Patent Abstract:
An occupant safety system for a vehicle door is disclosed. The vehicle door includes a series of pads that help to absorb the force of a side impact collision. The pads cooperate to help push an occupant away from the door during the collision. This can help reduce injuries sustained by the occupant by increasing the available energy absorbing stroke.

Full Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates generally to the field of motor vehicles, and in particular to an occupant safety system for a motor vehicle. 
   2. Description of Related Art 
   Devices and systems that attempt to reduce occupant injury in the event of a collision have been proposed. In some cases, a soft padding material has been used to absorb energy and provide protection for the occupant. Often, the size of the padding material was increased to improve the level of occupant protection. U.S. Pat. No. 5,395,135 to Lim et al. is an example of such a system. The Lim et al. patent teaches various bolsters attached to the outer and inner walls of the door. In some embodiments, bolsters are attached only to the inner panel of the door. These embodiments can be seen in FIGS. 3 and 4. 
   A key feature of the Lim et al. patent is the arrangement of the bolsters with respect to door trim panel 38. Lim et al. provides a bolster that is attached to inner panel 18 and extends beyond door trim panel 38 and into the passenger compartment. Lim teaches the use of apertures or holes formed in door trim panel 38 that allow the bolsters 46 and 48 to extend into the passenger compartment. The &#39;135 patent uses the term “protract” to describe this arrangement. See, for example, column 3, lines 42-45 of the Lim et al. patent: “The energy absorbing bolsters 46, 48 protract through the apertures 41, 42, respectively, in the door trim panel 38 and into the occupant compartment of the vehicle 12.” 
   These systems, while possibly improving occupant protection, proved to be wide and cumbersome. The additional padding material also intruded into the passenger compartment, and reduced interior space. 
   Another source of occupant injury that has recently been discovered is injury caused by protruding objects. Occupants can be cut or injured by metal protruding into passenger cabin during a collision. The protruding metal is often broken, bent or twisted during a collision and this deformation of the metal can introduce sharp edges to the protruding metal objects. A system is needed that offers protection from sharp metal protruding into the passenger compartment. 
   U.S. Pat. No. 5,749,600 to Yamada et al. is directed to an energy absorbing door trim member. The &#39;600 patent discloses a number of different embodiments. In one kind of embodiment, shown in FIGS. 4 to 8, the deflection of a portion of the door trim serves as an energy absorbing structure. Notice that in FIGS. 5, 7 and 8, a portion of the arm rest is deflected. In another embodiment, referred to in the specification as the fourth embodiment, one or more pads are used to help absorb energy. See column 7, line 41 to column 8, line 67; see also FIGS. 9 and 10. In all of these embodiments, Yamada is concerned with providing an energy absorbing device in the vicinity of an occupant&#39;s femur and below the illium (shown in the Figures as 18C) of the femur. While this arrangement may offer some protection against femur injury, it does little to prevent injury from protruding metal objects entering the passenger compartment during a collision. 
   There is currently a need for an occupant protection system that maintains a low profile and does not project into the passenger compartment and a system that is capable of displacing or moving occupant away from incoming metal objects. 
   SUMMARY OF THE INVENTION 
   An occupant safety system for a motor vehicle is disclosed. The invention can be used in connection with a motor vehicle. The term “motor vehicle” as used throughout the specification and claims refers to any moving vehicle that is capable of carrying one or more human occupants and is powered by any form of energy. The term motor vehicle includes, but is not limited to cars, trucks, vans, minivans, SUV&#39;s, motorcycles, scooters, boats, personal watercraft, and aircraft. 
   The vehicle door includes a series of pads that help to absorb the force of a side impact collision. The series of pads maximizes the available energy absorbing stroke. 
   In one aspect, the invention provides a vehicle door comprising: an outer shell facing an exterior of the vehicle; a trim panel having an inner surface facing an interior of the vehicle and an outer surface facing an inner shell, the outer surface including an inner pad; an impact bar disposed proximate the outer shell, the impact bar including an outer pad associated with the impact bar; the inner shell being disposed between the outer shell and the trim panel; an intermediate pad disposed between the inner shell and the outer shell; and where the outer pad is configured to contact the intermediate pad during a side impact collision. 
   In another aspect, the intermediate pad is configured to contact the inner pad after the outer pad has contacted the intermediate pad. 
