Patent Description:
Protection systems have been installed in vehicles to protect occupants during collision events. Some protection systems suffer from one or more drawbacks or may perform less than optimally in one or more respects. Certain embodiments disclosed herein can address one or more of these issues. <CIT> relates to a passenger seat air-bag module. The document <CIT> discloses An airbag assembly according to the preamble of claim <NUM>.

The written disclosure herein describes illustrative embodiments that are nonlimiting and non-exhaustive. Reference is made to certain of such illustrative embodiments that are depicted in the figures, in which:.

Occupant protection systems, such as airbag assemblies, may be installed at various locations within a vehicle to reduce or minimize occupant injury during a collision event. In the following disclosure, specific reference is made to airbag assemblies that are designed to deploy in the direction of a knee area of an occupant seated in a vehicle seating position, although the principles discussed herein may apply to other types of airbag assemblies that are designed to cushion other portions of an occupant.

Airbag assemblies generally include an airbag cushion. The airbag cushion is typically disposed within a housing in a packaged state (e.g., rolled, folded, and/or otherwise compressed) and may be retained in the packaged state behind a cover. During a collision event, an inflator may be triggered, which rapidly supplies the airbag cushion with inflation gas. The inflation gas may cause the airbag cushion to rapidly transition from a compactly packaged (i.e., undeployed) state to an expanded or deployed state. In some embodiments, the expanding airbag cushion opens an airbag cover (e.g., by tearing through a predefined tear seam or opening a door-like structure) to exit the housing. The inflator may be triggered by any suitable device or system, and the triggering may be in response to and/or influenced by one or more vehicle sensors.

Airbag assemblies may include a knee restraint or knee airbag to protect the knees and/or lower legs of an occupant during a collision event. Such knee restraints may absorb at least some of the impact energy of an occupant during a collision event, especially by restraining the lower torso by means of restraining or limiting the forward movement (or forward diagonal movement) of the knees. In some embodiments, the knee restraint may comprise an airbag cushion that contacts and cushions the knees of an occupant during a collision event.

Some embodiments of airbag assemblies disclosed herein may be useful for protecting occupants seated in a front seat of a vehicle. Other embodiments of the airbag assemblies disclosed herein may be particularly useful for protecting occupants who are seated rearward of the front seats of a vehicle.

For example, in some embodiments, the airbag assemblies include an airbag cushion that is deployed from a position immediately in front of the occupant at a relatively low position. For instance, the airbag cushion may deploy from an instrument panel or a seat back at a position that is level with or lower than the position of the knees of an occupant who is seated in a front or back seat.

The components of the embodiments as generally described and illustrated in the figures herein can be arranged and designed in a wide variety of different configurations. While various aspects of the embodiments are presented in drawings, the drawings are not necessarily drawn to scale unless specifically indicated.

The term "coupled to" is used in its ordinary sense, and is broad enough to refer to any suitable coupling or other form of interaction between two or more entities, including mechanical interactions. Two components may be coupled to each other even though they are not in direct contact with each other. "Attachment" refers to interaction between two or more entities that are in direct contact with each other and/or are separated from each other only by a fastener of any suitable variety (e.g., mounting hardware or an adhesive).

As used herein, the terms "forward" and "rearward" are used with reference to the front and back of the relevant vehicle. For example, an airbag cushion that deploys in a rearward direction deploys toward the back of a vehicle.

The directional terms "proximal" and "distal" are used herein to refer to opposite locations on an airbag cushion. The proximal end of an airbag cushion is the end of the airbag cushion that is closest to the inflator when the airbag cushion is fully inflated. The distal end of an airbag cushion is the end opposite the proximal end of the airbag cushion. In other words, the terms "proximal" and "distal" are with reference to a point of attachment, such as a point of attachment of the airbag cushion at an airbag assembly housing and a point of attachment of an airbag assembly at a seat back from which an airbag deploys. Specifically, "proximal" is situated toward such point of attachment and "distal" is situated away from such point of attachment.

