Abstract:
Systems for restraining movement of occupants within a vehicle are detailed. Such systems utilize vehicle headliners as parts thereof, with the headliners tensioned to help restrain passenger movement. The headliners may be connected directly or indirectly to inflatable structures typically positioned beneath the headliners. Thus, when the structures inflate, they may generate tension and tend to pull the headliners down from vehicle roofs toward vehicle sides.

Description:
FIELD OF THE INVENTION  
       [0001]     This invention relates to devices for protecting vehicle occupants and more particularly (but not exclusively) to restraint systems utilizing vehicle headliners.  
       BACKGROUND OF THE INVENTION  
       [0002]     U.S. Pat. No. 6,231,072 to Pywell, et al., whose contents are incorporated herein in their entirety by this reference, discloses a restraint assembly including a vehicle headliner. As noted in the Pywell patent, the assembly also includes an air bag positioned between the headliner and roof (and frame) of a vehicle. As the air bag inflates, it causes the headliner to extend downward toward the head and upper torso of a passenger.  
         [0003]     In the assemblies of the Pywell patent, the air bag performs a conventional role, acting effectively as an air “mattress” for the vehicle occupant. To do so, it must be positioned so as to intercept an occupant as he or she travels toward an injurious surface (such as the frame or roof of the vehicle). Accordingly, the air bag must be positioned directly behind the headliner, between the head of the occupant and the roof and frame of the vehicle. Although the Pywell patent refers to the headliner as forming “a reactionary surface,” it performs essentially no restraint function in favor of the air bag doing so.  
       SUMMARY OF THE INVENTION  
       [0004]     The present invention provides alternative restraints to those described in the Pywell patent. Although present systems too utilize vehicle headliners as parts thereof, the headliners function differently than as intended in the Pywell patent. Indeed, rather than merely acting as “reactionary surface[s]” for conventionally-performing air bags, headliners of the present invention themselves help restrain passengers of a vehicle.  
         [0005]     Presently preferred embodiments of the invention employ an inflatable structure attached, typically indirectly via a fabric piece, to the headliner. Such inflatable structure need not be positioned intermediate the headliner and the vehicle roof or act as a “mattress,” however. Instead, the inflatable structure beneficially is located below the headliner and functions to tension it, so that the headliner may provide restraint. Or, stated differently, whereas the air bag and headliner apparatus of the Pywell patent requires that the air bag absorb energy by dissipating applied pressure forces, the fabric and headliner of the present invention use tension to reflect the energy away from harmful surfaces.  
         [0006]     At least one version of the invention includes an inflatable structure anchored at or near the lower edge of a vehicle window. The structure preferably is tubular when inflated and braided as described in, for example, commonly-owned U.S. Pat. No. 5,322,322 to Bark, et al. and U.S. Pat. No. 6,124,194 to Yaniv, et al. (the contents of both of which patents are incorporated herein in their entireties by this reference). It need not necessarily be so shaped and configured, however. Indeed, in some embodiments, the structure may be knit, for example, rather than braided.  
         [0007]     The inflatable structure is adapted to be inflated by any appropriate type of inflation mechanism. A section of (typically non-inflatable) fabric or similar material attaches the inflatable structure to the outboard edge of a vehicle headliner. Thus, when the structure inflates, the tension it generates pulls the headliner down toward the lower edge of the window, creating a protective surface utilizing the membrane tension of the headliner and fabric material.  
         [0008]     Systems of the present invention provide numerous advantages over conventional approaches. For example, “closing” of the headliner around an unbelted occupant reduces the area within the vehicle passenger compartment in which the occupant may roam uncontrolled during vehicle rollover. This closure of the passenger compartment by the headliner as well may improve kinematics during side impacts, as the closing headliner operates to decelerate travel of the occupant earlier in time than do traditional head-protection systems.  
         [0009]     Systems of the present invention additionally may reduce possibility of occupants being ejected from vehicles during rollover events, regardless of vehicle window sizes. They further may limit exposure of occupants to roof intrusion into the passenger compartment during rollovers. These systems thus advantageously may provide rollover and primary and secondary impact protection with less additional material and less inflated volume than conventional apparatus.  
         [0010]     It thus is an optional, non-exclusive object of the present invention to provide restraint systems for occupants of vehicles.  
         [0011]     It is another optional, non-exclusive object of the present invention to provide restraint systems involving vehicle headliners.  
         [0012]     It is an additional optional, non-exclusive object of the present invention to provide restraint systems in which inflatable components are employed together with the headliners, with the inflatable components not being located between the headliners and roofs of vehicles.  
         [0013]     It is also an optional, non-exclusive object of the present invention to provide restraint systems in which the inflatable components are located below the headliners and function, when inflated, to apply tension to the headliners.  
         [0014]     It is, moreover, an optional, non-exclusive object of the present invention to provide restraint systems in which an inflatable structure is anchored at or near the lower edge of a vehicle window and which forms, when inflated, a braided tube.  