   In another aspect, the inner pad is configured to move the trim panel towards the interior of the vehicle and contact an occupant above the waist. 
   In another aspect, the inner pad is configured to contact the occupant&#39;s arm. 
   In another aspect, the inner pad is configured to contact the occupant&#39;s shoulder. 
   In another aspect, the trim panel moves further towards the interior of the vehicle than the impact bar in a collision. 
   In another aspect, at least one pad assists in moving the trim panel further towards the interior of the vehicle than the impact bar in a collision. 
   In another aspect, the invention provides a vehicle door comprising: an outer shell facing an exterior of the vehicle; a trim panel including an associated inner pad; an impact bar disposed proximate the outer shell; an inner shell disposed between the trim panel and the outer panel, the inner shell including a substantially vertical portion and a flange; and an intermediate pad associated with the inner shell, the intermediate pad including a projection configured to confront the substantially vertical portion and a hook configured to engage the flange. 
   In another aspect, the hook is disposed on a holder attached to a pad. 
   In another aspect, the intermediate pad includes a plurality of hooks. 
   In another aspect, the hooks are generally horizontally spaced. 
   In another aspect, the projection is disposed on a holder attached to a pad. 
   In another aspect, the projection is attached to the inner shell with a mechanical fastener. 
   In another aspect, the hook is also disposed on the holder and wherein the projection and the hook are integrally formed with the holder. 
   In another aspect, the invention provides a vehicle door comprising: an outer shell facing an exterior of the vehicle; a trim panel including an associated inner pad; an impact bar disposed proximate the outer shell, the impact bar including an outer pad associated with the impact bar; an inner shell disposed between the trim panel and the outer panel, and having an associated intermediate pad; and where the outer pad is configured to press the intermediate pad against the inner pad during a collision such that the trim panel moves further inward into an interior of the vehicle than the impact bar. 
   In another aspect, the trim panel is configured to push an occupant away from the impact bar during a collision. 
   In another aspect, the trim panel is configured to space an occupant from the impact bar during a collision. 
   In another aspect, the intermediate pad includes a holder configured to associate the intermediate pad with the inner shell, the holder being disposed on an inward side of the intermediate pad, and wherein the holder contacts the inner pad during a collision. 
   In another aspect, the outer pad, the intermediate pad and the inner pad are all substantially aligned. 
   In another aspect, the intermediate pad is disposed between the inner shell and the outer shell. 
   Other systems, methods, features and advantages of the invention will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the invention, and be protected by the following claims. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views. 
       FIG. 1  is a cross-sectional view of a preferred embodiment of a door; 
       FIG. 2  is an exploded view of a preferred embodiment of an outer pad; 
       FIG. 3  is a cross-sectional view of a preferred embodiment of an outer pad; 
       FIG. 4  is a front view of a preferred embodiment of an intermediate pad; 
       FIG. 5  is a cross-sectional view of a preferred embodiment of an intermediate pad; 
       FIG. 6  is a schematic diagram of a preferred embodiment of an inner shell; and 
       FIG. 7  is a cross-sectional view of a preferred embodiment of a door after a collision. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Embodiments of the present invention help to reduce occupant injury in the event of a collision. Preferably, one or more doors of a motor vehicle include provisions to prevent or reduce occupant injury in a collision. Referring to  FIG. 1 , which is a cross-sectional view of a preferred embodiment of a door  100 , safety features can be provided inside door  100 . Preferably, door  100  includes an outer shell  106  that faces exterior  102 , and an inner shell  108  disposed towards interior  104 . In some embodiments, outer shell  106  and inner shell  108  comprise the steel structure of door  100 . In some embodiments, window  110  is disposed between outer shell  106  and inner shell  108 . Window  110  is shown in the down position in the Figures. This is done to provide a better sense of the relative position of the various components. When reference is made to window  110  in this description, it is sometimes assumed that window  110  is in the down or lowered position. Of course, window  110  can also be raised to assume a closed or upward position, as well known in the art. 
   Some embodiments include an interior trim panel  120  that is associated with inner shell  108 . Interior trim panel  120  faces interior  104  of the motor vehicle and provides a finish to door  100 . In some embodiments, interior trim panel includes shoulder pad  122  disposed above arm rest  124 . Preferably, arm rest  124  is intergrally molded with interior trim panel  120 . Preferably, inner pad  122  includes an interior surface that is joined to interior trim panel  120  as shown in  FIG. 1 . 