The term "seat," as used herein, refers to a structure within the cabin of a vehicle installed such that an occupant may be seated thereon/therein for transport within the vehicle.

A "vehicle seating position" may be defined by a seat (e.g., a front passenger seat, a front driver seat, a back seat) of a vehicle. A vehicle seating position may be the position in which an occupant is generally positioned when seated in a seat of a vehicle. A vehicle seating position may also be a position in which an occupant may be seated prior to and/or during a collision event or a position in which the vehicle and/or the seat is designed to transport an occupant.

The term "vehicle" may refer to any vehicle, such as a car, truck, bus, airplane, etc..

The term "occupant" generally refers to a person within a vehicle. The term "occupant" can also include a crash test dummy within a vehicle.

<FIG> is a perspective view of a portion of an instrument panel <NUM> (e.g. dashboard) of a vehicle and an airbag assembly <NUM> coupled to the instrument panel <NUM> according to an embodiment of the present disclosure. Arrows representing a vehicle forward direction VF and a vehicle rear direction VR are shown for reference in <FIG> and various other figures. The airbag assembly <NUM> of the present disclosure may be a knee inflatable airbag assembly or any other suitable airbag assembly. A support member <NUM> may be integral with the instrument panel <NUM> and may be coupled to the instrument panel <NUM> of the vehicle. The airbag assembly <NUM> may be coupled to the support member <NUM>, as further described herein.

<FIG> is a partially exploded view of the airbag assembly <NUM> and support member <NUM> of <FIG>. An airbag assembly receiver <NUM> of the support member <NUM> may be configured to accommodate the airbag assembly <NUM>. The airbag assembly receiver <NUM> of the support member <NUM> may comprise at least three attachment apertures <NUM> for coupling the airbag assembly <NUM> to the support member <NUM>.

The airbag assembly <NUM> comprises a flexible housing <NUM>, an inflator (not shown, but see, e.g., inflator <NUM> in <FIG>), and an inflatable airbag cushion (see inflatable airbag cushion <NUM> in <FIG>). The flexible housing <NUM> may comprise at least two tab slots <NUM> for receiving tabs <NUM> that are coupled to the inflatable airbag cushion <NUM>.

A plurality of attachment studs <NUM>, <NUM>, <NUM> may protrude from (or through) the flexible housing <NUM>. The studs <NUM>, <NUM>, <NUM> may each pass through a corresponding attachment aperture <NUM> of the airbag assembly receiver <NUM>. Each stud <NUM>, <NUM>, <NUM>, may be secured to the airbag assembly receiver <NUM> by means of securing hardware <NUM>. Exemplary securing hardware <NUM> may include, without limitation, nuts, speed nuts, push nuts, etc., and may be used to affix the studs <NUM>, <NUM>, <NUM> to the airbag assembly receiver <NUM>.

Each tab <NUM> is coupled to the inflatable airbag cushion (see inflatable airbag cushion <NUM> in <FIG>) and pass through the corresponding tab slot <NUM> of the flexible housing <NUM>. The support member <NUM> serves as a reaction surface for the airbag assembly <NUM>. In other words, the airbag assembly <NUM> is coupled to a reaction surface comprising a support member <NUM> of the vehicle. More particularly, the airbag assembly receiver <NUM> may serve to anchor the deployed airbag assembly <NUM> during a collision event, including engagement by an occupant and through ride down.

<FIG> is a partially exploded view of the airbag assembly <NUM> of <FIG>, according to an embodiment of the present disclosure. The inflatable airbag cushion <NUM>, the inflator <NUM>, and a mounting plate <NUM> are disposed within the flexible housing <NUM>.

