Abstract:
An airbag assembly includes a canister including a plurality of hooks disposed about a perimeter thereof and a chute having a plurality of spaced-apart windows extending therethrough to an interior, at least one hook being operably engaged with at least one window. The assembly further includes a reinforcing strip molded into the interior of the chute including a plurality of apertures aligned with respective ones of the plurality of windows and a steel door coupled with the reinforcing strip.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This patent application is a divisional of co-pending U.S. patent application Ser. No. 13/830,707, filed on Mar. 14, 2013, entitled “STEEL REINFORCED PERSONAL AIRBAG SYSTEM”, the entire contents of which is hereby incorporated by reference in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention generally relates to a vehicle airbag system and the method for constructing therefore. 
       BACKGROUND OF THE INVENTION 
       [0003]    Known approaches of airbag assemblies often fail during deployment causing potentially dangerous pieces of the assembly to enter into the vehicle body or causing total replacement of the airbag assembly after deployment. 
       SUMMARY OF THE INVENTION 
       [0004]    According to one aspect of the present disclosure, an airbag assembly includes a canister including a plurality of hooks disposed about a perimeter thereof and a chute having a plurality of spaced-apart windows extending therethrough to an interior, at least one hook being operably engaged with at least one window. The assembly further includes a reinforcing strip molded into the interior of the chute including a plurality of apertures aligned with respective ones of the plurality of windows and a steel door coupled with the reinforcing strip. 
         [0005]    According to another aspect of the present disclosure, an airbag assembly includes an airbag canister including a plurality of hooks disposed about a perimeter thereof and a chute having a plurality of windows. The assembly further includes a reinforcing strip insert molded into the chute and including a plurality of apertures and aligned with the plurality of windows, wherein the plurality of hooks engage the plurality of windows through the plurality of apertures, and a steel door coupled with the reinforcing strip. 
         [0006]    Yet another aspect of the present disclosure includes a method for producing an airbag. The method includes providing an airbag canister which includes at least one hook disposed about the perimeter of the canister and the chute including a body having at least one window extending through the body. The at least one hook is operably engaged with the at least one window. Finally, the at least one reinforcing strip is insert molded into the chute. The reinforcing strip has at least one aperture which is aligned with the at least one hook and the at least one window. The at least one hook operably engages the at least one window in the at least one aperture. 
         [0007]    These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    In the drawings: 
           [0009]      FIG. 1  is an exploded side perspective view of one embodiment of the present invention prior to the insertion of the reinforcing strip; 
           [0010]      FIG. 2  is a side elevational view of the reinforcing strip of the present invention; 
           [0011]      FIG. 3  is a bottom perspective view of one embodiment of a chute of the present invention; 
           [0012]      FIG. 4  is a bottom perspective view of another embodiment of the chute of the present invention; 
           [0013]      FIG. 5  is a top perspective view of yet another embodiment of the chute of the present invention; 
           [0014]      FIG. 6  is a bottom perspective view of one embodiment of the airbag assembly of the present invention; 
           [0015]      FIG. 7  is a top exploded perspective view of one embodiment of the airbag assembly of the present invention; 
           [0016]      FIG. 8  is a top exploded perspective view of one embodiment of the airbag assembly of the present invention having a bottom surface of an airbag canister removed; and 
           [0017]      FIG. 9  is a top perspective view of yet another embodiment of the chute of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0018]    For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in  FIG. 1 . However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. 