   Preferably, inner pad  122  and arm rest  124  are designed with a driver  150  in mind. While this disclosure teaches an exemplary system and method for use with a driver, all of the principles, teachings and concepts are also applicable to any other occupant in a motor vehicle. Arm rest  124  is preferably located on trim panel  120  to naturally and comfortably receive the arm of driver  150 . Preferably, inner pad  122  is located proximate the shoulder or arm area of driver  150 . 
   To prevent intrusion by foreign objects during a side impact collision, some embodiments of door  100  can include a lower side impact bar  114  and/or an upper side impact bar  116 . Lower side impact bar  114  is optional and is omitted in some embodiments. In the embodiment shown in  FIG. 1 , door  100  includes an outer pad  130  disposed near upper side impact bar  116 . Some embodiments can include an intermediate pad  132  disposed between window slot  112  and inner shell  108 . 
   Preferably, outer pad  130  is disposed interior of outer shell  106  but exterior of window  110 . In other words, outer pad  130  is preferably disposed between outer shell  106  and window  110 . Preferably, outer pad  130  is generally aligned with at least a portion of intermediate pad  132 . In some embodiments, intermediate pad  132  is also aligned with inner pad  122 . This aligned pad arrangement can be particularly helpful in a collision, as described below. 
   Outer pad  130  can be placed near upper side impact bar  116  in a variety of different ways. In some embodiments, outer pad  130  is attached to outer shell  106 , while in other embodiments, outer pad  130  is mounted to upper side impact bar  116 .  FIGS. 2 and 3  show a preferred embodiment of a mounting system for outer pad  130 . Referring to  FIGS. 2 and 3 , outer pad  130  preferably comprises foam pad  210  and backing  212 . Preferably, foam pad  210  is attached to backing  212 , which is preferably made of a rigid material. In an exemplary embodiment, backing  212  is made of a durable plastic. 
   The composite outer pad  130  is preferably attached to a bracket  202  associated with upper side impact bar  116 . In the preferred embodiment shown in  FIGS. 2 and 3 , bracket  202  includes a mounting portion  204  and an engaging portion  206 . Mounting portion  204  is preferably designed to correspond to the shape of side impact bar  116 . In the exemplary embodiment shown in  FIG. 2 , upper side impact bar  116  has a generally round shape. Thus, in the embodiment shown in  FIGS. 2 and 3 , bracket  202  preferably includes a mounting portion  204  with a corresponding round shape. Mounting portion  204  can be attached to upper side impact bar  116  in a number of different ways. Some possibilities include using an adhesive or mechanical fasteners to join the two parts together. However, in a preferred embodiment, mounting portion  204  is attached to upper side impact bar  116  by welding the two components together. 
   Engaging portion  206  is preferably designed to associate outer pad  130  with bracket  202  and ultimately with upper side impact bar  116 . Many different devices or fasteners can be used to associate outer pad  130  with engaging portion  206 . In the preferred embodiment shown in  FIGS. 2 and 3 , a clip or anchoring system is used. As shown in  FIGS. 2 and 3 , engaging portion  206  includes at least one hole  208 . In an exemplary embodiment, engaging portion  206  includes a pair of horizontally-spaced holes  208 . Backing  212  of outer pad  130  includes a corresponding number of clips  214 . 
   As shown in  FIG. 3 , clip  214  is designed to engage and enter hole  208 . Preferably, clip  214  includes a forward penetrating portion  230  with a slot  232 . As clip  214  enters hole  208 , the taper of penetrating portion  230  forces penetrating portion  230  to contract to fit inside hole  208 . Slot  232  permits penetrating portion  230  to deform to enter hole  208 . After penetrating portion  230  emerges on the other side of engaging portion  206 , backing  212  embraces engaging portion  206  on one side and shoulder  234  contacts engaging portion  206  in the opposite side. Using this arrangement, outer pad  130  is associated with upper impact bar  116 . 
