3A  shows opposing sides  141  of pocket  140  located in extension  122  of inflatable curtain airbag  110 .  FIG. 3A  also shows ramp  130  positioned for insertion into pocket  140  via opening  142 .  FIG. 3B  shows ramp  130  positioned in pocket  140  and confined by the perimeter  144  of pocket  140  other than at opening  142 .  FIG. 3C  shows stitching  146  being used to confine ramp  130  within pocket  140  to yield pillar guide  150 . Stitching  146 , welding, adhesives are each examples of a closure that is a confining feature used to close opening  142 . Similarly, perimeter  144  of pocket  140  may be defined by stitching, gluing or any other way of joining opposing sides together that are known in the art. 
         [0036]      FIG. 4  depicts another embodiment of a curtain airbag at  210 .  FIG. 4  shows a pillar guide  250  comprising a ramp  230  in a pocket  240  of curtain airbag  210 . Sides  241  of pocket  240  has been formed using conventional one-piece woven technology to form a closed pocket. Pocket  240  is configured such that its perimeter is just slightly larger than the perimeter of ramp  230 . Note that the embodiment shown in  FIG. 4  depicts pocket  240  as an integral part of extension  222  just like pocket  140  is shown as an integral part of extension  122 . 
         [0037]      FIG. 5  depicts another embodiment of a curtain airbag at  310  fully inflated. Curtain airbag  310  has an outboard-facing face  314  that faces toward guide  350 . More particularly, outboard-facing face  314  directly faces an extension  322 . Ramp  330  is attached to extension  322  via stitches  446  such that ramp  330  is directly opposite from B-pillar  14  and can contact pillar  14  during deployment. Guide  350  comprises extension  322  and ramp  330 . 
         [0038]    The embodiment shown in  FIG. 6 , like the embodiment shown in  FIG. 5 , features a ramp  430  attached to an extension  422  via stitching  446 . In this embodiment, curtain airbag  410  has an outboard-facing face  414  that faces toward guide ramp  430 . Extension  422  is directly opposite from B-pillar  14  and can contact pillar  14  during deployment. Guide  450  comprises extension  422  and ramp  430 . 
         [0039]      FIG. 7  depicts an additional embodiment of a curtain airbag at  510  fully inflated. Curtain airbag  510  has an outboard-facing face  514  that faces toward guide  550 . More particularly, outboard-facing face  314  directly faces a first ramp  530   a.  An extension  522  is sandwiched between first ramp  530   a  and second ramp  530   b.  Second ramp  530   b  is directly opposite from B-pillar  14  and can contact pillar  14  during deployment. First ramp  530   a,  extension  522  and second ramp  530   b  are connected together via stitches  446 . Guide  550  comprises first ramp  530   a,  extension  522  and second ramp  530   b.  However, other fasteners can also be used alone or in combination with stitches such as a clip or an adhesive. 
         [0040]    The embodiments of the inflatable curtain airbag assembly depicted at  110 ,  210 ,  310 ,  410  and  510  feature an extension coupled to an inflatable curtain airbag at an upper portion of the inflatable curtain airbag. These embodiments depict an extension coupled to the inflatable curtain airbag via a non-inflatable bridge, however, other configurations are also possible. The embodiments of the extensions depicted at  122  and  222  are each coupled to a ramp. More particularly, extensions  122  and  222  each comprise a pocket that holds a ramp, as discussed above. Together, each ramp in a pocket comprises a pillar guide. Similarly, the combination of a ramp coupled to an extension without a pocket also provides a pillar guide as exemplified by the assemblies depicted at  310 ,  410  and  510 . 
         [0041]    Each guide is located and configured such that, upon deployment of the inflatable curtain airbag, the pillar guide is positioned outboard with respect to the inflatable curtain airbag such that the pillar guide spans over a top of a pillar of a vehicle during an early stage of inflation of the inflatable curtain airbag. Each ramp is sufficiently flexible to be folded or rolled when stored and mounted for use and to be unfolded or unrolled upon deployment of the inflatable curtain. Additionally, each ramp is sufficiently rigid to guide the deployment of the inflatable curtain airbag to minimize interference between the inflatable curtain airbag and the pillar. 
         [0042]    Each ramp disclosed herein is non-inflatable, semi-flexible and semi-rigid. Each disclosed embodiment of a ramp is sufficiently rigid to prevent the curtain airbag from entering a void defined by the top of the pillar and a headliner of the vehicle. Also, each disclosed embodiment of a ramp is sufficiently rigid to enable the curtain airbag to push against the ramp via the extension or the pocket without being pushed substantially into the void. Additionally, each ramp is sufficiently flexible to be unfolded or unrolled after being folded or rolled around the upper portion when stored and mounted for use, such that upon deployment of the inflatable curtain airbag the ramp has a relatively vertical orientation. 
         [0043]    One skilled in the art will recognize that a variety of configurations of semi-rigid, semi-flexible, non-inflatable ramps may be used without departing from the spirit of the present disclosure. For example, the ramp may not be rectangular. Further, the thickness of the ramp may vary depending on the particular plastic or metal that is used. Also various configurations of extensions and pockets are also within the scope of this disclosure. 
         [0044]    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. 
         [0045]    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. 
         [0046]    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. 
         [0047]    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.