Abstract:
Inflatable airbags often have inflation gas deflectors to protect the airbag or airbag seams from sustaining damage from the force of the inflation gas and to direct the inflation gas to predetermined areas of the airbag. The deflectors can be coupled to the airbag so that the deflector projects radially away from the surface of the airbag to which the deflector is coupled. The deflectors can also have a plurality of vent apertures.

Description:
TECHNICAL FIELD 
       [0001]    The present disclosure relates generally to the field of automotive safety systems. More specifically, the present disclosure relates to inflatable airbag cushion assemblies having inflation gas deflectors. 
     
    
     
       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 an airbag assembly, wherein the airbag assembly is located at a steering wheel of a vehicle and the airbag assembly is in a packaged, undeployed configuration. 
           [0004]      FIG. 1B  is a perspective view of the airbag assembly of  FIG. 1A  after the inflatable airbag of the airbag assembly has been deployed. 
           [0005]      FIG. 2  is a cutaway perspective view of a portion of the airbag assembly of  FIG. 1B  wherein the airbag is in a deployed, inflated configuration. 
           [0006]      FIG. 3  is a perspective view of a portion of the airbag assembly of  FIG. 2 . 
           [0007]      FIG. 4  is a cross-sectional view of the airbag assembly of  FIG. 1B   
           [0008]      FIG. 5  is another cutaway perspective view of the airbag assembly of  FIG. 1A . 
           [0009]      FIG. 6  is a perspective view of a portion of another embodiment of an inflatable airbag assembly. 
           [0010]      FIG. 7  is a perspective view of a portion of another embodiment of an inflatable airbag assembly. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0011]    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. 
         [0012]    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. 
         [0013]    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 a front passenger airbag, a driver&#39;s airbag, or any other airbag type. 
         [0014]    Front airbags are typically installed in the steering wheel and instrument panel of a vehicle. During installation, the airbags are rolled, folded, or both, and are retained in this 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 confirmations from the packaged configuration to a deployed and inflated configuration. 
         [0015]      FIGS. 1A-1B  depict airbag assembly  100 , wherein  FIG. 1A  depicts airbag assembly  100  in a packaged configuration, and  FIG. 1B  depicts the assembly in a deployed and inflated configuration.  FIGS. 1A-1B  depict a steering wheel  12  and a steering column  14  of a vehicle  10 . Steering wheel  12  comprises a cover  16 , behind which airbag assembly  100  is located. Airbag assembly  100  may comprise an inflatable airbag  110 , an inflator  120 , and an airbag housing  150 . Airbag  110  comprises a front panel  113 , which in the deployed and inflated configuration is directed toward an occupant and may partially define a cabin side of the airbag. A rear panel  114  is located opposite front panel  113  and may define a windshield side of the airbag. 
         [0016]      FIG. 2  depicts airbag assembly  100 , from a perspective view. Airbag assembly  100  may comprise an inflatable airbag  110 , an inflator  120 , and an inflation gas deflector  130 . Airbag assembly  100  may further comprise an airbag housing (not shown). In an undeployed state, assembly  100  may be configured to be packaged and mounted within an instrument panel or steering wheel located at the front of a vehicle. Upon activation, cushion  110  may deploy out of the instrument panel or steering wheel toward an intended occupant position in a vehicle seat. 
         [0017]    According to the embodiment depicted in  FIG. 2 , cushion  110  has a front panel  113 , and a rear panel  114 , that are attached together at perimeter seam  117 . The various panels of cushion membrane  110  define an interior inflatable void  118 , which is in fluid communication with inflator  120  via deflector  130 . In the depicted embodiment perimeter seam  117  is formed by stitching. Deflector  130  may comprise a woven nylon material, which may be coated with one or more materials, such as silicone. Deflector  130  may comprise a flexible fabric or a more rigid material that is still able to be folded and/or rolled into a packaged configuration. Deflector  130  may be located on an interior side  115  of rear panel  114 , such that the deflector is located within inflatable void  118  of airbag  110 . In the depicted embodiment, deflector  130  comprises a first arm  131 , a second arm  132 , a third arm  133 , and a central region  134 . Each arm of deflector  130  extends from central region  134  and may have a distal aperture  136 . Deflector  130  may be placed in fluid communication with inflator  120 . 
         [0018]    One skilled in the art will recognize that a variety of types and configurations of deflectors can be utilized without departing from the scope and spirit of the present disclosure. For example, the size, shape, and proportions of the deflector may vary from the depicted embodiment. Also, the deflector may comprise more or fewer arms that the depiction of  FIG. 2 . Further, the deflector may be coupled to the airbag via a technique other than stitching. 
