Abstract:
An airbag module including an airbag, comprising an elongated backbone, and an airbag housing having the airbag therein coupled to the backbone. A sleeve is secured about the airbag housing, and coupled to the backbone. The module also includes tubular chute having open ends that receives the elongated backbone, airbag housing, and sleeve therein, wherein the airbag housing restricts expansion of the airbag through the open ends of the tubular chute during deployment of the airbag.

Description:
FIELD 
       [0001]    The present disclosure relates to an airbag module of a motor vehicle and, specifically, to an airbag module for a passenger-side of a motor vehicle. 
       BACKGROUND 
       [0002]      FIG. 8  illustrates a conventional passenger-side airbag module  10 . Airbag module  10  includes a housing  12  that includes an airbag  14 . Housing  12  is generally rectangular-shaped, and includes sidewalls  16  and  18 . To inflate airbag  14 , airbag module  10  also includes an inflator (not shown) that rapidly releases gas to inflate airbag  14 . 
         [0003]    To enclose housing  12  after airbag  14  has been folded therein, airbag module  10  includes a chute  22  that attaches to housing  12  via hook-shaped tabs  24  that engage with apertures  26  formed in chute  22 . Chute  22  includes a seam  28  formed in an upper surface  30  thereof. During deployment of airbag  14 , seam  28  will open and allow airbag  14  to escape housing  12  and chute  22 . Upper surface  30  of chute  22  is engaged with an underside of the passenger-side instrument panel  31 , with a foam material (not shown) therebetween. To assist in ensuring that airbag  14  properly deploys, the instrument panel may also include a seam (not shown) that is aligned with seam  28  of chute  22 . Accordingly, when airbag  14  is inflated and seam  28  of chute  22  opens, the seam (not shown) of the instrument panel will also open to allow airbag  14  to fully inflate. 
         [0004]    During release of the rapidly expanding gas from inflator  20 , forces will be experienced by airbag module  10  in all directions. That is, the force of the rapidly expanding gas is not only directed toward seam  28  of chute  22  to open seam  28 , but rather the force will be directed at sidewalls  16  and  18  of housing  12  as well. To ensure that housing  12  maintains structural integrity while experiencing these forces, housing  12  is formed of rigid materials such as heavy gauge steel. The use of such rigid materials for housing  12  can increase the mass of airbag module  10 , as well as increase the mass of the vehicle. Further, because the force of the rapidly expanding gas is released in all directions, only a portion of the force of the rapidly expanding gas is used to open seam  28  of chute  22  and to open the seam (not shown) of the instrument panel (not shown). As only a portion of the force is used to open seam  28 , seam  28  may not fully open, which is undesirable. 
         [0005]    Moreover, to increase fuel economy of motor vehicles, there is a continual push to develop vehicles having lower mass. As such, considerable efforts are being made to use and develop devices and materials for motor vehicles that can assist in the reduction of mass of the vehicle. Accordingly, it is desirable to produce an airbag module that is lower in mass, but more effective in ensuring that the airbag properly deploys. 
       SUMMARY 
       [0006]    According to a first aspect of the present disclosure, an airbag module including an airbag is provided that includes an elongated backbone, and an airbag housing having the airbag therein coupled to the backbone. A sleeve is secured about the airbag housing, and coupled to the backbone. The module also includes tubular chute having open ends that receives the elongated backbone, airbag housing, and sleeve therein, wherein the airbag housing restricts expansion of the airbag through the open ends of the tubular chute during deployment of the airbag. 
         [0007]    According to the first aspect of the present disclosure, the tubular chute is formed of a flexible thermoplastic elastomer. 
         [0008]    According to the first aspect of the present disclosure, the airbag housing is formed of a fabric or mesh material. 
         [0009]    According to the first aspect of the present disclosure, the airbag housing includes a plurality of first straps that secure the airbag housing to the elongated backbone. 
         [0010]    According to the first aspect of the present disclosure, the backbone includes a plurality of L-shaped flanges extending therefrom, and the first straps pass between adjacent L-shaped flanges. 
         [0011]    According to the first aspect of the present disclosure, the sleeve includes a plurality of second straps that secure the sleeve to the elongated backbone. 
         [0012]    According to the first aspect of the present disclosure, the second straps pass between adjacent L-shaped flanges. 
         [0013]    According to the first aspect of the present disclosure, the chute defines an elongate channel that is configured to slidably mate with the backbone. 
         [0014]    According to the first aspect of the present disclosure, the channel includes a pair of opposing recesses that extending along a length of channel that are configured to receive the L-shaped flanges therein. 
         [0015]    According to the first aspect of the present disclosure, the recesses are defined by a lip that is operable to contact a surface of each of the L-shaped flanges. 
         [0016]    According to a second aspect of the present disclosure, a method of assembling an airbag module is provided that includes coupling an airbag housing having an airbag therein to an elongated backbone member. A fabric sleeve is then positioned about the airbag housing, and the fabric sleeve is coupled to the backbone in a manner that compresses the airbag housing. A tubular chute is slid over the elongated backbone having the airbag housing and sleeve secured thereto, wherein the tubular chute is configured to slidably mate with the elongated backbone. 