The flexible housing <NUM> comprises a ductile fabric material including a plurality of polymeric fibers <NUM> in which at least some of the polymeric fibers <NUM> may be fused together by simultaneously heating and applying pressure to impart a particular stable shape. The shape may be a predetermined shaped. <FIG> illustrates the polymeric fibers <NUM> fused together to form a shape that conforms to the airbag assembly <NUM> in a compressed state. Possible shapes may include a generally rectangular shape, ovoid, obround, triangular, etc. The inflatable airbag cushion <NUM>, in an uninflated state, may be assembled with the inflator <NUM>, the mounting plate <NUM>, and tabs <NUM>, etc., and compressed, then wrapped with the initially ductile fabric (e.g., initially flexible cover), forming an intermediate package. The airbag assembly <NUM> may then be subjected to an appropriate amount of heat and pressure so as to conform the ductile fabric to the shape of the compressed inflatable airbag cushion/inflator/tabs <NUM>/<NUM>/<NUM>, and to fuse together at least some of the fibers <NUM> of the ductile fabric to retain the shape achieved during the heat fusing process, forming a compressed package. After the heat fusing process, the flexible housing <NUM> attains a rigid, semi-rigid, or quasi-rigid state. The flexible housing <NUM> may both support the airbag assembly <NUM> and protect the airbag assembly <NUM> from exposure to a local environment (such as, for example, dust, mud, etc.).

The inflator <NUM> comprises the inflator connector end <NUM>, a first stud <NUM>, and a second stud <NUM>. The inflator <NUM> may comprise more or less than the illustrated two studs <NUM>, <NUM>. The inflator <NUM> may be partially inserted into the inflatable airbag cushion <NUM> via an inflator aperture <NUM> such that at least the inflator connector end <NUM> remains exposed outside the airbag cushion <NUM>. The inflator aperture <NUM> may be configured to accommodate passage of the first stud <NUM> into the inflatable airbag cushion <NUM>. The first stud <NUM> may then be passed through an inflator stud aperture <NUM> of the inflatable airbag cushion <NUM>. In some embodiments, both the first stud <NUM> and the second stud <NUM> may pass through apertures in the inflatable airbag cushion <NUM>.

The mounting plate <NUM> may comprise an elongate member having at least two stud apertures <NUM>, two tab slots <NUM>, and at least one stud <NUM>. The mounting plate <NUM> may include more or fewer than two stud apertures <NUM> and two tab slots <NUM>. Once the inflator <NUM> is inserted into the inflatable airbag cushion <NUM>, the studs <NUM>, <NUM> may pass through the corresponding stud apertures <NUM> of the mounting plate <NUM>. Each tab <NUM> comprises a first end <NUM> and a second end <NUM>. The second end <NUM> of each tab <NUM> passes through the corresponding tab slot <NUM> of the mounting plate <NUM>. With the inflatable airbag cushion <NUM> and inflator <NUM> assembled to the mounting plate <NUM>, the studs <NUM>, <NUM>, <NUM> and the second ends <NUM> of the tabs <NUM> may pass through the corresponding stud apertures <NUM> and tab slots <NUM> of the flexible housing <NUM>.

In some embodiments, assembly of the inflatable airbag cushion <NUM>, inflator <NUM>, and mounting plate <NUM> to the flexible housing <NUM> may be accomplished prior to a forming/fusing process to give the flexible housing <NUM> a shape.

In some embodiments, the inflatable airbag cushion <NUM>, inflator <NUM>, and mounting plate <NUM> may be disposed in the flexible housing <NUM> such that the inflator connector end <NUM> is exposed at or through an inflator connector aperture <NUM>. In other words, prior to the application of heat and/or pressure to impart a preferred form to the flexible housing <NUM>, the flexible housing <NUM> may be folded or otherwise manipulated to ensure that the inflator connector end <NUM> is exposed at or protrudes through the inflator connector aperture <NUM> of the flexible housing <NUM>.

Prior to assembly, the inflatable airbag cushion <NUM> may be rolled or folded into a compact state, as shown in <FIG>. Although the inflatable airbag cushion <NUM> is shown rolled, the present disclosure anticipates other methods of compacting the inflatable airbag cushion <NUM>, such as, e.g., rolling, folding, etc. The first end <NUM> of each tab <NUM> is coupled to the inflatable airbag cushion <NUM> so as to assist in properly disposing the inflatable airbag cushion <NUM> during deployment.

