Abstract:
Inflatable airbag cushions often have modular components attached to them after the main airbag has been manufactured. Such modular components can include external tethers, mounting tabs, mounting assemblies, inflatable curtain ramps, and fill tubes. Often, these modular components are positioned at predetermined locations on the airbag. The modular component can be coupled to the airbag by employing one or more adhesives. Also, the modular component can be coupled to the airbag by stitching.

Description:
TECHNICAL FIELD 
       [0001]    The present disclosure relates generally to the field of automotive protective systems. More specifically, the present disclosure relates to modular components of inflatable curtain airbags, and methods of manufacturing inflatable airbag assemblies with modular components. 
     
    
     
       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 perspective view of one embodiment of an airbag assembly, wherein the airbag assembly comprises a mounting assembly that is coupled to an inflatable curtain 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 inflatable curtain airbag is in a deployed configuration. 
           [0005]      FIG. 2A  is a perspective view of a portion of the airbag assembly of  FIG. 1A , wherein the inflatable curtain airbag is partially cutaway and a mounting assembly is not yet coupled to the inflatable curtain airbag. 
           [0006]      FIG. 2B  is a perspective view of the portion of the airbag assembly of  FIG. 2A  after the mounting assembly has been coupled to the inflatable curtain airbag. 
           [0007]      FIG. 3A  is a perspective view of a portion of the airbag assembly of  FIG. 1A , wherein the inflatable curtain airbag is partially cutaway and an external tether is not yet coupled to the inflatable curtain airbag. 
           [0008]      FIG. 3B  is a perspective view of the portion of the airbag assembly of  FIG. 3A  after the external tether has been coupled to the inflatable curtain. 
           [0009]      FIG. 4A  is an exploded perspective view of a portion of the inflatable airbag assembly of  FIG. 1A , wherein a fill tube is not yet coupled to the inflatable curtain airbag. 
           [0010]      FIG. 4B  is a perspective view of the portion of the inflatable airbag assembly of  FIG. 4A  after the fill tube has been coupled to the inflatable curtain airbag, but before the fill tube has been sewn to the airbag. 
           [0011]      FIG. 4C  is a perspective view of the portion of the inflatable airbag assembly of  FIG. 4B  after the fill tube has been sewn to the inflatable curtain airbag. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0012]    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. 
         [0013]    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. 
         [0014]    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. 
         [0015]    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. 
         [0016]    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. 
         [0017]      FIG. 1A  depicts airbag assembly  100  from a perspective view, wherein an inflatable curtain airbag  110  that is in a packaged configuration, and is mounted adjacent a vehicle roof rail  12 . Airbag assembly  100  may comprise inflatable curtain airbag  110 , an airbag mounting assembly  120 , tethers  170 , a fill tube  180 , and an inflator  190 . Airbag assembly  100  may be considered to comprise one or more modular components. 
         [0018]    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  120 , tethers  170 , and fill tube  180  can be considered modular components of inflatable curtain airbag assembly  100 . 
         [0019]    A modular component may be located at a predetermined position on an inflatable airbag, wherein the predetermined position is defined by a location along one or more axes. For example, a modular component may have a predetermined position along an axis that runs from a top portion or a bottom portion of an airbag (Y-axis), but its position along an axis that runs laterally from a first side to a second (X-axis) side can vary. Alternatively, a predetermined location for a modular component may be defined by a position on both X- and Y-axes. Further a predetermined location for a modular component may be defined by a position on X-, Y-, and Z-axes. 
         [0020]    A plurality of mounting assemblies  120  may be employed to couple inflatable curtain airbag  110  to a vehicle. Mounting assembly  120  may comprise a mounting member  130 , a wrapping member  140 , and a connecting member (not visible). The mounting member, the wrapping member, and the connecting member are examples of members of a modular component. Mounting assembly  120  may be employed to couple airbag  110  adjacent to a vehicle roof rail  12  or other vehicle structure. As such, mounting assembly may be said to be a portion of an airbag assembly, which may comprise an inflatable curtain airbag and a mounting assembly. In the depicted embodiment, airbag  110  is an inflatable curtain airbag cushion, which extends from an A-pillar  14  to a D-pillar  19 . Inflatable curtain airbag  110  also extends past a B-pillar  16  and a C-pillar  18  such that in a deployed configuration, the curtain airbag at least partially covers the B- and C-pillars, as depicted in  FIG. 1B . 
         [0021]      FIG. 1B  is a perspective view of mounting assembly  120 , wherein inflatable curtain airbag  110  is depicted in a deployed configuration. Inflatable curtain airbag  110  is configured to become inflated upon activation of one or more inflators such that the inflatable curtain airbag transitions from the packaged configuration to the deployed configuration. During deployment, wrapping member  140  is configured to rupture such that inflatable curtain airbag  110  can adopt the deployed configuration. Inflatable curtain airbag  110  may be described as having an upper portion  111 , a lower portion  112 , a first face  113 , a second face (not visible) a first side  115 , and a second side  116 . The various 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 various faces of inflatable curtain airbag  110  may comprise panels of a woven nylon fabric that are coupled together at a seam. 