         [0017]    According to the second aspect of the present disclosure, the tubular chute is formed of a flexible thermoplastic elastomer. 
         [0018]    According to the second aspect of the present disclosure, the airbag housing is formed of a fabric or mesh material. 
         [0019]    According to the second aspect of the present disclosure, the coupling of the airbag housing to the elongated backbone includes a wrapping plurality of first straps around the backbone. 
         [0020]    According to the second aspect of the present disclosure, the backbone includes a plurality of L-shaped flanges extending therefrom, and the first straps are passed between adjacent L-shaped flanges. 
         [0021]    According to the second aspect of the present disclosure, the coupling of the sleeve to the elongated backbone includes wrapping a plurality of second straps around the elongated backbone. 
         [0022]    According to the second aspect of the present disclosure, the second straps are passed between adjacent L-shaped flanges. 
         [0023]    According to the second aspect of the present disclosure, the chute defines an elongate channel that is configured to slidably mate with the backbone. 
         [0024]    According to the second aspect of the present disclosure, the channel includes a pair of opposing recesses that extend along a length of channel that are configured to receive the L-shaped flanges therein. 
         [0025]    According to the second aspect of the present disclosure, the recesses are defined by a lip that is operable to contact a surface of each of the L-shaped flanges. 
         [0026]    Further areas of applicability of the teachings of the present disclosure will become apparent from the detailed description, claims and the drawings provided hereinafter, wherein like reference numerals refer to like features throughout the several views of the drawings. It should be understood that the detailed description, including disclosed embodiments and drawings referenced therein, are merely exemplary in nature intended for purposes of illustration only and are not intended to limit the scope of the present disclosure, its application or uses. Thus, variations that do not depart from the gist of the present disclosure are intended to be within the scope of the present disclosure. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0027]      FIG. 1  is a perspective view of an airbag module according to the present disclosure mounted to a mounting surface of a vehicle; 
           [0028]      FIG. 2  is a perspective view of the airbag module illustrated in  FIG. 1 ; 
           [0029]      FIG. 3  is a perspective view of a frame of the airbag module according to the present disclosure; 
           [0030]      FIG. 4  is a perspective view of an airbag housing including an airbag mounted to the frame illustrated in  FIG. 3 ; 
           [0031]      FIG. 5  is a perspective view of a sleeve wrapped about the airbag housing mounted to the frame illustrated in  FIG. 4 ; 
           [0032]      FIG. 6  is a perspective view of a chute positioned about the sleeve, airbag housing, and frame illustrated in  FIG. 5 ; 
           [0033]      FIG. 7  is a side perspective view of the chute positioned about the sleeve, airbag housing, and frame illustrated in  FIG. 6 ; and 
           [0034]      FIG. 8  is a cross-sectional view of a conventional airbag module mounted to a support of a vehicle. 
       
    
    
     DETAILED DESCRIPTION 
       [0035]    The present disclosure provides an airbag module that has reduced mass, as well as an improved seam release mechanism that assists in ensuring that the airbag will properly deploy during inflation thereof. Although the below description will primarily be directed to an airbag module designed for use as a passenger-side airbag module, the present disclosure should not be limited thereto. Rather, it should be understood that the teachings of the present disclosure are equally applicable to a driver-side airbag module or a side-curtain airbag module without departing from the scope of the present disclosure. 
         [0036]    Referring to  FIGS. 1-7 , an exemplary airbag module  100  in accordance with the present disclosure is illustrated. Airbag module  100  may include a frame or backbone  102 , a chute  104 , a sleeve or wrap  106  (best shown in  FIG. 5 ), and an airbag housing  108 . As best shown in  FIG. 3 , backbone  102  is a elongate member  110  including a first end  112 , a second end  114 , and a planar support  116  positioned between first end  112  and second end  114 . Planar support  116  provides a mounting surface  118  for a cushion retainer  119 , which also includes an inflator device  120 . Cushion retainer  119  and inflator device  120  may be fixed to a backbone  102  using a plurality of fasteners (not shown). 
         [0037]    First and second ends  112  and  114  each define a mounting flange  122  including an aperture  124  for fixedly securing backbone  102  and airbag module  100  to a cross-vehicle support beam  126  with a pair of fasteners (not shown). In this regard, cross-vehicle support beam  126  includes a pair of mounting brackets  128  that correspond to each mounting flange  122 . It should be understood, however, that backbone  102  is not necessarily attached to cross-vehicle support beam  126 . Rather, backbone  102  may be fixed to any rigid support structure located within the instrument panel (not shown) of the vehicle. 
         [0038]    Backbone  102  includes a plurality of structural ribs  130  that extend between first end  112  and planar support  116 , and between second end  114  and planar support  116  to increase the structural rigidity of backbone  102 . In addition, backbone  102  includes a plurality of L-shaped flanges  132  that assist in locating backbone  102  between mounting brackets  128 , and also provide passage for straps  134  ( FIG. 7 ) of sleeve  106  to attach sleeve  106  to backbone  102 . 