<FIG> is a perspective view of the assembled airbag assembly <NUM> of <FIG>. The mounting plate <NUM> and inflator <NUM> are shown assembled to and within the flexible housing <NUM>. The inflator connector end <NUM> is shown exposed through the inflator connector aperture <NUM> of the flexible housing <NUM>. The inflator studs <NUM>, <NUM> and mounting plate stud <NUM> each protrude through a corresponding stud aperture <NUM> of the flexible housing <NUM>. The tabs <NUM> are each shown having been passed through a corresponding tab slot <NUM> of the flexible housing <NUM>. Each of the studs <NUM>, <NUM>, <NUM> is oriented in the same direction and orthogonal to the mounting plate <NUM>. In one embodiment, the studs <NUM>, <NUM>, <NUM> may be oriented in differing directions and/or may be other than orthogonal to the mounting plate <NUM>.

<FIG> is a plane view of the inflatable airbag cushion <NUM> of the airbag assembly <NUM> of <FIG>. The inflatable airbag cushion <NUM> may be formed of any suitable fabric, and may be formed of a single, unitary panel of such fabric, or of multiple panels of such fabric. The fabric may be folded, cut, sewn, etc., so as to form an inflatable chamber. The inflatable airbag cushion <NUM> comprises a first panel <NUM> and a second panel <NUM>. By way of example without limitation, a panel of suitable fabric may be folded along a midline <NUM> and coupled together at a panel coupling <NUM> to form an inflatable chamber. The panel coupling <NUM> may be a seam. A seam may be formed by sewing, radio-frequency (RF) welding, adhesive, taping, or any suitable method or combination of suitable methods. The inflatable airbag cushion <NUM> further comprises an inflator region <NUM> having the inflator aperture <NUM> and the inflator stud aperture <NUM>. During assembly, the inflator (see inflator <NUM> in <FIG>) may be partially inserted through the inflator aperture <NUM> such that the first inflator stud <NUM> may be passed through the inflator stud aperture <NUM>.

Each of the tabs <NUM> may couple at a lateral portion of the inflatable airbag cushion <NUM> near the inflator region <NUM>. The first end <NUM> of each tab <NUM> couples to the inflatable airbag cushion <NUM> at a tab coupling <NUM>.

<FIG> illustrate a method of coupling the tabs <NUM> to the mounting plate <NUM> and the flexible housing <NUM>. <FIG> is a plane view of a tab <NUM> of the airbag assembly <NUM> of <FIG>, according to an embodiment of the present disclosure. Each tab <NUM> may be formed of a fabric panel <NUM>.

<FIG> is a side view of the tab <NUM> having a plurality of folds <NUM> proximal to the second end <NUM>. Each fold <NUM> may be secured by a seam 145a, 145b. In other words, the opposing sides of each fold <NUM> may be coupled together by seams 145a, 145b. More particularly, a central seam 145a may be disposed at a position medial or nearly medial between the folds <NUM> of the fabric panel <NUM>. An auxiliary seam 145b may be disposed at or near the fold <NUM> distal to the first end <NUM> of the fabric panel <NUM>.

<FIG> is a side view of the tab <NUM> with additional auxiliary seams 145c, 145d. The first end <NUM> of the tab <NUM> is illustrated disposed orthogonally from the central seam 145a. The auxiliary seam 145c may be disposed adjacent the central seam 145a. Another auxiliary seam 145d may be disposed distal to the auxiliary seam 145b of <FIG>.