         [0022]    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. 
         [0023]    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. As cushion  110  becomes inflated, tension is applied to wrapping member  140 , which causes the wrapping member to cease to retain the inflatable curtain airbag in the packaged configuration. 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. 
         [0024]    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 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. 
         [0025]      FIGS. 2A-2B  are perspective views of a portion of airbag assembly  100  of  FIG. 1A , wherein the inflatable curtain airbag is partially cutaway, and mounting assembly  120  is depicted adjacent to upper portion  111  of cushion  110 . In the depiction of  FIG. 2A , mounting assembly  120  has not yet been coupled to inflatable curtain airbag  110 . Mounting assembly  120  may comprise a mounting member  130  and a connecting member  150 . Adhesive  160  may be employed to couple mounting assembly  120  to inflatable curtain airbag  110 . Adhesive  160  may comprise single-sided tape, double-sided tape, glue, sealant, any other suitable adhesive, or a combination of the preceding. In one embodiment, the adhesive comprises Wacker 4070/60, which can adhere to silicone coated nylon material and uncoated nylon material. [QUERY: Is the Wacker 4070/60 sealant used to seal the seams of the airbag, or is the sealant used to adhere a modular component to an airbag? If the sealant is used to adhere a modular component to an airbag, please provide technical information regarding the Wacker 4070/60 sealant and how the sealant is used. For example, is the adhesive cured, and if so, at what temperature and for how long, etc.?] 
         [0026]    [QUERY: What is the tape used to couple the modular component to the airbag? Please provide technical information regarding the tape as well as a description of how the tape is used.] In the depiction of  FIG. 2A , two pieces of adhesive  160  are used; however one skilled in the art will recognize that more or fewer pieces of adhesive may be used and that the depiction of  FIG. 2A  is not intended to imply discrete units of adhesive. For example, if a liquid adhesive is employed, then the adhesive will not look like the depiction of  FIG. 2A . 
         [0027]    Mounting member  130  may comprise a planar metal member or in other embodiments, a fabric, such as a woven nylon material. Mounting member  130  may have a receiving aperture  134  that can be configured as an elongated slot. If the mounting member comprises a fabric, the mounting member may not have a receiving aperture. Receiving aperture  134  is configured to receive connecting member  150 . Connecting member  150  may comprise a first portion  151  and a second portion  152 . Connecting member  150  may comprise a rectangular piece of a non-frangible material, and is configured to interconnect mounting member  130  with an inflatable curtain airbag. Connecting member  150  may be folded across its long axis to form a loop, which can surround a bottom portion of mounting member  130 . 
         [0028]    In the depiction of  FIG. 2B , stitching  122  has been employed to couple mounting assembly  120  to upper portion  111  of inflatable curtain airbag  110 . Stitching  122  is configured to fixedly couple mounting member  130  to inflatable curtain cushion  110  via connecting member  150 . As such, stitching  122  protrudes through connecting member  150 . Stitching  122  may protrude through adhesive  160 . Stitching  122  may be distinct from stitching  117 . First and second portions  151  and  152  are depicted as being coupled to opposite sides of inflatable curtain airbag  110 ; however, in another embodiment, the first and second portions are coupled to the same side of inflatable curtain airbag  110 . 
         [0029]    One skilled in the art will recognize that a variety of configurations of mounting assemblies may be used without departing from the spirit of the present disclosure. For example, the mounting assembly may have a wrapping member coupled to the connecting member and/or mounting member, wherein the wrapping member is configured to retain the inflatable curtain cushion in a packaged configuration. 
         [0030]      FIGS. 1A-1B  and  FIGS. 3A-3B  depict another embodiment of a modular component coupled to an inflatable airbag. External tether  170  may be a modular component of inflatable airbag assembly  100 . The external tether is an example of a member of a modular component.  FIGS. 3A-3B  depict a portion of airbag assembly  100 , wherein external tether  170  is located adjacent to inflatable curtain cushion  110 . Inflatable curtain airbag assembly  100  may comprise one or more external tethers. External tethers may be employed to tension inflatable curtain airbag  110  when the airbag is in a deployed configuration, as such, the airbag may be coupled to a vehicle structure, such as D-pillar 19, via tether  170 . Tether  170  may comprise an elongated piece of woven nylon material that has a first portion  171  and a second portion  172 . First portion  171  may be configured to receive mounting member  126 . Second portion  172  may be coupled to a side of inflatable curtain airbag  110 , such as first side  115 , via stitching  125 . Tether  170  comprises a predetermined length, such that in a deployed state, inflatable curtain airbag  110  has a predetermined tension. Tether  170  may comprise a tether assembly having a tether, and a mounting member, wherein the mounting member is configured to be coupled to the tether and the vehicle structure. 