         [0039]    Backbone  102  also includes a connector flange  136  for mounting an electrical connector assembly  138  that provides for electrical communication between airbag module  100  and either various sensors (e.g., collision-detection sensors, occupancy sensors, etc.—not shown) or the vehicles central processing unit (CPU—not shown). To reduce mass of airbag module  100 , backbone  102  is preferably formed of a rigid plastic material such as glass-reinforced polyamide (i.e., nylon). It should be understood, however, that other rigid plastic materials and light-weight metal materials such as aluminum are contemplated. 
         [0040]    Chute  104  is attached to backbone  102 . In accordance with the present disclosure, chute  104  is a tubular member  140  that is formed of a rigid, yet soft and flexible material such as a thermoplastic elastomer. Tubular member  140  of chute  104  includes opposing open ends  142 , a pair of side walls  144 , a lower surface  146 , and an upper surface  148 . A seam  150  is formed in upper surface  148  of chute  104 . Seam  150  is designed to open during deployment of the airbag from airbag housing  108 , and corresponds to another seam  152  formed in a passenger-side instrument panel  31 . 
         [0041]    As best shown in  FIG. 7 , lower surface  146  of chute  104  defines an elongate channel  154  configured to slidably mate with backbone  102 . Channel  154  extends along an entire length of chute  104 , and includes a pair of opposing recesses  156  extending along an entire length of channel  154  that are configured to receive L-shaped flanges  132  therein. In this regard, recesses  156  are defined by a lip  158  that is operable to contact a surface  160  of L-shaped flanges  132 . Thus, chute  104  may be secured to backbone  102  in a manner sufficient to maintain attachment during deployment of airbag from airbag housing  108 . Although chute  104  is illustrated as being parallelpiped in shape, it should be understood that chute  104  can be cylindrical without departing from the scope of the present disclosure. 
         [0042]    During inflation of the airbag, rapidly expanding gas is released by inflator device  120 . As gases released by inflator device  120  begin to fill the airbag within the airbag housing  108 , the airbag will expand in all directions, as indicated by the arrows in  FIG. 7 . That is, the airbag will begin expanding in a direction toward opposing open ends  142 , side walls  144 , lower surface  146 , and upper surface  148 . To assist in preventing the airbag from expanding outward through opposing open ends  142 , the airbag is positioned within airbag housing  108 . Housing  108  may be formed from a dense fabric material, or some other lightweight material such as steel or aluminum mesh that reduces the mass of airbag module  100 . Regardless, airbag housing  108  assists in preventing, or least substantially minimizing, the airbag from expanding outward from open ends  142  of chute  104 . That is, airbag housing  108  focuses the expanding airbag toward a seam  162  formed in airbag housing  108  that corresponds to and is essentially aligned with seams  150  and  152  of chute and instrument panel  31 , respectively. To secure airbag housing  108  to backbone  102 , airbag housing  108  includes straps  164  that are sized to wrap about backbone  102  and fit between adjacent L-shaped flanges  132  to secure housing  108  to backbone  102 . 
         [0043]    Now referring to  FIGS. 5 and 7 , sleeve  106  is illustrated as being a tubular fabric member that wraps about airbag housing  108 . The fabric that forms sleeve  106  may be lighter in density in comparison to that of airbag housing  108 . It should be understood, however, that sleeve  106  may be formed of materials other than fabric. For example, thermoplastic elastomer materials may be used. Sleeve  106  is designed to slightly compress airbag housing  108  and maintain airbag housing in an essentially tubular shape. 
         [0044]    To secure sleeve  106  about airbag housing, sleeve  106  includes straps  134  that are configured to secure sleeve  106  about airbag housing  108  and to backbone  102  in a manner similar to straps  164  of airbag housing  108 . Specifically, straps  134  are also sized to wrap about backbone  102  and fit between adjacent L-shaped flanges  132  to secure sleeve  106  to backbone  102 . Sleeve  106  also includes a plurality of perforations  166  that allow sleeve  106  to rupture during deployment of the airbag from airbag housing  108 . Perforations  166 , therefore, are essentially aligned with seam  162  of airbag housing  108 , seam  150  of chute  104 , and seam  152  of instrument panel  152 . 
         [0045]    To assemble airbag module  100 , cushion retainer  119 , inflator  120 , and electrical connector assembly  138  are first secured to backbone  102 . Then, airbag housing  108  including the airbag folded therein is secured to backbone  102  by pulling straps  164  about backbone  102  and through adjacent L-shaped flanges  132 . Sleeve  106  is then wrapped about airbag housing  108 , and secured to backbone  102  by pulling straps  134  about backbone  102  and through adjacent L-shaped flanges  132 . As noted above, sleeve  106  is tensioned about airbag housing  108  to slightly compress airbag housing  108  and maintain housing  108  in a tubular shape. The slight compression of airbag housing  108  by sleeve  106  assists in allowing tubular chute  104  to be slid over backbone  102  including the airbag housing  108  and sleeve  106  strapped thereto in a direction from first end  112  to second end  114  of backbone  102 , or vice versa, to complete assembly of the airbag module  100 . The airbag module  100  is now free to be coupled to mounting brackets  128  that are secured to cross-bar  126  of the vehicle. 
         [0046]    The foregoing description has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.