The plurality of folds <NUM> and seams 145a, 145b, 145c, 145d may configure the tab <NUM> to have a first wing <NUM> disposed to one side of the first end <NUM>, and a second wing <NUM> disposed to the opposite side of the first end <NUM>. In other words, the tab <NUM> comprise the first end <NUM> and the second end <NUM>, the second end <NUM> having the first wing <NUM> and the second wing <NUM>. The first wing <NUM> has a first thickness <NUM>. The second wing <NUM> has a second thickness <NUM>. In some embodiments, the first wing <NUM> has a thickness less than the thickness of the second wing <NUM>.

<FIG> is a side view of the tab <NUM> during assembly to the airbag assembly <NUM> of <FIG>. The second wing <NUM> of the second end <NUM> of the tab <NUM> may be passed through the tab slot <NUM> of the mounting plate <NUM>. In one embodiment, the second wing <NUM> may be passed through the tab slot <NUM> of the flexible housing <NUM>. The inflatable airbag cushion (see inflatable airbag cushion <NUM> in <FIG>) is not shown; however, the first end <NUM> will have been previously coupled to the inflatable airbag cushion <NUM>. The tab slot <NUM> of the flexible housing <NUM> and the tab slot <NUM> of the mounting plate <NUM> may each have a dimension to accommodate the second thickness <NUM> of the second wing <NUM>, but less than the second thickness <NUM> of the second wing <NUM> combined with the first thickness <NUM> of the first wing <NUM>. The second end <NUM> of the tab <NUM> may be advanced through the tab slots <NUM>, <NUM> sufficiently to draw the first wing <NUM> of the tab <NUM> through the tab slots <NUM>, <NUM>.

<FIG> is a side view of the tab <NUM> once the airbag assembly <NUM> of <FIG> is mounted to a vehicle (not shown). The second end <NUM>, comprising the first wing <NUM> and second wing <NUM>, has been drawn through the tab slots <NUM> and <NUM> of the mounting plate <NUM> and flexible housing <NUM>, respectively. The first wing <NUM> and second wing <NUM> of the tab <NUM> may be disposed to opposite sides of the tab slots <NUM>, <NUM>, and may engage an interior surface of the support member <NUM>. As in <FIG>, the first end <NUM> of the tab <NUM> is coupled to the inflatable airbag cushion (see inflatable airbag cushion <NUM> in <FIG>).

<FIG> is a side view of the tab <NUM> in a deployed configuration of the airbag assembly <NUM> of <FIG>, according to an embodiment of the present disclosure. With the inflatable airbag cushion (see inflatable airbag cushion <NUM> in <FIG>, <FIG>) deployed, the first end <NUM> may draw the tab <NUM> downward. As the tab <NUM> is drawn downward, the first and second wings <NUM>, <NUM> are drawn together. Because the tab slots <NUM>, <NUM> of the flexible housing <NUM> and mounting plate <NUM> are narrower than the combination of the first thickness <NUM> and second thickness <NUM>, the second end <NUM> of the tab <NUM> may function as a stopper knot to prevent the tab <NUM> from pulling through the tab slots <NUM>, <NUM>. This may enable the tabs <NUM> to assist in disposing the inflatable airbag cushion <NUM> so as to engage the lower anatomy of an occupant during a collision event.

<FIG> is a perspective view of the mounting plate <NUM> of the airbag assembly <NUM> of <FIG>, according to an embodiment of the present disclosure. The mounting plate <NUM> is an elongate member having a length and width approximately equal to the length and width of the inflatable airbag cushion <NUM> in a compressed state. The mounting plate <NUM> may be fabricated from metal, a metal alloy, plastic, or a combination thereof. The mounting plate <NUM> may be rigid, or generally rigid, so as to support and/or lend form to the assembled airbag assembly <NUM>. The mounting plate <NUM> may comprise two arms <NUM> at opposing ends of the elongate member, with each arm <NUM> oriented transverse to a longitudinal axis of the elongate member. The mounting plate <NUM> may further comprise at least one mounting stud <NUM>, <NUM>. The mounting plate <NUM> illustrated in <FIG> illustrates a single stud <NUM>. However, the mounting plate <NUM> may include more, such as mounting stud <NUM> illustrated in broken lines on <FIG>. The mounting plate <NUM> further comprises a tab slot <NUM> near either opposite end of the elongate member. More particularly, a tab slot <NUM> may be disposed within each arm <NUM> and transverse to the elongate dimension of the mounting plate <NUM>. The mounting plate <NUM> may also comprise two stud apertures <NUM> to accommodate the inflator studs (see inflator studs <NUM>, <NUM> in <FIG>) and to facilitate mounting the airbag assembly <NUM> to the airbag assembly receiver of the support member (see airbag assembly receiver <NUM> and support member <NUM> in <FIG>). In some embodiments, the mounting plate <NUM> may have more or fewer than two stud apertures <NUM>, and the number of stud apertures <NUM> may correspond with the number of studs of the inflator <NUM>. The mounting plate <NUM> may provide structure to the airbag assembly and prevent sagging of the airbag assembly after installation in the vehicle.