         [0019]    As shown in  FIG. 1 , reference number  10  generally designates an airbag assembly. The airbag assembly  10  generally includes an airbag canister  20  and an airbag chute  40 . The airbag canister  20  has a top surface  24  and a bottom surface  22  and is generally made of a plastic polymer material. The canister  20  further includes a plurality of sidewalls  26  which connect the top surface  24  and the bottom surface  22 . The top surface  24 , the bottom surface  22 , and the perimeter sidewalls  26  create a compartment  27 , which houses an airbag  29  when the airbag  29  is not deployed. The bottom surface  22  of the airbag canister  20  includes an inflator  30 , a mounting bracket  28 , and a plurality of mounting screws  32  mounted to the bottom surface  22  of the airbag canister  20 . The bottom surface  22  of the airbag canister  20  further includes a plurality of apertures  23  configured to receive the inflator  30 , the mounting screws  32 , and the mounting bracket  28 . The bottom surface  22  of the airbag canister  20  further includes a tether cutter  34 . The tether cutter  34  is configured to deploy the airbag  29  to a desired length based on individual passengers. Attachment brackets  36  are attached to opposite sidewalls  26  of the airbag canister  20  and provide an attachment mechanism for the airbag canister  20  to engage the airbag chute  40 . Additionally, the airbag canister  20  includes a plurality of hooks which are disposed around the perimeter sidewalls  26  and are configured to provide engagement with the airbag chute  40 . 
         [0020]    Further,  FIG. 1  shows that the airbag chute  40  has a top surface  42 , has at least one perimeter sidewall  44  extending upwardly from the top surface  42 , and is generally made of a plastic polymer material. Preferably, the plastic polymer is TEO Mitsubishi Chemical (TT850N). The perimeter sidewall  44  and the top surface  42  create a lip portion  46  on the top surface  42 . The top surface  42  and the perimeter sidewalls  44  form an aperture configured to receive the airbag canister  20 . The perimeter sidewalls  44  of the airbag chute  40  also include a plurality of windows  50  extending therethrough. The top surface  42  of the airbag chute  40  is generally rounded and includes a plurality of apertures  43 . The plurality of windows  50  are generally configured to receive hooks  38  of the airbag canister  20 . An outside surface of the perimeter sidewall  44  also includes wedge-shaped support protrusions  52  which provide further support to the lip portion  46  of the top surface  42  and the sidewall  44 . Side apertures  54  are also included in the perimeter sidewall  44  and are configured to receive the attachment brackets  36  of the airbag canister  20 . 
         [0021]      FIG. 2  shows a reinforcing strip  60  including a plurality of reinforcing apertures  62  and mounting apertures  63 . The mounting apertures  63  may or may not be present. As shown in  FIG. 3 , the reinforcing strip  60  is insert molded into or otherwise securely fastened to the perimeter sidewall  44  of the airbag chute  40 . The reinforcing strip  60  and its reinforcing apertures  62  are in alignment and configured to reinforce the plurality of windows  50  of the airbag chute  40 . The reinforcing strip  60  is generally rectangular in shape and the apertures  62  and  63  are arranged in a generally alternating pattern in order to more securely fasten the strip  60  to the airbag chute  40 . The strip  60  may be mounted to the airbag chute  40  through mounting apertures  63  by any suitable mechanical means. The apertures  62  and  63  of the reinforcing strip  60  may be of any shape including square, rectangular, circular, triangular, etc, in order to more securely fasten the strip  60  to the airbag chute  40 , and thus reducing the tendency for the airbag chute  40  to rip out during deployment. The reinforcing strip  60  is generally made of stamped steel or any other reinforcing material. The steel of the reinforcing strip  60  may be hard or cold rolled, stamped, forged, or cast. Additionally, the reinforcing strip  60  has a thickness of at least  1  mm. The strip  60  can be also adapted to a variety of different airbag chute  40  dimensions based on specific instrument panel designs. 
         [0022]    As shown in  FIG. 3 , one embodiment of the reinforcing strip  60  can be multiple reinforcing bands insert molded into or otherwise attached to the airbag chute  40 . In another embodiment, shown in  FIG. 4 , the reinforcing strip  60  is a single continuous strap molded into or otherwise attached to the entire perimeter sidewall  44  of the airbag chute  40 . The reinforcing strip  60  provides extra support to the airbag chute  40  and reduces the tendency for the plurality of windows  50  or the airbag chute  40  to rip during deployment of the airbag  29 . 