         [0019]    As will be appreciated by those skilled in the art, a variety of types and configurations of airbag cushion membranes can be utilized without departing from the scope and spirit of the present disclosure. For example, the size, shape, and proportions of the cushion membrane may vary according to its use in different vehicles or different locations within a vehicle such that the cushion may comprise an inflatable 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 pieces 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. 
         [0020]      FIG. 3  depicts a perspective view of a portion of airbag assembly  100 . The front panel of airbag  110  has been removed such that more of deflector  130  is visible; however, for clarity, perimeter seam  117  has been added to the figure. As described above, deflector  130  is located on inner side  115  of rear panel  114  and is in fluid communication with the inflator. Deflector  130  comprises a central region  134 , which may be located above the inflator. Three arms,  131 ,  132 , and  133  radiate outward from central region  134 . Each arm  131 ,  132 , and  133  comprises a distal portion  135 , a distal aperture  136  and vents  140 . Vents  140  may comprise two species of vents: top vents  141  and side vents  142 . 
         [0021]    Top vents  141  may be configured such that they direct inflation gas toward front panel  113  of inflatable airbag  110 . In one embodiment, top vents  141  direct inflation gas toward front panel  113  in a direction that is substantially perpendicular to the front panel, when the front panel is in a deployed and inflated configuration, such as is depicted in  FIGS. 2 and 4 . In some embodiments, top vents  141  may be configured such that the top vents only direct inflation gas toward front panel  113  in a direction that is substantially perpendicular to the front panel, when airbag  110  and front panel  113  are in a deployed and inflated configuration, such as is depicted in  FIGS. 2 and 4 . 
         [0022]    Side vents  142  may be configured such that they direct inflation gas toward a periphery of inflatable airbag  110 . The periphery of airbag  110  may be defined as perimeter seam  117 , or in embodiments that lack a perimeter seam, the periphery may be defined as a “side” portion of the airbag. In one embodiment, side vents  142  direct inflation gas toward perimeter seam  117 . In some embodiments side vents  142  direct inflation gas toward perimeter seam  117  in a direction that is substantially perpendicular to the perimeter seam, when the airbag is in a deployed and inflated configuration, such as is depicted in  FIGS. 2 and 4 . In some embodiments, side vents  142  may be configured such that the side vents only direct inflation gas toward perimeter seam  117  in a direction that is substantially perpendicular to the perimeter seam, when airbag  110  is in a deployed and inflated configuration, such as is depicted in  FIGS. 2 and 4 . In other embodiments, the side vents may be configured to direct inflation gas in one or more directions that may or may not include the front panel and/or the periphery of the airbag. 
         [0023]    One skilled in the art will recognize that in a packaged configuration, the top and side vents may not be directed toward the front panel and periphery of airbag  110 , respectively. Further, in early stages of airbag deployment, the airbag and deflector may comprise rolls, folds, and/or wrinkles such that the top and side vents may not be directed toward the front panel and periphery of airbag  110 , respectively. However, once the deflector is in an inflated configuration, such as depicted in  FIGS. 2-4 , one skilled in the art will recognize that the top and side vents may direct inflation gas toward what will become the front and periphery of the airbag, once the airbag is in a deployed and inflated configuration. 
         [0024]    Arms  131 ,  132 , and  133  may have identical, similar, or disparate features. In the depicted embodiment, arms  131 ,  132 , and  133  each extend to a predetermined location, such that their distal apertures  136  are a predetermined distance D 1  from perimeter seam  117 . Distance D 1  may comprise a range from about 10 mm to about 200 mm. Also, distance D 1  may not be the same for each arm of the deflector. 
         [0025]    The material that forms each arm  131 ,  132 , and  133 , as well as central region  134  has a width that is greater than a width W 1 , defined by a deflector attachment seam  139 . In other words, the material of deflector  130  is not pulled tightly by its attachment seam such that the deflector comprises a planar shape. Rather, there is slack in the material of deflector  130 , such that even when inflation gas is not passing through the deflector, the deflector comprises a non-planer, three-dimensional shape, although that shape may vary from the depictions of the figures herein. 
         [0026]    Distal apertures  136  of each of arms  131 ,  132 , and  133  may comprise a smaller width W 2  than width W 1 . In other words, the distal ends of the arms of the deflector may be partially closed, such that the distal aperture has a smaller diameter or width than the rest of the arm. As such, less inflation gas can escape through the distal aperture than if the distal aperture did not have a reduced width. One skilled in the art will recognize that the amount of inflation gas that can escape through the distal aperture can be reduced in a number of ways. In the depicted embodiment, the distal portion of each of the arms is tapered; however in other embodiments, the distal portion may simply be folded, or the width W 1  of the stitching may be reduced, rather than the width of the fabric. Width W 1  may comprise a range from about 75 mm to about 300 mm. Width W 2  may comprise a range from about 25% to about 50% of width W 1 , such that width W 2  may comprise a range from about 37 mm to about 150 mm. In other embodiments the distal portion of each arm may not be reduced such that the distal aperture comprises a full width of the deflector arm. 