         [0031]      FIGS. 1A ,  1 B and  FIGS. 4A-4C  depict another embodiment of a modular component, fill tube  180 . Fill tube  180  may be a component of inflatable airbag assembly  100 .  FIGS. 4A-4C  are perspective views of a portion of inflatable curtain airbag assembly  100 . Fill tube  180  may be located at upper portion  111  of inflatable curtain airbag  110  and may be employed to couple an inflator  190  with inflatable void  118  of the airbag. As depicted in  FIGS. 1A-1B , inflator  190  may comprise an inflator tube that projects into inflatable void  118  of airbag  110  via fill tube  180 . In some embodiments, a body portion of the inflator may be partially received by the fill tube, and the inflator may not comprise an inflator tube or a diffuser. In some embodiments, the inflator may be coupled to an inflator housing that acts as an inflator tube and/or diffuser. [QUERY: Is the inflator fill tube accurately depicted in  FIGS. 1A ,  1 B, and  4 A- 4 C?] 
         [0032]      FIG. 4A  depicts an exploded perspective view of fill tube  180  and a portion of inflatable curtain airbag  110 , which comprise airbag assembly  100 . Inflator tube  180  may comprise a first panel  181 , and a second panel  182 . First and second panels  181  and  182  may be coupled together to form a fill tube prior to being coupled to airbag  110 , or the panels may be coupled together at the time of their coupling to airbag  110 . The first and second panels of the fill tube are examples of members of a modular component. Inflatable curtain airbag  110  may comprise a gap in perimeter seam  117 , which can be formed from stitching. The gap in stitching  117  may allow an inflator or inflator tube to protrude through the gap, between the two panels of material that define the inflatable curtain airbag, and into the inflatable void of the airbag. Adhesive  160  may be employed to affix fill tube  180  to inflatable airbag curtain  110 . 
         [0033]      FIG. 4B  depicts the portion of inflatable airbag assembly  100  shown in  FIG. 4A  after first and second panels  181  and  182  have been affixed to inflatable curtain airbag  110  via adhesive  160 . In the depicted embodiment, adhesive  160  appears to be tape; however, one skilled in the art will recognize that the adhesive may comprise one or a combination of many materials, as described herein. Further, in the depicted embodiment, the adhesive forms a contiguous perimeter adjacent to a perimeter of fill tube  180 , except at aperture  183 , which comprises an open end. Aperture  183  is located on a top portion of fill tube  180  and is in fluid communication with the inflatable void of airbag  110 . 
         [0034]      FIG. 4C  depicts the portion of inflatable airbag assembly  100  shown in  FIG. 4B  after first and second panels  181  and  182  have been sewn together and coupled to inflatable curtain airbag  110  via stitching  184 . As described herein, adhesive  160  may be employed alone to couple modular components to an inflatable airbag; however, in some embodiments a combination of adhesive and stitching may be employed. Stitching  184  protrudes through first panel  181 , second panel  182 , and both layers of adhesive  160 . Aperture  183  is not sewn closed such that the aperture can receive an inflator or inflator tube. 
         [0035]    During manufacture, coupling of a modular component at a predetermined location on an inflatable airbag can be facilitated by one or more assembly aides. For example, a landmark on the modular component can be aligned with a landmark on the inflatable airbag or a landmark on another modular component. Landmarks on an inflatable airbag or a modular component may be at a predetermined location and may include edges, seams, folds, apertures, protrusions, marks, or any combination of the proceeding. The marks can be made by printing, stamping, melting, or contacting the material from which the inflatable airbag or modular component is manufactured with ink, chalk, graphite, wax, or any other suitable substance. Prior to inflatable airbag or modular component manufacture, the markings may be made on the fabric from which the airbag or modular component will be manufactured, and/or the marking may be made after manufacture of the airbag or modular component. Also, hardware such as templates or guides may be mounted to an assembly table or laid over the inflatable airbag to aid in proper location and orientation of the modular component. Additionally, a combination of landmarks and hardware may be employed to properly position and orient the modular component on the inflatable airbag. 
         [0036]    An aperture in a modular component can be located at a predetermined position such that when the aperture is aligned with a landmark on an inflatable airbag or second modular component, the first modular component is proper aligned along at least one axis. For example, an aperture in a modular component can be aligned with a printed line on an inflatable airbag such that the line bisects the aperture. Since the aperture and the printed line are both in predetermined locations, after being fixedly coupled to the inflatable airbag, the modular component will be correctly positioned along an axis that is perpendicular to the printed line. Further, another mark can be added to the printed line, wherein the additional mark notes a target location for a modular component so that when an alignment aperture of the modular component is aligned with the marks, a “+” or “×” shape is visible within the aperture. If the landmark is located on one side or surface of the inflatable airbag or modular component, then the landmark may further define a position along the Z-axis at which the modular component is to be located. One skilled in the art will recognize that a variety of continuous and/or discrete marks can be utilized to identify target locations for modular components without departing from the spirit of the present disclosure. 
         [0037]    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. 
         [0038]    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. 
         [0039]    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. 
         [0040]    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.