   As noted above, intermediate pad  132  is generally aligned with at least a portion of outer pad  130 . Many different systems can be used to place intermediate pad  132  between window  110  and inner shell  108 , and in a position that is generally aligned with outer pad  130 .  FIGS. 4 and 5  show a preferred embodiment of a system for placing intermediate pad  132  in the desired location. Referring to  FIGS. 4 and 5 , intermediate pad  132  comprises foam pad  500  and pad holder  504 . Preferably, foam pad  500  is securely attached to pad holder  504 . Holder  504  is preferably disposed on the interior side of foam pad  500 . However, holder  504  includes an upper portion  520  that extends in an exterior direction from the interior side of foam pad  500 . In the preferred embodiment shown in  FIG. 5 , a hook  506  extends upwards from upper portion  520 . 
   Inner shell  108  extends generally vertically downward and includes a flange  502  that extends in a direction that is generally exterior of inner shell  108 . In the embodiment shown in  FIGS. 4 and 5 , hook  506  is designed to engage flange  502 . Hook  506  includes a generally vertical portion and a portion that extends in an interior direction, hook  506  generally forms a pocket that receives flange  502 . 
   Preferably, intermediate pad  132  also includes a projection  508  that extends upwards towards inner shell  108 . Preferably, projection  508  is disposed on the opposite side of inner shell  108  as hook  506 . In the embodiment shown in  FIGS. 4 and 5 , projection  508  is disposed on the interior side of inner shell  108  and hook  506  is disposed on the exterior side of inner shell  108 . Preferably, projection  508  includes a mechanical fastener  510  that attaches projection  508  to inner shell  108 . Preferably, mechanical fastener  510  is attached on a vertical portion of inner shell  108 . In a preferred embodiment, mechanical fastener  510  includes a pin and grommet arrangement. A grommet is placed on projection  508  and is inserted through the grommet and through a hole  522  in inner shell  108 . In some embodiments, a second hook  512  is also used to help secure intermediate pad  132  to inner shell  108 . In the exemplary embodiment shown in  FIG. 4 , second hook  512  is horizontally spaced from first hook  506  and is designed similarly to first hook  506 . 
     FIG. 6  is an exposed view of door  100 . In  FIG. 6 , trim panel  120  has been removed. In the embodiment shown in  FIG. 6 , inner shell  108  includes a shell hole  602 . The upper portion  604  of shell hole  602  includes flange  502  (see  FIG. 5 ). As disclosed above, intermediate pad  132  can be attached to inner shell  108  by using an assembly designed to engage flange  502 . 
   In  FIG. 6 , the alignment of outer pad  130  and intermediate pad  132  can be observed. In some embodiments, only a portion of outer pad  130  is aligned with intermediate pad  132 , however, in the preferred embodiment shown in  FIG. 6 , the entirety of outer pad  130  is almost completely aligned with the entirety of intermediate pad  132 . This arrangement can maximize the effectiveness of the safety system. Because of their alignment and their respective positions, the outer and intermediate pads  130  and  132  produce a pad system that can provide additional energy absorbing stoke during a collision. 
     FIG. 7  is a cross-sectional view of a preferred embodiment of door  100  in a post-impact condition. The force of the impact causes upper side impact bar  116  to move towards interior  104  of the motor vehicle. As upper side impact bar  116  moves towards interior  104 , outer pad  130  also moves towards interior  104 . Upper side impact bar  116  travels past window  110  and eventually, outer pad  130  contacts at least a portion of intermediate pad  132 . After the two pads make contact, side impact bar  116  continues to move towards interior  104  and the two pads  130  and  132  move together and eventually make contact with inner pad  122 . In some embodiments, side impact airbags may deploy if the collision is severe enough. As the collision continues, inner pad  122  makes contact with driver  150  via trim panel  120  and pushes driver towards the interior  104 . 
   In some embodiments, the force of the collision is so great that the pads are unable to push the driver towards interior  104 . Rather, in those cases, the pads help driver  150  maintain his or her position or the pads help to space driver  150  from upper side impact bar  116  or inner shell  108 . 
   Through the use of the disclosed pad arrangement, occupant injury can be reduced by providing additional energy absorbing stroke. Also, the arrangement of the pads and their particular location at shoulder height help to ensure that the widest part of driver  150  is pressed inwards towards interior  104 . Other pad devices or systems disposed at hip or leg level may not accomplish this spacing function, because those pad systems or devices are not disposed at or near shoulder level. 
   While various embodiments of the invention have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the invention. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.

Technology Classification (CPC): 1