         [0023]    As shown in  FIG. 5 , a steel or steel insert molded door  70  covering the top surface  42  of the airbag chute  40  is illustrated. The door  70  has a hinge  72  which is continuous with the reinforcing strip  60 . The hinge  72  is integrally formed with the steel door  70 . In operation, the airbag  29  is deployed, in the direction of Arrow A, through the airbag chute  40 , causing the door  70  to swing open on its hinge  72 . The steel hinge  72  and steel door  70  provide additional reinforcement to the airbag chute  40 , reducing the tendency to rip the airbag chute  40  during airbag  29  deployment. 
         [0024]    In operation, and as shown in  FIG. 6 , the airbag canister  20  is engaged with the airbag chute  40  such that the hooks  38  and the attachment brackets  36  of the airbag canister  20  are engaged with the plurality of windows  50  and the side apertures  54  of the airbag chute  40 , respectively. During a collision event, the inflator  30  is actuated to inflate the airbag  29  such that the airbag  29  extends out of the compartment  27  and through the top surface  24  of the airbag canister  20 . The airbag  29  is then deployed, in the direction of Arrow A, through the top surface  24  of the airbag chute  40  and out into a body of a vehicle to provide protection to a vehicle passenger. In prior art configurations, during deployment, the pressure from the deploying airbag  29  could possibly cause the airbag  29  to completely destroy the airbag chute  40 , resulting in replacement of the entire airbag assembly  10 . However, the reinforcing strip  60  provides added reinforcement to the plurality of windows  50  and the sidewalls  44  of the airbag chute  40 , reducing the tendency to rip the airbag chute  40  during deployment of the airbag  29 . The reinforcing strips  60  are especially important for leather applications where the airbag chute  40  needs to be more robust and the airbag  29  must deploy at a faster rate in order to enter into the body of the vehicle. 
         [0025]    In the alternate embodiment, shown in  FIG. 5 , which includes the steel or steel insert molded door  70  and the hinge  72 , once the airbag  29  is deployed, the airbag  29  bursts through the top surface  42  of the airbag chute  40  and causes the door  70  to rotate on its hinge  72 , thereby allowing the airbag  29  to deploy into the body of the vehicle in front of a passenger. This provides added structure and support to the airbag chute  40  to effectively reinforce the airbag assembly  10  and to prevent the failure of the airbag chute  40 . 
         [0026]    In another embodiment shown in  FIG. 7 , the airbag chute  40  has a top surface  42  including a door  74  generally made of the same plastic polymer material as the airbag chute  40  to allow the airbag  29  to deploy through the airbag chute  40  and into the vehicle body. 
         [0027]      FIG. 8  again shows the top surface  42  of the airbag chute  40 . However, in this embodiment, the top surface  24  of the airbag canister  20  has been removed to more clearly show the compartment  27 , which houses the airbag  29  prior to deployment. 
         [0028]    In yet another embodiment shown in  FIG. 9 , the top surface  42  of the airbag chute  40  includes a plurality of steel filets  80  in order to strengthen the door  74  in the deployment direction. The door  74  further includes at least one steel hinge reinforcement  82 . The steel hinge reinforcement  82  and the door  74  include apertures  84  strategically placed to allow the plastic polymer to flow through during the molding process. Proper placement of the apertures  84  ensures that maximum strength of the airbag assembly  10  is maintained. 
         [0029]    Leather wrapped applications often require higher burst pressure for successful airbag deployment requiring more robust airbag systems. This reinforced airbag assembly  10  provides the necessary strength to reduce chute failures during deployment. 
         [0030]    It will be understood by one having ordinary skill in the art that construction of the described invention and other components is not limited to any specific material. Other exemplary embodiments of the invention disclosed herein may be formed from a wide variety of materials, unless described otherwise herein. 
         [0031]    For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated. 
         [0032]    It is also important to note that the construction and arrangement of the elements of the invention as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown in multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of the wide variety of materials that provide sufficient strength or durability, in any of the wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations. 
         [0033]    It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present invention. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting. 
         [0034]    It is to be understood that variations and modifications can be made on the aforementioned structure and methods without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.