         [0027]      FIG. 4  is a cross-sectional view of a portion of airbag assembly  100 . Arm  131  of deflector  130  is coupled on inner side  115  of rear panel  114  via stitching  139  to form inflatable void  138 . Inflatable void  138  may be called a second inflatable void, wherein the first inflatable void is defined by front and rear panels  113  and  114  of airbag  110 . The material from which arm  131  is formed comprises a length L 1 , that is defined by a distance between attachment points (sew lines)  139 . Width W 1  is defined by a distance between stitching  139 . Length L 1  comprises a magnitude that is greater than W 1 , such that arm  131  of deflector  130  comprises a non-planar shape, even when inflation gas is not passing through inflatable void  138 . 
         [0028]      FIG. 5  depicts a cutaway perspective view of airbag assembly  100 , wherein airbag  110  and deflector  130  have been partially cutaway to reveal inflator  120 . Front panel  113  and rear panel  114  are coupled together to form inflatable void  118 . Deflector  130  is coupled to inner side  115  of rear panel  114 , such that a second inflatable void  138  is formed. Inflatable void  118  is in fluid communication with inflator  120  via vent apertures  136 ,  141 , and  142  of deflector  130 . Inflator  120  is in fluid communication with inflatable void  138  because a gas-emitting portion of the inflator protrudes into the inflatable void via a throat portion  116  of airbag  110 . Throat portion  116  may be an integral portion of rear panel  114 , or the throat portion may comprise an extension of, or an extension from the rear panel. 
         [0029]      FIG. 6  is a perspective view of a portion of airbag assembly  200  with a deflector  230 , wherein the airbag assembly  200  and the deflector  230  resemble airbag assembly  100  and deflector  130 , 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 airbag assembly  100  and deflector  130  can be employed with assembly  200  and deflector  230 , and vice versa. 
         [0030]    In the view of  FIG. 6 , a front panel of airbag  210  has been removed. Airbag assembly  200  may comprise an inflatable airbag  210  and deflector  230 . Airbag  210  may be configured similarly, and may function similarly as airbag  110 , described herein, wherein airbag  210  comprises a rear panel  214 . Deflector  230  is coupled to an inner side  215  of rear panel  214  at seam  239  to form an inflatable void. In the depicted embodiment, seam  239  comprises stitching. Deflector  230  comprises an “I” shape, having a central portion  234  and two opposing distal portions  235 . Each distal portion  235  has a distal aperture  236 , which in the depicted embodiment is not narrowed compared to the rest of the deflector, as are distal apertures  136 , described herein. Deflector  230  may comprise a plurality of vents  240 , which may comprise two species: top vents  241  and side vents,  242 . In other embodiments, the side vent apertures may be configured to direct inflation gas in one or more directions that may or may not include the front panel and/or the periphery of the airbag. 
         [0031]      FIG. 7  is a perspective view of a portion of airbag assembly  300  with a deflector  330 , wherein the airbag assembly  300  and the deflector  330  resemble airbag assemblies  100  and  200  and deflectors  130  and  230 , 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 airbag assemblies  100  and  200  and deflectors  130  and  230  can be employed with assembly  300  and deflector  330 , and vice versa. 
         [0032]    In the view of  FIG. 7 , a front panel of airbag  210  has been removed. Airbag assembly  300  may comprise an inflatable airbag  310  and deflector  330 . Airbag  310  may be configured similarly, and may function similarly as airbag  110 , described herein, wherein airbag  310  comprises a rear panel  314 . Deflector  330  is coupled to an inner side  315  of rear panel  314  at seam  339  to form an inflatable void. In the depicted embodiment, seam  339  comprises stitching. Deflector  330  comprises an “X” shape, having a central portion  334  and four arms  331 . Each arm  331  has a distal portion  335 . Each distal portion  335  lacks a distal aperture like those of deflectors  130  or  230 , described herein. Distal portions  335  are closed such that inflation gas may primarily escape the inflatable void of deflector  330  via vent apertures  340 . Vent apertures  340  may comprise two species: top vents  341  and side vents  342 . In other embodiments, the side vent apertures may be configured to direct inflation gas in one or more directions that may or may not include the front panel and/or the periphery of the airbag. In some embodiments, seam  339  may comprise a sealed seam such that inflation gas can only escape the inflatable void of deflector  330  via vent apertures  340 . 
         [0033]    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. 
         [0034]    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. 
         [0035]    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. 
         [0036]    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.