<FIG> is a cross-sectional view of the airbag assembly <NUM> of <FIG> taken along line <NUM>-<NUM>. The inflatable airbag cushion <NUM> is shown, along with the inflator <NUM>. The first and second studs <NUM>, <NUM> of the inflator <NUM>, and the stud <NUM> of the mounting plate <NUM> are shown for reference. The flexible housing <NUM> is disposed closely around the compacted inflatable airbag cushion <NUM>, in which the inflator <NUM> is partially disposed. The connector end <NUM> of the inflator <NUM> is exposed or protrudes through the inflator connector aperture <NUM> of the flexible housing <NUM>. Two tabs <NUM> are shown disposed toward opposite ends of the mounting plate <NUM>, hence toward opposite ends of the flexible housing <NUM> of the airbag assembly <NUM>. The first end <NUM> of each tab <NUM> is coupled to the inflatable airbag cushion <NUM>. The second end <NUM> of each tab <NUM> has been passed through the tab slots <NUM>, <NUM> of the mounting plate <NUM> and flexible housing <NUM>, respectively, and the second end <NUM> is disposed at an outer portion of the flexible housing <NUM>.

<FIG> is a side schematic view of the airbag assembly <NUM>, according to an embodiment of the present disclosure, disposed within a vehicle. The instrument panel/dashboard <NUM> and support member <NUM> are shown for reference. The airbag assembly <NUM> is shown coupled to the airbag assembly receiver <NUM> of the support member <NUM>.

The first stud <NUM> of the inflator <NUM> and the stud <NUM> of the mounting plate <NUM> couple the airbag assembly <NUM> to the airbag assembly receiver <NUM>, and are secured in place by securing hardware <NUM>. The second inflator stud (not shown, but see inflator stud <NUM> in <FIG>) similarly couples the airbag assembly <NUM> to the airbag assembly receiver <NUM>. In other words, at least three attachment studs <NUM>, <NUM>, <NUM> couple the airbag assembly <NUM> to the airbag assembly receiver <NUM> of the support member <NUM>. At least one of the at least three studs <NUM>, <NUM>, <NUM> may be inflator studs <NUM>, <NUM>. At least one of the at least three studs <NUM>, <NUM>, <NUM> may be studs <NUM>, <NUM> of the mounting plate <NUM>. The studs <NUM>, <NUM>, <NUM> may be secured to the support member <NUM> via the airbag assembly receiver <NUM> so as to tightly couple the second end <NUM> of each tab <NUM> between the airbag assembly receiver <NUM> and the flexible housing <NUM>. In other words, the securing hardware <NUM> may draw the studs <NUM>, <NUM>, <NUM> and, hence, the mounting plate <NUM> tightly against the airbag assembly receiver <NUM> so as to firmly affix the second end <NUM> of each tab <NUM> between the airbag assembly receiver <NUM> and the flexible housing <NUM>.