         [0015]     It is a further optional, non-exclusive object of the present invention to provide restraint systems in which fabric or similar material connects the inflatable component with the headliner so that, when the component inflates, it generates tension that pulls the headliner down toward the lower edge of the window.  
         [0016]     Other objects, features, and advantages of the present invention will be apparent to those skilled in the relevant field with reference to the remaining text and the drawings of this application. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]      FIGS. 1-7  present various views of an exemplary restraint system of the invention as it deploys.  
         [0018]      FIG. 8  provides a view of portions of the system of  FIGS. 1-7  stowed prior to deployment. 
     
    
     DETAILED DESCRIPTION  
       [0019]     Illustrated in  FIGS. 1-8  is system  10  of the present invention. System  10  preferably forms part of a human occupant-protection system for a ground-based vehicle such as an automobile or truck. System  10  is not necessarily so limited, however, and may be employed as well in other vehicles (whether or not ground-based), in other objects or containers likely to be subjected to substantial forces, and to protect (i) animals other than humans or (ii) cargo or other non-living items.  
         [0020]     The version of system  10  depicted in  FIGS. 1-8  is adapted especially for use in an automobile  12 , a portion of which is detailed in the figures. Automobile  12  may comprise frame F including, on each side thereof, pillars A, B, and C. Frame F additionally includes roof R formed with or connected to upper sections  14 ,  18 , and  22  of, respectively, pillars A, B, and C. The region of automobile  12  in which sections  14 ,  18 , and  22  intersect roof R may be denoted a “roof rail.” Automobile  12  typically also includes one or more passenger seats  24  and a headliner  26  which extends from the roof rail on one side of frame F to the roof rail of the other side and is positioned within the passenger compartment  30  immediately below roof R.  
         [0021]     Illustrated somewhat schematically in  FIG. 1  is a cross-section of portions of system  10 . Included as part of system  10  are material  34  and inflatable structure  38 . Material  34 , which preferably is not inflated, beneficially (but not necessarily) comprises nylon or other fabric. Regardless of composition, material  34  should be designed generally to retain its integrity even when tensioned and subjected to substantial force from impact by the head or torso of an occupant of automobile  12 .  
         [0022]     Material  34  is connected to headliner  26 , typically along edge  42  positioned at or near the roof rail of automobile  12 . Material  34  likewise is connected to inflatable structure  38 . As noted earlier, structure  38  may comprise a braided or knit component that, when inflated, increases in diameter and decreases in length.  
         [0023]     Structure  38  preferably is anchored to pillars A and C of automobile  12  near lower edge  46  of windows W. When not inflated, it may extend from its anchor points along the pillars A and C and the intermediate roof rail. Material  34  likewise may be stowed either along the roof rail or, instead, between headliner  26  and roof R adjacent the roof rail (as shown in  FIG. 8 ).  
         [0024]     System  10  additionally may include any mechanism suitable for inflating structure  38  and an initiator for commencing such inflation upon command. Typically the initiator will include a sensor designed to recognize that automobile  12  is being impacted from the side or at an oblique angle. Upon actuation, the inflator inflates structure  38 , whose configuration causes it to travel downward toward lower edge  46  and form a taut, semi-rigid structural member across the lower edge  46 .  
         [0025]     This downward travel of structure  38  pulls connected material  34  downward too, so that material  34  covers at least portions of windows W and, perhaps, pillar B. Material  34 , in turn, pulls edge  42  of headliner  26  downward. Because structure  38  is anchored and semi-rigid and headliner  26  is anchored elsewhere along the roof R, inflating structure  38  tensions material  34  and headliner  26  in an area between occupant H and frame F.  
         [0026]     Material  34  may be connected to headliner  26  and structure  38  in any appropriate manners.  FIGS. 1 and 6 - 7  especially illustrate material  34  wrapping around the (tubular) structure  38  to supply the connection, effectively acting as a sling. Alternatively, material  34  may be sewn onto or into structure  38  or otherwise fastened or attached thereto. Similarly, although material  34  preferably is sewn onto or into headliner  26 , other connection means may be employed instead.  
         [0027]     Although capable of use with conventional headliners  26 , operation of system  10  may benefit in some instances from modification to such conventional headliners  26 . For example, headliners  26  could be modified so as to bend along selected longitudinal lines (as shown at point L of  FIG. 1 ). Likewise, system  10  could substitute a conventional air bag for inflatable structure  38 . Finally, system  10  could, if desired, directly connect inflatable structure  38  (or an air bag) to headliner  26 , avoiding the need for material  34 .  
         [0028]     The foregoing is provided for purposes of illustrating, explaining, and describing exemplary embodiments and certain benefits of the present invention. Modifications and adaptations to the illustrated and described embodiments will be apparent to those skilled in the relevant art and may be made without departing from the scope or spirit of the invention.