The flexible housing <NUM> may comprise a tear bias <NUM>. The tear bias <NUM> may be formed, for example without limitation, by crimping the flexible housing <NUM> at the tear bias <NUM> location prior to the flexible housing <NUM> being heat-formed to the compressed inflatable airbag cushion <NUM>. The tear bias <NUM> may permit the flexible housing <NUM> to tear open or rupture at, near, or along a desired location so as to assist in disposing the inflatable airbag cushion <NUM> during deployment and inflation.

<FIG> is a side schematic view of the airbag assembly <NUM> of <FIG> in an at least partially deployed state, according to an embodiment of the present disclosure. The inflatable airbag cushion <NUM> comprises a first panel <NUM> and a second panel <NUM>. The first panel <NUM> and second panel <NUM> may be coupled at the panel coupling <NUM> so as to define an inflatable chamber within the inflatable airbag cushion <NUM>.

The inflator <NUM> has been activated so as to supply inflation gas into the inflatable airbag cushion <NUM>. As the inflatable airbag cushion <NUM> begins to inflate, the inflatable airbag cushion <NUM> may begin to expand (unroll, if rolled; unfold, if folded; etc.). Expansion of the inflatable airbag cushion <NUM> may cause the flexible housing <NUM> to rupture. In particular, the flexible housing <NUM> may rupture along or near the tear bias (see tear bias <NUM> in <FIG>). Continued expansion of the inflatable airbag cushion <NUM> may cause the inflatable airbag cushion <NUM> to initially deploy with a downward and rearward trajectory. The inflatable airbag cushion <NUM> may be configured via folds, seams, etc. (not shown) to cause the inflatable airbag cushion <NUM> to turn so as to deploy rearward and upward once the inflatable airbag cushion <NUM> has exited the flexible housing <NUM>. The tabs <NUM> may assist in properly disposing the inflatable airbag cushion <NUM> during deployment and inflation.

As the inflatable airbag cushion <NUM> deploys rearward and upward, the first panel <NUM> of the inflatable airbag cushion <NUM> may engage a portion of the instrument panel <NUM> (and/or dashboard). The instrument panel <NUM> may be supported by the support member <NUM>. The instrument panel <NUM> may thus serve as a reaction surface to support the inflatable airbag cushion <NUM> as the inflatable airbag cushion <NUM> is engaged by an occupant (not shown). In particular, the inflatable airbag cushion <NUM> may be disposed during a collision event to receive at least a portion of the lower anatomy (i.e., legs) of an occupant, and to support the portion of the lower anatomy of the occupant during ride down.

The configuration of the airbag assembly <NUM> with the flexible housing <NUM> and mounting plate <NUM> may permit the airbag assembly <NUM> to be smaller and/or lighter than may be possible with a conventional rigid housing. The flexible housing <NUM> may provide the inflatable airbag cushion <NUM> and other components of the airbag assembly <NUM> protection from the environment in a manner similar to a conventional rigid housing. The mounting plate <NUM> may provide support to the airbag assembly <NUM> in an undeployed state and, in particular, to the inflatable airbag cushion <NUM> during a collision event.

<FIG> is a partially exploded view of an airbag assembly <NUM> according to an embodiment. The airbag assembly <NUM> may be similar in many respects to the embodiment of <FIG>. of the present disclosure. The inflatable airbag cushion <NUM>, the inflator <NUM>, the mounting plate <NUM>, the flexible housing <NUM> and the polymeric fibers <NUM> of the flexible housing <NUM> are shown for reference. The inflator connector end <NUM>, the first stud <NUM>, the second stud <NUM>, the inflator stud aperture <NUM> of the inflatable airbag cushion <NUM>, and the inflator aperture <NUM> of the inflatable airbag cushion <NUM> are also shown. The tabs <NUM>, and the first ends <NUM> and second ends <NUM> of the tabs <NUM> are shown.

In the embodiment of an airbag assembly <NUM> of <FIG>, the flexible housing <NUM> comprises the stud apertures <NUM>, the tab slots <NUM>, and a mounting arm slot <NUM>. The mounting plate <NUM> comprises a stud <NUM>, two stud apertures <NUM>, two tab slots <NUM>, an attachment aperture <NUM>, and a mounting arm <NUM> having an attachment aperture <NUM>. The mounting plate <NUM> may have a dimension greater than a corresponding dimension of the inflatable airbag cushion <NUM> in a compressed configuration. In other words, the mounting plate <NUM> including the mounting arm <NUM> may be wider than is the compressed inflatable airbag cushion <NUM>.

The inflatable airbag cushion <NUM>, the inflator <NUM>, the mounting plate <NUM>, and the flexible housing <NUM> may be assembled together in a manner similar to the embodiment discussed above in connection with <FIG>. Additionally, the mounting arm <NUM> of the mounting plate <NUM> may be passed through the mounting arm slot <NUM> of the flexible housing <NUM>. The assembled airbag assembly <NUM> may be coupled to the support member <NUM> by pressing the studs <NUM>, <NUM>, and <NUM> through the attachment apertures <NUM>, and securing the studs <NUM>. <NUM>, <NUM> in place via securing hardware <NUM>. In the embodiment of <FIG>, the support member <NUM> may comprise a stud <NUM> and/or a stud <NUM>. The stud <NUM> may be passed through a stud aperture <NUM> of the flexible housing <NUM> and couple to the attachment aperture <NUM>. The stud <NUM> may pass through the attachment aperture <NUM> of the attachment arm <NUM> and be secured by securing hardware <NUM>.

The disclosure anticipates other, similar embodiments. For example, the stud <NUM> may be replaced by an attachment aperture similar to the attachment aperture <NUM>, and the support member <NUM> may comprise a corresponding stud similar to the stud <NUM> which passes through the attachment aperture disposed in the place of the stud <NUM>. Similarly, the attachment aperture <NUM> of the mounting plate <NUM> and the stud <NUM> of the support member <NUM> may be reversed such that a stud replaces the attachment aperture <NUM> and an attachment aperture replaces the stud <NUM>. The same is true for the stud <NUM> of the support member <NUM> and the attachment aperture <NUM> of the attachment arm <NUM>.

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.

Claim 1:
An airbag assembly (<NUM>, <NUM>) comprising:
a flexible housing (<NUM>, <NUM>);
an inflatable airbag cushion (<NUM>, <NUM>) disposed within the flexible housing (<NUM>, <NUM>) in a compressed configuration;
an inflator (<NUM>, <NUM>) to supply inflation gas to the inflatable airbag cushion (<NUM>, <NUM>), the inflator (<NUM>, <NUM>) at least partially disposed within the flexible housing (<NUM>, <NUM>);
a mounting plate (<NUM>, <NUM>) coupled to the flexible housing (<NUM>, <NUM>), the mounting plate (<NUM>, <NUM>) comprising an attachment point to couple the airbag assembly (<NUM>, <NUM>) to a reaction surface (<NUM>) of a vehicle; characterized by
a plurality of tabs (<NUM>, <NUM>) wherein a first end (<NUM>,<NUM>) of each tab (<NUM>,<NUM>) couples to the airbag cushion (<NUM>, <NUM>) and a second end (<NUM>, <NUM>) of each tab (<NUM>, <NUM>) extends through an aperture (<NUM>, <NUM>) of the mounting plate (<NUM>, <NUM>)
whereby the second end (<NUM>, <NUM>) of each tab (<NUM>, <NUM>) is configured to one of:
extend through the aperture (<NUM>, <NUM>) of the mounting plate (<NUM>, <NUM>) and to be disposed between the mounting plate (<NUM>, <NUM>) and a portion of the housing (<NUM>, <NUM>); and
extend through the aperture (<NUM>, <NUM>) of the mounting plate (<NUM>, <NUM>) and an aperture (<NUM>, <NUM>) of the housing (<NUM>, <NUM>) and to be disposed between the housing (<NUM>, <NUM>) and the reaction surface (<NUM>).